description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
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FIELD OF THE INVENTION
This invention relates to RF (including microwave) interconnections among layers of assemblies of multiple integrated circuits, and more particularly to compliant interconnection arrangements which may be sandwiched between adjacent circuits.
BACKGROUND OF THE INVENTION
Active antenna arrays are expected to provide performance improvements and reduce operating costs of communications systems. An active antenna array includes an array of antenna elements. In this context, the antenna element may be viewed as being a transducer which converts between free-space electromagnetic radiation and guided waves. In an active antenna array, each antenna element, or a subgroup of antenna elements, is associated with an active module. The active module may be a low-noise receiver for low-noise amplification of the signal received by its associated antenna element(s), or it may be a power amplifier for amplifying the signal to be transmitted by the associated antenna element(s). Many active antenna arrays use transmit-receive (T/R) modules which perform both functions in relation to their associated antenna elements. The active modules, in addition to providing amplification, ordinarily also provide amplitude and phase control of the signals traversing the module, in order to point the beam(s) of the antenna in the desired direction. In some arrangements, the active module also includes filters, circulators, andor other functions.
A major cost driver in active antenna arrays is the active transmit or receive, or T/R module. It is desirable to use monolithic microwave integrated circuits (MMIC) to reduce cost and to enhance repeatability from element to element of the array. Some prior-art arrangements use ceramic-substrate high-density-interconnect (HDI) substrate for the MMICs, with the substrate mounted to a ceramic, metal, or metal-matrix composite base for carrying away heat. These technologies are effective, but the substrates may be too expensive for some applications.
FIG. 1 illustrates a cross-section of an epoxy-encapsulated HDI module 10 in which a monolithic microwave integrated circuit (MMIC) 14 is mounted by way of a eutectic solder junction 16 onto the top of a heat-transferring metal deep-reach shim 18. The illustrated MMIC 14, solder 16, and shim 18 are encapsulated, together with other like MMIC, solder and shim assemblies (not illustrated) within a plastic encapsulant or body 12, the material of which may be, for example, epoxy resin. The resulting encapsulated part, which may be termed "HDI-connected chips" inherently has, or the BP ΔN lower surfaces are ground and polished to generate, a flat lower surface 12 ls BP ΔN. The flat lower surface 12 ls , and the exposed lower surface 18 ls , of the shim, are coated with a layer 20 of electrically and thermally conductive material, such as copper or gold. As so far described, the module 10 of FIG. 1 has a plurality of individual MMIC mounted or encapsulated within the plastic body 12, but no connections are provided between the individual MMICs or between any one MMIC and the outside world. Heat which might be generated by the MMIC, were it operational, would flow preferentially through the solder junction 16 and the shim 18 to the conductive layer 20.
In FIG. 1, the upper surface of MMIC 14 has two representative electrically conductive connections or electrodes 14 1 and 14 2 . Connections are made between electrodes 14 1 and 14 2 and the corresponding electrodes (not illustrated) of others of the MMICs (not illustrated) encapsulated within body 12 by means of HDI technology, including flexible layers of KAPTON on which traces or patterns of conductive paths, some of which are illustrated as 32 1 and 32 2 , have been placed, and in which the various layers are interconnected by means of conductive vias. In FIG. 1, KAPTON layers 24, 26, and 30 are provided with paths defined by traces or patterns of conductors. The layers illustrated as 24 and 26 are bonded together to form a multilayer, double-sided structure, with conductive paths on its upper and lower surfaces, and additional conductive paths lying between layers 24 and 26. Double-sided layer 24/26 is mounted on upper surface 12 us of body 12 by a layer 22 of adhesive. A further layer 30 of KAPTON, with its own pattern of electrically conductive traces 32 2 , is held to the upper surface of double-sided layer 24/26 by means of an adhesive layer 28. The uppermost layer of electrically conductive traces may include printed antenna elements in one embodiment of the invention. As mentioned above, electrical connections are made between the conductive traces of the various layers, and between the traces and appropriate ones of the MMIC contacts 14 1 and 14 2 , by through vias, some of which are illustrated as 36. The items designated MT0, MT1, MT2, and MT3 at the left of FIG. 1 are designations of various ones of the flexible sheets carrying the various conductive traces. Those skilled in the art will recognize this structure as being an HDI interconnection arrangement, which is described in U.S. Pat. No. 5,552,633, issued Sep. 3, 1996 in the name of Sharma.
As illustrated in FIG. 1, at least one radio-frequency (RF) ground conductor layer or "plane" 34 is associated with lower layer 24 of the double-sided layer 24/26. Those skilled in the art will realize that the presence of ground plane 34 allows ordinary "microstrip" transmission-line techniques to carry RF signals in lateral directions, parallel with upper surface 12 us of plastic body 12, so that RF signals can also be transmitted from one MMIC to another in the assembly 10 of FIG. 1.
Allowed U.S. patent application Ser. No. 08/815,349, in the name of McNulty et al., describes an arrangement by which signals can be coupled to and from an HDI circuit such as that of FIG. 1. As described in the McNulty et al. application, the HDI KAPTON layers with their patterns of conductive traces are lapped over an internal terminal portion of a hermetically sealed housing. Connections are made within the body of the housing between the internal terminal portion and an externally accessible terminal portion.
One of the advantages of an antenna array is that it is a relatively flat structure, by comparison with the three-dimensional curvature of reflector-type antennas. When assemblies such as that of FIG. 1 are to be used for the transmit-receive modules of an active array antenna, it is often desirable to keep the structure as flat as possible, so as, for example, to make it relatively easy to conform the antenna array to the outer surface of a vehicle. FIG. 2a illustrates an HDI module such as that described in the abovementioned McNulty patent application. In FIG. 2a, representative module 210 includes a mounting base 210, to which heat is transferred from internal chips. A plurality of mounting holes are provided, some of which are designated 298. A contoured lid 213 is hermetically sealed to a peripheral portion of base 212, to protect the chips within. A first set of electrical connection terminals, some of which are designated as 222a, 224a, and 226a are illustrated as being located on the near side of the base, and a similar set of connection terminals, including terminals designated as 222b, 224b, and 226b are located on the remote side of the base. FIG. 2b is a perspective or isometric view, partially exploded, of an active array antenna 200. In FIG. 2b, the rear or reverse side (the non-radiating or connection side) of a flat antenna element structure 202 is shown, divided into rows designated a, b, c, and d and columns 1, 2, 3, 4, and 5. Each location of array structure 202 is identified by its row and column number, and each such location is associated with a set of terminals, three in number for each location. Each array location of antenna element array 202 is associated with an antenna element, which is on the obverse or front side of structure 202. Each antenna element on the obverse side of the antenna element structure 202 is connected to the associated set of three terminals on the corresponding row and column of the reverse side of the antenna element array 202. Each antenna element of active antenna array 200 of FIG. 2b is associated with a corresponding active antenna module 210, only one of which is illustrated. In FIG. 2b, active antenna module 210b3 is associated with antenna element or array element 202b3. Active module 210b3 is identical to module 210 of FIG. 2a and to all of the other modules (not illustrated) of FIG. 2b. Representative module 210b3 has its terminals 222a, 224a, and 226a connected by means of electrical conductors to the set of three terminals associated with array element 202b3 of antenna structure 202. The other set of terminals of module 210b3, namely the set including terminals 222b, 224b, and 226b, is available to connect to a source or sink of signals which are to be transmitted or received, respectively. It will be clear that the orientation of module 210b3, and of the other modules which it represents, will, when all present, will extend for a significant distance behind or to the rear of the antenna element support structure 202, thereby tending to make the active antenna array 200 fairly thick. Also, the presence of the many modules will make it difficult to support the individual modules in a manner such that heat can readily be extracted from the mounting plates (212 of FIG. 2a). Also, the presence of many such active modules 210 will make it difficult to make the connections between the terminal sets of the active modules and the terminal sets of the antenna elements. The problem of thickness of the structure of FIG. 2b is exacerbated by the need for a signal distribution arrangement, partially illustrated as 290. Distribution arrangement 290 receives signal from a source 292, and distributes some of the signal to the near connections of each of the modules, such as connections 222b. 224b, and 226b of module 210b3.
A further problem with the structure of FIG. 2b is that the connections between the active module 210b3 and the set of terminals for array element 202b3 is by way of an open transmission-line. Those skilled in the art of RF and microwave communications know that such open transmission-lines tend to be lossy, and in a structure such as that illustrated in FIG. 2b, the losses will tend to result in cross-coupling of signal between the terminals of the various array elements.
A further problem with interconnecting the structure of FIG. 2b is that of tolerance build-up between the antenna terminal sets on the reverse side of the antenna element structure 202, the terminals of the modules 210, and the terminals of beamformer 290.
Improved arrangements are desired for producing flat HDI-connected structures which can be arrayed with other flat structures.
SUMMARY OF THE INVENTION
In one aspect, the invention lies in a short electrical transmission-line which includes a center electrical conductor having the form of a circular cylinder centered about an axis. The circular cylinder of the center conductor defines an axial length between first and second ends of the center conductor. An outer electrical conductor arrangement comprises a plurality of mutually identical electrical outer conductors, each being in the form of a circular cylinder centered about an axis, and each having an axial length between first and second ends which is equal to the axial length of the center conductor. The axes of the outer conductors are oriented parallel with each other and with the axis of the center conductor. The first ends of the center and outer conductors are coincident with a first plane which is orthogonal to the axes of the center and outer conductors, and the second ends of the center and outer conductors are coincident with a second plane parallel with the first plane. The outer conductors have their axes equally spaced from each other at a first radius from the axis of the center conductor. The short electrical transmission-line also includes a rigid dielectric disk defining a center axis and an axial length no greater than the axial length of the center conductor. The rigid dielectric disk also defines a periphery spaced from the center axis by a second radius which is greater than either (a) the first radius or (b) the axial length of the center conductor. The dielectric disk surrounds and supports the center and outer conductors on side regions thereof lying between the first and second ends of the center and outer conductors, for holding the center and outer conductors in place. However, the dielectric disk does not overlie the first ends of the center and outer conductors.
In a more particular embodiment, the center conductor defines a diameter, and the outer conductors each have the same diameter. More particularly, the material of the center and outer conductors comprises at least a copper core, and the material of the dielectric disk is epoxy resin.
A method, according to an aspect of the invention, for producing a flat connection assembly includes the step of affixing a plurality of microwave integrated-circuit chips to a support, with connections of the chips adjacent to the support. A plurality of short electrical transmission-lines are made or generated. Each of the short electrical transmission-lines is similar to that summarized above. A plurality of the short transmission-lines are applied to the support, with the first ends of the conductors adjacent the support. The chips and the short transmission-lines are encapsulated in rigid dielectric material, to thereby produce encapsulated chips and transmission-lines. The support is removed from the encapsulated chips and transmission-lines, to thereby expose a first side of the encapsulated chips and transmission-lines, and at least the connections of the chips and the first ends of the center and outer conductors of the short transmission-lines. At least one layer of flexible dielectric sheet carrying a plurality of electrically conductive traces is applied to the first side of the encapsulated chips and transmission-lines. The flexible dielectric sheet interconnects, by way of some of the traces and by through vias, at least one of the connections of at least one of the chips with the first end of the center conductor of one of the transmission-lines, and at least one other of the connections of the one of the chips to the first ends of all of the outer conductors of the one of the transmission-lines, to thereby produce a first-side-connected encapsulated arrangement. So much material is removed from that side of the first-side-connected encapsulated arrangement which is remote from the first side as will expose second ends of the center and outer conductors of the transmission-lines, to thereby produce a first planar arrangement having exposed second ends of the center and outer conductors of the transmission-lines. A planar conductor arrangement is applied over the first planar arrangement, and adjacent that side of the first planar arrangement which has the exposed second ends of the center and outer conductors. The planar conductor arrangement includes a plurality of individual electrical connections which, when the planar conductor arrangement is registered with the first planar arrangement, are registered with the center and outer conductors of the transmission-lines. The planar conductor arrangement is registered with the first planar arrangement, and electrical connections are made between the first ends of the center and outer conductors of the transmission lines of the first planar arrangement and the individual electrical connections of the planar conductor arrangement.
In a particular method according to an aspect of the invention, the step of making electrical connections comprises the steps of placing a compressible floccule of electrically conductive material between the first ends of each of the center and outer conductors of the transmission lines of the first planar arrangement and the registered ones of the planar conductor arrangement, and compressing the compressible floccule of electrically conductive material between the first ends of the center and outer conductors of the transmission lines of the first planar arrangement and the registered ones of the planar conductor arrangement, to thereby establish the electrical connections and to aid in holding the compressible floccules in place. The step of encapsulating the chips and the short transmission-lines in dielectric material includes the step of encapsulating the chips and the short transmission-lines in the same dielectric material as that of the dielectric disk.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified cross-sectional view of a portion of a prior-art high-density interconnect arrangement by which connections are made between multiple integrated-circuit chips mounted on a single supporting substrate;
FIG. 2a is a simplified perspective or isometric view of a prior-art module which contains HDI-connected integrated-circuit chips, and FIG. 2b illustrates how a flat or planar antenna array might use a plurality of the modules of FIG. 2a to form an active antenna array;
FIGS. 3a and 3b are simplified plan and elevation views, respectively, of a short transmission-line, and
FIG. 3c is a cross-section of the structure of FIG. 3a taken along section lines 3c--3c;
FIGS. 4a, 4b, 4c, 4d, 4e, 4f, 4g, and 4h illustrate steps, in simplified form, in the fabrication of an RF HDI structures using a short transmission-line as in FIGS. 3a, 3b, and 3c to interface to another planar circuit, illustrated as a beamformer or manifold;
FIG. 5 illustrates an arrangement similar to that of FIG. 4h with a cold plate interposed between the HDI-connected chips and the beamformer, and using a rigid fuzz button holder;
FIG. 6a is a simplified plan view of a compressible or conformable short transmission line,
FIG. 6b is a simplified cross-section of the arrangement of FIG. 6a taken along section lines 6a--6a,
FIG. 6c is a simplified perspective or isometric view of the short transmission line of FIGS. 6a and 6b, with the fuzz button conductors illustrated in phantom, and
FIG. 6d is a simplified perspective or isometric view of a representative fuzz button;
FIG. 7 is a simplified cross-sectional representation of an assemblage including a cold plate, in which a compressible fuzz button holder is used;
FIG. 8 is a simplified perspective or isometric view, exploded to reveal certain details, of the assemblage of FIG. 7;
FIG. 9a is a simplified perspective or isometric view of a short-circuited transmission line according to an aspect of the invention,
FIG. 9b is a side or elevation view of the transmission line of FIG. 9a,
FIG. 9c illustrates the arrangement of FIG. 9a in encapsulated form, and
FIG. 9d is a side elevation of the encapsulated structure of FIG. 9c;
FIG. 10a illustrates the result of certain fabrication steps corresponding to the steps of FIGS. 4a, 4b, 4c, and 4d applied to the short-circuited transmission line of FIGS. 9c and 9d, and
FIG. 10b illustrates the result of further fabrication steps applied to the structure of FIG. 10a;
FIG. 11 illustrates a short-circuited multiple transmission line which may be encapsulated as described in conjunction with FIGS. 9c or 9d, and used for interconnecting planar circuit arrangements at frequencies somewhat lower than the higher RF frequencies, such as the clock frequencies of logic circuits;
FIG. 12 is a perspective or isometric view of a structure according to an aspect of the invention, including a planar plastic HDI circuit, a bipartite separator plate, and a second planar circuit, some of which are cut away to reveal interior details;
FIG. 13 is an exploded view of the structure of FIG. 12, showing the planar plastic HDI circuit associated with one portion of the separator plate as one part, the second portion of the separator plate, and the second planar circuit as other parts of the exploded structure;
FIG. 14 is an exploded view of a portion of the second part of the separator plate, showing rigid and compliant transmission lines, and other structure; and
FIG. 15 is a more detailed cross-sectional view of the structure of FIG. 12.
DESCRIPTION OF THE INVENTION
In FIGS. 3a 3b, and 3c, a short transmission line or "molded coaxial interconnect" 310 is in the form of a flat disk or right circular cylinder 311 having a thickness 312 and an outer diameter 314 centered about an axis 308. Thickness 312 should not exceed diameter 314. An electrically conductive center conductor 316 is in the form of a right circular cylinder defining a central axis which is concentric with axis 308. A set 318 of a plurality, in this case eight, of further electrical conductors 318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h, are also in the form of right circular cylinders, with axes which lie parallel with the axis 308 of the flat disk. The further electrical conductors have their axes equally spaced by an incremental angle of 45° on a circle of diameter 320, also centered on axis 308. The main body of short transmission line 310 is made from a dielectric material, which encapsulates the sides, but not the ends, of center conductor 316 and outer conductors 318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h. The diameter of circle 320 on which the axes of the outer conductors lie is selected so that the outer conductors lie completely within the outer periphery of the dielectric disk. A first end of the center conductor and the outer conductors lies adjacent a plane 301, and a second end of each lies adjacent to a second plane 302. In a particular embodiment of the short transmission line, the thickness 312 is 0.055 in., and the diameter is 0.304 in. In another embodiment, the diameter is the same, but the thickness is 0.115 in. In both embodiments, the axes of the outer conductors of set 308 are centered on a circle of diameter 0.192 in., and the conductors have diameters of 0.032 in. The material of the dielectric disk is Plaskon SMT-B-1 molding compound, and the conductors are copper. As described below, these short transmission lines are used for interconnecting RF circuits. The characteristic impedance of the short transmission line of FIGS. 3a, 3b, and 3c is selected to substantially match the impedances of the signal source and sink, or to substantially match the impedances of the stripline or microstrip transmission lines to which the short transmission line is connected in an HDI circuit. The impedance Z 0 of the short transmission line is determined by ##EQU1## where ε is the dielectric constant of the dielectric disk;
D 0 is the diameter of the inside surface of the outer conductor; and
D i is the outer diameter of the center conductor. To produce a 50-ohm characteristic impedance, with center conductor wire diameter of 0.032" and epoxy encapsulation material having a dielectric constant of 3.7, the axes of the outer conductors should be on a circle having a diameter of 0.192 inches.
FIGS. 4a, 4b, 4c, 4d, 4e, 4f, and 4h illustrate steps in the fabrication of an RF HDI structure. In a step preceding that illustrated in FIG. 4a, one or more short transmission lines 310 are fabricated, and monolithic RF circuits 14 are assembled with heat-transferring metal deep-reach shims 18. In FIG. 4a, the chip/shim assemblages 14/18 and the short transmission lines 310 are mounted face-down onto an adhesive backed KAPTON substrate 410. FIG. 4b illustrates the encapsulation of the assemblages 14/18 and the short transmission line 310 within an epoxy or other encapsulation to form a structure with encapsulated chips and transmission-lines. The structure of FIG. 4b with encapsulated chips and transmission lines then continues through conventional HDI processing. As illustrated in FIG. 4c, vias are laser-drilled to die bond pads 14 1 and 14 2 and to the conductors of the short transmission line 310 which are against the substrate 410. Conductive traces are then patterned on the exposed substrate 410, making the necessary electrical connections. FIG. 4d illustrates the result of applying a plurality (illustrated as three) of layers of conductive-trace bearing flexible HDI connection material designated together as 424, with the traces appropriately registered with the connections 14 1 and 14 2 of the chips 14, and with the center conductor 316 and the set 318 of outer conductors of the short transmission line 310.
Following the step illustrated in FIG. 4c, plated through-vias 36 are formed in the conductive-trace bearing flexible HDI connection material 424, with the result that the chip connections are made, and the connections to the short transmission line 18 are made as illustrated in FIG. 4e. The metallization layers 32 connect the short transmission line to at least one of the chips 14, so that one connection of a chip connects to center conductor 316 of short transmission line 310 of FIG. 4e, and so that a ground conductor associated with the chip connects to the set 318 of outer conductors of the short transmission line. FIGS. 4f represents the cutting off of that portion of the encapsulated structure (the structure of FIG. 4e) which lies, in FIG. 4f, above a dash line 426. This produces a planar structure 401, illustrated in FIG. 4g, in which the connections among the chips 14, and between the chips and one end of the short transmission lines, lie within the conductive-trace layers 424 on the "bottom" of the encapsulated structure, and in which a heat interface end 18 hi of each of the heat-conducting shims 18, and the ends of the center conductor 316 and of the set 318 of outer conductors of a coaxial connection structure 490 at the end of the short transmission line, are exposed on the "upper" side of the structure as contacts. The center conductor contact is illustrated as 316 c , and some of the outer conductor contacts are designated as 318a c and 318f c .
FIG. 4h illustrates a cross-section of a structure resulting from a further step following the step illustrated in conjunction with FIGS. 4f and 4g. More particularly, the structure of FIG. 4g is attached to an RF manifold or beamformer 430, which distributes the signals which are to be radiated by the active array antenna. The surface 430s of manifold 430 which is adjacent to the encapsulated structure bears conductive traces, some of which are designated 432. In order to make contact between the conductive traces 432 on the RF distribution manifold and the exposed ends of the center conductor 316 and the set 318 of outer conductors of the short transmission line, compressible electrical conductors 450, termed "fuzz buttons," are placed between the conductive traces 432 on the distribution manifold 430 and the exposed ends of the center conductor 316 and set 318 of outer conductors of each of the short transmission lines 310. The manifold 430 is then pressed against the remainder of the structure, with the fuzz buttons between, which compresses the fuzz buttons to make good electrical connection to the adjacent surfaces, and which also tends to hold the fuzz buttons in place due to compression. Appropriate thermal connection must also be made between the manifold and the shims 18 to aid in carrying away heat. Thus, in the arrangement of FIGS. 4a-4h, electrical RF signals are distributed to the ports (only one illustrated) of the distribution manifold 430 to a plurality of the ports (only one of which is illustrated) represented by short transmission lines 310 of planar circuit 401 of FIG. 4g, and the signals are coupled through the short transmission lines to appropriate ones of the metallization layers 32 0 , 32 1 , and 32 2 , as may be required to carry the signals to the MMIC for amplification or other processing, and the signals processed by the MMIC are then passed through the signal paths defined by the paths defined by conductive traces 32 0 , 32 1 , and 32 2 to that layer of conductive traces which is most remote from the distribution manifold 430. More particularly, when the distribution manifold 430 is in the illustrated position relative to the encapsulated pieces, the uppermost layer 32 2 of conductive traces may itself define the antenna elements. Thus, the structure 400 defined in FIG. 4h, together with other portions which appear in other ones of FIGS. 4a-4g, comprises the distribution, signal processing, and radiating portions of a planar or flat active array antenna.
The fuzz buttons 450 of FIG. 4h may be part no. 3300050, manufactured by TECKNIT, whose address is 129 Dermodry Street, Cranford, N.J. 07016, phone (908) 272-5500.
If the conductors 32 2 of metallization layer MT2 of FIG. 4h are elemental antenna elements, the RF manifold 430 can be a feed distribution arrangement which establishes some measure of control over the distribution of signals to the active MMICs of the various antenna elements. On the other hand, the structure of FIG. 4h denominated as RF manifold 430 could instead be an antenna array, with the elemental antennas on side 430p, while the metallization layers 32 1 and 32 2 would in that case distribute the signals to be radiated, or collect the received signals. Thus, the described structure is simply a connection arrangement between two separated planar distribution sets.
It will be noted that in FIG. 4h, the region 460 about the fuzz buttons 450 is surrounded by air dielectric, which has a dielectric constant of approximately 1. Since the fuzz buttons 450 have roughly the same diameter as the center conductor 316 and the outer conductors 318, the characteristic impedance of the section 460 of transmission line extending from exposed traces 432 to short transmission line 310 is larger than that of the short transmission line. If the short transmission line has a characteristic impedance of about 50 ohms, the characteristic impedance of the region 460 will be greater than 50 ohms. Those skilled in the art know that such a change of impedance has the effect of interposing an effective inductance into the transmission path, and may be undesirable.
FIG. 5 represents a structure such as that of FIG. 4h with a cold plate 510 interposed between the HDI-connected chips 10 on structure 12 and the beamformer 430. The cold plate 510 has an interface surface 510is which makes contact with the adjacent surface of the plastic body 12 of the HDI circuit 10. The cold plate may be, as known in the art, a metal plate with fluid coolant channels or tubes located within, for carrying heat from heat interface surfaces 18 hi to a heat rejection location (not illustrated). Those skilled in the art know that a heat conductive grease or other material may be required at the interface. As illustrated in FIG. 5, a fuzz button housing 512 has a thickness about equal to that of the cold plate, for holding fuzz buttons 450 in a coaxial pattern similar to that of center conductor 316 and outer conductors 318, for making connections between the center conductor 316/outer conductors 318 and the corresponding metallizations 432 of the beamformer 430. More particularly, the outer conductors 318 and the outer conductor fuzz buttons 450 lie on a circle with diameter d192. The dielectric constant of the material of fuzz button housing 512 is selected to provide the selected characteristic impedance. As also illustrated in FIG. 5, fuzz button housing 512 is not quite as large in diameter as the cut-out or aperture in cold plate 510, in order to take tolerance build-up. Consequently, an air-dielectric gap 512 g1 exists around fuzz button housing 512. The axial length of fuzz button housing 512 is similarly not quite as great as the thickness of the cold plate 510, resulting in a gap 512 g2 . Gaps 512 g1 and 512 g2 have an effect on the characteristic impedance of the transmission path provided by the fuzz buttons 450 which is similar to the effect of the air gap 460 of FIG. 4h. In an analysis of an arrangement similar to that of FIG. 5, the calculated through loss was 0.8 dB, and the return loss was only 10.5 dB.
The fuzz button housing or holder 512 is made from an elastomeric material, which compresses when compressed between the HDI-connected chips 10 and the underlying beamformer 430, so as to eliminate air gaps which might adversely affect the transmission path. FIGS. 6a, 6b, and 6c are views of a compressible or compliant RF interconnect with fuzz button conductors. In FIGS. 6a, 6b, and 6c, elements corresponding to those of FIGS. 3a, 3b, and 3c are designated by like reference numerals, but in the 600 series rather than in the 300 series. As illustrated in FIGS. 6a, 6b, and 6c, compliant RF interconnect 610 includes a fuzz button center conductor 616 defining an axis 608, and a set 618 including a plurality, illustrated as eight, of fuzz button outer conductors 618a, 618b, 618c, 618d, 618e, 618f, 618g, and 618h, spaced at equal angular increments, which in the case of eight outer conductor elements corresponds to 45°, about center axis 608, on a radius 620 having a diameter of 0.200". Dielectric body 611 has an outer periphery 611p, and is made from a silicone elastomer having a dielectric constant within the range of 2.7 to 2.9, and has an overall diameter 614 of about 0.36", and a thickness 612 of 0.10". As can be best seen in FIGS. 6a and 6c, the dielectric body 611 has two keying notches 650a and 650b. Dielectric body 611 also has a flanged inner portion 648 with a diameter of 0.30", and the maximum-diameter portion 652 has a thickness 654 of about 0.44". The fuzz buttons 616, 618 have a length 613 in the axial direction which is slightly greater (0.115" in the embodiment) than the axial dimension 612 of body 611 (0.10"). FIG. 6d illustrates a representative one of the outer conductor fuzz buttons, which is selected to be fuzz button 618f for definiteness. In FIG. 6d, outer conductor fuzz button 618f is in the form of a right circular cylinder centered on an axis 617, and defines first and second ends 618f 1 and 618f 2 which are coincident with planes 601 and 602, respectively, of FIG. 6b. The cylindrical form of fuzz button 618f of FIG. 6d defines an outer surface 618 fs lying between the first and second ends 618f 1 and 618f 2 .
FIG. 7 is similar to FIG. 5, and corresponding elements are designated by the same reference numerals. In FIG. 7, the compliant RF interconnect 610 is compressed between the broad surface 430 fs of beamformer manifold 430 and the broad surface 712 ls of HDI-connected chip arrangement 10, and is somewhat compressed axially, to thereby eliminate the gap 512 g2 which appears in FIG. 5. This, in turn, eliminates the principal portion of the impedance discontinuity at the interface which is filled by the compliant RF interconnect 610. The axial compression of the dielectric body 611 of the compliant RF interconnect 610, in turn, tends to cause the compliant body 611 to expand radially, to thereby somewhat fill the circumferential or annular gap 512 g1 , which further tends to reduce impedance discontinuities at the interface. A further advantage of the axial compression of body 611 is that the compression tends to compress the body 611 around the fuzz button conductors 616, 618, to help in holding them in place. Analysis of the arrangement of FIG. 7 indicated that the through loss would be 0.3 dB and the return loss 28 dB, which is much better than the values of 0.8 dB and 10.5 dB calculated for the arrangement of FIG. 5.
As illustrated in FIG. 7, a heat-transfer interface surface 18 hi on the broad surface 712 ls of HDI-connected chip structure 10 is pressed against cold plate 510.
In the view of FIG. 7, the fuzz button conductors 616 and 618 of the compliant coaxial interconnect 610 are illustrated as being of a different diameter than the conductors 316, 318 of the molded coaxial interconnect 310, and the outer conductors 618 are centered on a circle of somewhat different diameter than the outer conductors 318. The difference in diameter of the wires and the spacing of the outer conductor from the axis of the center conductor is attributable to differences in the dielectric constant of the epoxy which is used as the dielectric material in the molded coaxial interconnect 310 and the silicone material which is the dielectric material of compliant interconnect 610. In order to minimize reflection losses, both interconnects are maintained near 50 ohms, which requires slightly different dimensioning. This should not be a problem, so long as the diameters of the circles on which the outer conductors of the molded and compliant interconnects are centered allow an overlap of the conductive material, so that contact is made at the interface.
A method for making electrical connections as described in conjunction with FIGS. 6a, 6b, 6c, 7, and 8 includes the step of providing or procuring a first planar circuit 10 including at least a first broad surface 712 ls . The first broad surface 712 ls of the first planar circuit 10 includes at least one region 490 defining a first coaxial connection. It may also include at least a first thermally conductive region 18 hi to which heat flows from an active device within the first planar circuit. The first coaxial connection 490 of the first planar circuit 10 defines a center conductor contact 616 c centered on a first axis 608 orthogonal to the first broad surface of the first planar circuit 10, and also defines a first plurality of outer conductor contacts, such as 618a c and 618f c . Each of the outer conductor contacts such as 618a c , 618f c of the first coaxial connection 490 of the first planar circuit 10 is centered and equally spaced on a circle spaced by a first particular radius, equal to half of diameter dl92, from the first axis 608 of the center conductor contact 616 of the first coaxial connection 490. The first broad surface 712 ls of the first planar circuit 10 further includes dielectric material electrically isolating the center conductor contact 616 c of the first planar circuit 10 from the outer conductor contacts, such as 618a c , 618f c , and the outer conductor contacts, such as 618a c , 618f c , from each other. The method also includes the step of providing a second planar circuit 430, which includes at least a first broad surface 430 fs . The first broad surface 430 fs of the second planar circuit 430 includes at least one region 431 defining a coaxial connection. The coaxial connection 431 of the second planar circuit 430 includes a center conductor contact 432 c centered on a second axis 808 orthogonal to the first broad surface 430 fs of the second planar circuit 430, and also includes the first plurality (eight) of outer conductor contacts 432 o . Each of the outer conductor contacts, such as 432 co , 432 o , of the coaxial connection 431 of the second planar circuit 430 is centered and equally spaced on a circle spaced by a second particular radius, close in value to the first particular radius, from second axis 808 of the center conductor contact 432 c of the coaxial connector 431 of the second planar circuit 430. The first broad surface 430 fs of the second planar circuit 430 further includes dielectric material electrically isolating the center conductor contact 432 c of the second planar circuit 430 from the outer conductor contacts, such as 432 co , 432 o of the second planar circuit 430, and the outer conductor contacts, such as 432 co , 432 o of the second planar circuit 430, from each other. A compliant coaxial connector 610 is provided, which includes (a) a center conductor 616 which is electrically conductive and physically compliant, at least in the axial direction. The compliant center conductor 616 has the form of a circular cylinder centered about a third axis 608, and defines an axial length 613 between first 617 f1 and second 617 f2 ends. The compliant coaxial connector 610 also includes (b) an outer electrical conductor arrangement 618 including a set 618 including the first plurality (eight) of mutually identical, electrically conductive, physically compliant outer conductors 618a, 618b, 618c, 618d, 618e, 618f, 618g, and 618h. Each of the compliant outer conductors 618a, 618b, 618c, 618d, 618e, 618f, 618g, and 618h is in the form of a circular cylinder centered about an axis 617, and each has an axial length 613 between first 617 f1 and second 617 f2 ends which is equal to the axial length 613 of the compliant center conductor 616. The axes 617 of the compliant outer conductors 618a, 618b, 618c, 618d, 618e, 618f, 618g, and 618h are oriented parallel with each other, and with the third axis 608 of the compliant center conductor 616. The first ends 617 f1 of the compliant center conductor 616 and the compliant outer conductors 618a, 618b, 618c, 618d, 618e, 618f, 618g, and 618h coincide with a first plane 601 which is orthogonal to the axes 608, 617 of the compliant center conductor 616 and the compliant outer conductors 618a, 618b, 618c, 618d, 618e, 618f, 618g, and 618h, and the second ends 617 f2 of the compliant center conductor 616 and the compliant outer conductors 618a, 618b, 618c, 618d, 618e, 618f, 618g, and 618h coincide with a second plane 602 parallel with the first plane 601. The compliant outer conductors 618a, 618b, 618c, 618d, 618e, 618f, 618g, and 618h have their axes 617 equally spaced from each other at the particular radius from the axis 608 of the compliant center conductor 616. The compliant coaxial connector 610 further includes (c) a compliant dielectric disk-like structure 611 defining a fourth center axis 608 coincident with the third axis 608 of the compliant center conductor 616 and also defining an uncompressed axial length no more than about 10% greater than the uncompressed axial length of the compliant center conductor 616. The compliant disk-like structure 611 also defines a periphery 611p spaced from the center axis 608 by a second radius which is greater than both (a) the first radius (half of diameter 620) and (b) the axial length 613 of the compliant center conductor 616. The compliant dielectric disk 611 surrounds and supports the compliant center conductor 616 and the compliant outer conductors 618a, 618b, 618c, 618d, 618e, 618f, 618g, and 618h at least on side regions 618 fs thereof lying between the first 618 f1 and second 618 f2 ends of the compliant center conductor 616 and the compliant outer conductors 618a, 618b, 618c, 618d, 618e, 618f, 618g, and 618h. The compliant dielectric disk-like structure 611 does not overlie the first 618 f1 ends of the compliant center conductor 616 and the compliant outer conductors 618a, 618b, 618c, 618d, 618e, 618f, 618g, and 618h, so that electrical connection thereto can be easily established.
The method described in conjunction with FIGS. 6a, 6b, 6c, 7, and 8 also includes the further step of placing the first broad surfaces 712 ls , 430 fs of the first and second planar circuits 10, 430 mutually parallel, with the first axis 8 passing through the center of the center conductor contact 316c of the first planar circuit 10 and orthogonal to the first broad surface 712 ls of the first planar circuit 10, and coaxial with the second axis 808 passing through the center of the center conductor contact 432 c of the second planar circuit 430 orthogonal to the first broad surface 430 ls of the second planar circuit 430, with the first and second planar circuits 10, 430 rotationally oriented around the coaxial first and second axes 8, 808 so that a fourth axis 880 orthogonal to the first broad side 712 ls of the first planar circuit 10 and passing through the center of one of the outer conductor contacts 318 cc of the first coaxial connector 431 of the first planar circuit 10 is coaxial with a fifth axis 882 orthogonal to the first broad side 430 fs of the second planar circuit 430 and passing through the center of one of the outer conductor contacts 432 cc of the first coaxial connector 431 of the second planar circuit 430. The compliant coaxial connector 310 is placed between the first and second planar circuits 10, 430, with the third axis 608 of the compliant center conductor 616 substantially coaxial with the mutually coaxial first and second axes 8, 808. The compliant coaxial connector 610 is oriented so that a sixth axis 884 of one of the compliant outer conductors 618a, 618b, 618c, 618d, 618e, 618f, 618g, and 618h is coaxial with the mutually coaxial fourth and fifth axes 880, 882. Force is applied to translate the first and second planar circuits 10, 430 toward each other until the compliant coaxial connector 610 is compressed between the first broad surface 712 ls of the first planar circuit 10 and the first broad surface 430 fs of the second planar circuit 430 sufficiently to make contact between the center conductor contacts 316 c , 432 c of the first and second planar circuits 10, 430 through the compliant center conductor 616, and to make contact between outer conductor contacts 318a c , 318f c of the first planar circuit and corresponding outer conductor contacts 432 ac , 432f c of the second planar circuit 430 through some of the compliant outer conductors 618.
In a particular version of the method described in conjunction with FIGS. 6a, 6b, 6c, 7, and 8 also includes the further step of procuring a first planar circuit 10 in which the first broad surface 712 ls includes a first thermally conductive region 18 hi to which heat flows from an active device within the first planar circuit. In this version of the method, before the step of applying force to translate the first and second planar circuits 10, 430 toward each other, a planar spacer or cold plate 510 is interposed between the first broad surface 712 ls of the first planar circuit 10 and the first broad surface 430 fs of the second planar circuit 430. In this method, the step of interposing a planar cold plate 510 between the first broad surfaces 712 ls , 430 fs comprises the step of interposing a planar cold plate 510 having an aperture 810 with internal dimensions no smaller than twice the second radius of the compliant dielectric disk-like structure 610, with the outer periphery of the aperture 810 surrounding the compliant coaxial connector 610.
FIG. 9a is a simplified perspective or isometric view of a short monolithic (one-piece without joints) conductive short-circuited transmission line or RF interconnect 900 according to an aspect of the invention, FIG. 9b is a side or elevation view of the transmission line of FIG. 9a, and FIGS. 9c and 9d illustrate the arrangement of FIG. 9a in encapsulated form. In FIGS. 9a and 9b, the short-circuited transmission line or RF interconnect 900 has an air dielectric, and is made by machining from a block, or preferably by casting. Transmission line 900 includes a center conductor 916 centered on an axis 908, and having a circular cross-section. Center conductor 916 ends at a plane 903 in a flat circular end 916e, and each of the outer conductors 918a, 918b, 918c, 918d, 918e, 918f, and 918h also has a corresponding flat circular end 918ae, 918be, 918ce, 918de, 918ee, 918fe, and 918he. The cross-sectional diameters of the center conductor 916 and the outer conductors 918a, 918b, 918c, 918d, 918e, 918f, and 918h taper from a relatively small diameter d 1 of the circular ends at plane 903 to a larger diameter d 2 at a second plane 902. At (or immediately adjacent to) plane 902, a short-circuiting plate 907 interconnects the ends of the center conductor 916 and the outer conductors 918a, 918b, 918c, 918d, 918e, 918f, and 918h which are remote from plane 903. In FIGS. 9a and 9b, the axes of outer conductors 918a, 918b, 918c, 918d, 918e, 918f, and 918h, only one of which is illustrated and designated 918aa, lie on a circle illustrated as a dash line 921, which lies at a radius 920 from axis 908 of center conductor 916. The periphery lip of short-circuiting plate 907 is illustrated as being circular, with a diameter or radius measured from axis 908 which is just large enough so that the outer edges of the various outer conductors of set 918 are coincident or tangent with periphery llp at plane 902.
While not the best mode of using the short-circuited transmission line of FIGS. 9a and 9b, FIGS. 9c and 9d illustrate the short-circuited transmission line 900 of FIGS. 9a and 9b encapsulated in a cylindrical body 911 of dielectric material corresponding to the dielectric body 311 of FIG. 3, to form an encapsulated short-circuited transmission line 901. As illustrated in FIG. 9c, the encapsulating body 911 does not cover the ends 916e and 918ae, 918be, 918ce, 918de, 918ee, 918fe, and 918he of the center and outer conductors, thereby making them available for connections. As also illustrated in FIG. 9c, the diameter of dielectric body 911 of encapsulated short-circuited transmission line 901 is the same as the diameter 914 of the short-circuiting plate 907, so the side of the short-circuiting plate 907 is exposed. The diameter of the dielectric encapsulating body could be greater than diameter 914 of the short-circuiting plate 907, in which case the plate 907 would not be visible in FIG. 9c.
With the unencapsulated short-circuited transmission-line 900 made as described in conjunction with FIGS. 9a, 9b, or with the encapsulated short-circuited transmission line 901 made as described in conjunction with FIGS. 9a, 9b, 9c, and 9d, the unencapsulated (900) or encapsulated transmission line (901) can then be made a part of a planar circuit. The unencapsulated short-circuited transmission line 900 of FIGS. 9a and 9b, or the encapsulated transmission line 901, is placed on a substrate 410 as illustrated for circuit 310 in FIG. 4a, with its exposed conductor ends 916e, 918ae, 918be, 918ce, 918de, 918ee, 918fe, and 918he adjacent substrate 410. The steps of FIGS. 4b, 4c, and 4d are followed.
FIG. 10a is a simplified representation of the result of applying the steps of FIGS. 4a, 4b, 4c, and 4d to the encapsulated transmission line 901 of FIGS. 9a, 9b, and 9c. In FIG. 10a, elements corresponding to those of FIG. 4e are designated by like reference numerals, and elements corresponding to those of FIGS. 9a, 9b, 9c, and 9d are designated by like reference numerals. As illustrated in FIG. 10a, the planar circuit structure 1000, which may be an antenna array, has the location of the short-circuiting plate 907 below the parting plane 426 at which a cut is made to expose a newly formed end 1016e of the tapered center conductor and to also expose newly formed ends of the set of outer conductors 918, respectively. As illustrated in FIG. 10a, the parting plane lies between planes 903 and 902 associated with the RF interconnect 900. FIG. 10b is a simplified cross-section of a structure generally similar to that of FIG. 4h, in which the structure of FIG. 10a is the starting point; elements of FIG. 10b corresponding to those of FIG. 10a are designated by like reference numerals, and elements corresponding to those of FIG. 4h are designated by like reference numerals. It will be apparent to those skilled in the art that the structure of FIG. 10B is equivalent to that of FIG. 4h, with the sole difference lying in the tapered diameter of the center conductor 916 and of the outer conductors represented by 918b and 918f between the small ends 916e and newly formed large ends 1018be and 1018fe, respectively. This taper may change the characteristic impedance somewhat between the ends of the RF interconnect, but this effect is mitigated by the relatively small taper, and because the axial length of the RF interconnect is selected to be relatively short in terms of wavelength at the highest frequency of operation. Naturally, if one or more unencapsulated short-circuited transmission lines 900 are used to make the planar circuit according to the method described in conjunction with FIGS. 4a, 4b, 4c, 4d, 10a, and 10b, the dielectric constant of the encapsulant material of the transmission line is the same as that of the planar circuit itself. If an encapsulated transmission line such as 901 is used to make the planar circuit of FIG. 10b, it is desirable that the encapsulating materials be identical.
FIG. 11 illustrates a monolithic electrically conductive structure which forms multiple short-circuited transmission paths, each consisting of at least one conductor paired with another; as known to those skilled in the art, one of the pair may be common with other circuit paths, and may be used at somewhat lower frequencies than the coaxial structures, down to zero frequency. In FIG. 11, the multiple short-circuited transmission paths take the form of a monolithic electrically conductive structure 1110, including a baseplate 1112 and a plurality, eleven in number, of tapered pins or posts 1114a, 1114b, 1114c, 1114d, 1114e, 1114f, 1114g, 1114h, 1114i, 1114j, and 1114k. The short-circuited multiple transmission-line structure is used instead of the coaxial arrangement 900 in the method described in conjunction with FIGS. 4a, 4b, 4c, 4d, 10a, and 10b, to make a planar structure. Those skilled in the art know that antenna array/beamformer combinations require not only connection of RF signals, but also require transmission between elements of power and control signals, which can be handled by the structure made with the multiple transmission paths of FIG. 11.
FIGS. 12, 13, 14, and 15 illustrate a planar plastic HDI circuit 10 similar to those described in conjunction with FIGS. 3a, 3b, 3c, 4a, 4b, 4c, 4d, 4e, 4f, and 4g. More particularly, planar plastic HDI circuit 10 includes a molded interconnect 310 such as that described in conjunction with FIGS. 3a, 3b, and 3c, assembled to the substrate 12 as described in conjunction with FIGS. 4a, 4b, 4c, 4d, 4e, 4f, and 4g. The planar plastic HDI circuit 10 is mounted on a stiffening plate 510a, which is part of a bipartite separation plate 510. First portion 510a of the bipartite separation plate 510 has an aperture 810 formed therein to accommodate the flanged disk-like body of compliant interconnect 610, with the fuzz-button conductors 616, 618 of the compliant interconnect registered with the conductors of molded interconnect 310 so as to be in contact therewith.
Second portion 510b of separation plate 510 of FIGS. 12, 13, 14, and 15 has a through aperture 1312 including a cylindrical portion, and also including a recess 1214 2 adjacent side 1310b of second portion 510b of separation plate 510, which recess accommodates a hold-down flange 1214. Through aperture 1312 also includes a lip or flange 1314 adjacent side 1310c, which aids in holding the body of a rigid coaxial transmission line 1210 in place. Rigid coaxial transmission line 1210 is similar to molded interconnect 310, but may be longer, so as to be able to carry signals through the first and second portions of the separation plate 510. Aperture 1312 also defines a key receptacle 1316 which accepts a key 1212 protruding from the body of rigid transmission line 1210. The number of conductors of rigid transmission line 1210 is selected, and the conductors are oriented about the longitudinal axis of the rigid transmission line, in such a manner as, when keyed into the aperture 1312 in separation plate 510, the conductors each match and make contact with corresponding conductors of compliant interconnects 610a and 610b. Compliant interconnect 610a is compressed between molded interconnect 310 and rigid coaxial transmission line 1210, and is oriented to make the appropriate connections between the center fuzz button 616 of molded interconnect 610a and the center conductor 1210c, and between the outer fuzz buttons 618 of molded interconnect 610a and the outer conductors, one of which is designated 1210o, of the rigid transmission line 1210.
Molded interconnect 610b of FIGS. 12, 13, 14, and 15 is compressed between a surface 1210s of rigid transmission line 1210 and face 430s of second circuit 430, and, when the second circuit 430 is registered with separation plate 510, the center and outer metallizations 1332 and 1334, respectively, of its coaxial port 1331 are registered with the corresponding center fuzz button 616 and outer fuzz buttons 618 of compliant interconnect 610b. The second compliant interconnect 610b is held in place by flange 1214, which in turn is held down by screws 1216a and 1216b in threaded apertures 1218a and 1218b, respectively.
It will be clear from FIGS. 12, 13, 14, and 15 that when the center axis 308 of the center-conductor connection 316c of port 490 of the HDI circuit 10 are coaxial with the axis 1308 of the center-conductor connection 1332 of the port 1331 of the beamformer or second circuit 430, and with the axes 1408, 1210cca, and 1432ca of the center conductors of the first compliant interconnect 610a, the rigid transmission line 1210, and the second compliant interconnect 610b, and the compliant interconnects are of sufficient length, an electrically continuous path will be made between the two center conductor contacts. Similarly, with the center conductors and center conductor contacts coaxial, all that is required to guarantee that the outer conductors make corresponding contact is that they have the same number and be equally spaced about the center conductors, and that one of the outer conductors or outer conductor contacts in each piece lie in a common plane with the common axes of the center conductors. When any one of the eight outer conductors or contacts of any one of the interconnection elements is aligned with the corresponding others, all of the outer conductors or outer conductor contacts is also aligned with its corresponding elements.
In the particular embodiment of the invention illustrated in FIGS. 12, 13, 14, and 15, the separation plate 510 consists of a stiffener plate 510a which is adhesively or otherwise held to the otherwise flexible plastic HDI circuit 12, and the second portion 510b of separator plate 510 is a cold plate, which includes interior chambers (not illustrated) into which chilled water or other coolant may be introduced by pipes illustrated as 1230a and 1230b. In a particular embodiment of the invention, the planar plastic HDI circuit (only a portion illustrated) defines an antenna array, and the MMIC (not illustrated in FIGS. 12, 13, 14, and 15) associated with the planar plastic HDI circuit include chips operated as active amplifiers for the antenna elements. The second circuit 430 is part of a beamformer which supplies signals to, and receives signals from, the MMIC associated with the planar plastic HDI circuit 12.
Other embodiments of the invention will be apparent to those skilled in the art. For example, while the described flat antenna structure lies in a plane, it may be curved to conform to the outer contour of a vehicle such as an airplane, so that the flat antenna structure takes on a three-dimensional curvature. It should be understood that an active antenna array may, for cost or other reasons, define element locations which are not filled by actual antenna elements, such an array is termed "thinned." The term "RF" has been used to indicate frequencies which may make use of the desirable characteristics of coaxial transmission lines; this term is meant to include all frequencies, ranging from a few hundred kHz to at least the lower infrared frequencies, about 10 13 Hz., or even higher if the physical structures can be made sufficiently exactly. While the short transmission line illustrated in FIGS. 3a, 3b, and 3c has eight outer conductors, the number may greater or lesser. The dielectric constant of the dielectric conductor holder of the short transmission lines is selected to provide the proper impedance, whereas the specified ranges are suitable for 50 ohms. While the cold plate has been described as being for carrying away heat generated by chips in the first planar circuit 10, it will also carry away heat from the distribution beamformer. While the diameters of the center and outer conductors have been illustrated as being equal, the center conductor may have a different diameter or taper than the outer conductors, and the outer conductors may even have different diameters among themselves.
Thus, an aspect of the invention lies in a short electrical transmission-line (310) which includes a center electrical conductor (316) having the form of a circular cylinder centered about an axis (308). The circular cylinder of the center conductor (316) defines an axial length (312) between first (plane 301) and second (plane 302) ends of the center conductor (316). An outer electrical conductor arrangement (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) comprises a plurality of mutually identical electrical outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h), each being in the form of a circular cylinder centered about an axis, and each having an axial length between first (plane 301) and second (plane 302) ends which is equal to the axial length of the center conductor (316). The axes of the outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) are oriented parallel with each other and with the axis (308) of the center conductor (316). The first ends of the center and outer conductors are coincident with a first plane (301) which is orthogonal to the axes of the center (316) and outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h), and the second ends of the center (316) and outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) are coincident with a second plane (302) parallel with the first plane. The outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) have their axes equally spaced from each other at a first radius (320) from the axis (308) of the center conductor (316). The short electrical transmission-line (310) also includes a rigid dielectric disk (311) defining a center axis and an axial length (312) no greater than the axial length of the center conductor (316). The rigid dielectric disk (311) also defines a periphery spaced from the center axis by a second radius (314) which is greater than either (a) the first radius or (b) the axial length of the center conductor (316). The dielectric disk encapsulates, or (311) surrounds and supports the center (316) and outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) on side regions thereof lying between the first and second ends of the center (316) and outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, for holding the center (316) and outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) in place. However, the dielectric disk (311) does not overlie the first ends (the ends coincident with plane 301) of the center (316) and outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h).
In a more particular embodiment, the center conductor (316) defines a diameter (d), and the outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) each have the same diameter. More particularly, the material of the center (316) and outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) comprises at least a copper interior, and the material of the dielectric disk (311) is epoxy resin.
A method, according to an aspect of the invention, for producing a flat connection assembly (400) includes the step of affixing a plurality of microwave integrated-circuit chips (14) to a support (410), with connections of the chips (14) adjacent to the support (410). A plurality of short electrical transmission-lines (310) are made or generated. Each of the short electrical transmission-lines (310) is similar to that described immediately above. A plurality of the short transmission-lines (310) are applied to the support (410), with the first ends of the conductors adjacent the support (410). The chips (14) and the short transmission-lines (310) are encapsulated in rigid dielectric material, to thereby produce encapsulated chips and transmission-lines (FIG. 4b). The support (410) is removed from the encapsulated chips and transmission-lines (FIG. 4b), to thereby expose a first side (411) of the encapsulated chips and transmission-lines (FIG. 4b), and at least the connections (14 1 , 14 2 ) of the chips (14) and the first ends (adjacent plane 301) of the center (316) and outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) of the short transmission-lines (310). At least one layer (424) of flexible dielectric sheet carrying a plurality of electrically conductive traces (32 1 , 32 2 ) is applied to the first side of the encapsulated chips and transmission-lines (FIG. 4b). The flexible dielectric sheet (424) interconnects, by way of some of the traces (32 1 , 32 2 ) and by through vias (36), at least one of the connections (14 1 , 14 2 ) of at least one of the chips (14) with the first end of the center conductor (316) of one of the transmission-lines (310), and at least one other of the connections (14 1 , 14 2 ) of the one of the chips (14) to the first ends of all of the outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) of the one of the transmission-lines (310), to thereby produce a first-side-connected encapsulated arrangement (FIG. 4e). So much material is removed from that side (413) of the first-side-connected encapsulated arrangement (FIG. 4e) which is remote from the first side (411) as will expose second ends (316 2 ; 318 2 ) of the center (316) and outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) of the transmission-lines (310), to thereby produce a first planar arrangement (401 of FIG. 4h) having exposed second ends (316 2 ; 318 2 ) of the center (316) and outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) of the transmission-lines (310). A planar conductor arrangement (430) is applied over the first planar arrangement (401), and adjacent that side (426) of the first planar arrangement (401) which has the exposed second ends (316 2 ; 318 2 ) of the center (316) and outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h). The planar conductor arrangement (430) includes a plurality of individual electrical connections (432) which, when the planar conductor arrangement (430) is registered with the first planar arrangement (430), are registered with the ends of the center (316) and outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) of the transmission-lines (310). The planar conductor arrangement (430) is registered with the first planar arrangement (401), and electrical connections (450) are made between the second ends of the center (316) and outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) of the transmission lines (310) of the first planar arrangement (401) and the individual electrical connections (450) of the planar conductor arrangement (430).
In a particular method according to an aspect of the invention, the step of making electrical connections comprises the steps of placing a compressible floccule (450) of electrically conductive material between the second ends of each of the center (316) and outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) of the transmission lines (310) of the first planar arrangement (401) and the registered ones of the conductors (432) of the planar conductor arrangement (430), and compressing the compressible floccule (450) of electrically conductive material between the second ends of the center (316) and outer conductors (318a, 318b, 318c, 318d, 318e, 318f, 318g, and 318h) of the transmission lines (310) of the first planar arrangement (401) and the registered ones of the connections (432) of the planar conductor arrangement (430), to thereby establish the electrical connections and to aid in holding the compressible floccules (450) in place. The step of encapsulating the chips (14) and the short transmission-lines (310) in dielectric material includes the step of encapsulating the chips (14) and the short transmission-lines (310) in the same dielectric material as that of the dielectric disk (311). | Interconnections are made through a planar circuit by a monolithic short-circuited transmission path which extends from a circuit portion of the planar circuit to the opposite side. The opposite side is ground sufficiently to remove the short-circuiting plate, thereby separating the previously monolithic conductors, and exposing ends of the separated conductors of the transmission path. Connection is made between the exposed conductors of the transmission path and the registered contacts of a second planar circuit by means of electrically conductive, compliant fuzz buttons. The transmission path may be a coaxial path useful for RF. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/398,122, filed on Apr. 5, 2006, which claims the benefit of U.S. Provisional Application No. 60/669,599, filed on Apr. 8, 2005, and U.S. Provisional Application No. 60/684,452, filed on May 25, 2005, which are incorporated by reference as if fully set forth.
FIELD OF INVENTION
[0002] This invention relates to wireless local area mesh networks. In particular, this invention relates to signaling mechanisms that can be implemented in a Mesh point (MP) in order to enable transmit (Tx) and receive (Rx) power control.
BACKGROUND
[0003] FIG. 1 shows a typical wireless system infrastructure, comprising a set of access points (APs), also referred to as base stations (BS), each connected to a wired network through what is referred to as a backhaul link. The wireless links exist between the APs and the user stations (STAs). In some scenarios, the cost of connecting a given AP directly to the wired network makes an alternative option more attractive, which is to connect the AP indirectly to the wired network via wireless connections to its neighboring APs. This is referred to as a Mesh architecture. FIG. 2 shows a block diagram of a simple Mesh architecture comprising a plurality of Mesh points (MPs), each capable of supporting control, management and operation services for the Mesh. The MPs may either be a dedicated infrastructure device (e.g., a Mesh AP (MAP)) or a user device (e.g., a STA) that is able to fully participate in the formation and operation of the Mesh network. Advantages of using a Mesh infrastructure include ease-of-use and speed of deployment since a radio network can be deployed without having to provide backhaul links and interconnection modules for each AP.
[0004] One very important operational consideration is that Tx power settings of Mesh nodes are regulated in order to meet regulatory requirements. Operation of wireless radio communications today is regulated by the FCC (and their counterparts in other countries). In particular, certain maximum Tx power settings are mandated in order to minimize interference of un-licensed radio equipment such as WLANs for most frequency bands. Moreover, these regulatory requirements usually change per regulatory domain (e.g., U.S., Europe, Japan). Typical regulatory requirements for conventional WLANs operating in infrastructure mode (basic service set (BSS)) or AdHoc mode (Independent BSS (IBSS)) are summarized as follows (i.e., Mesh operation is not addressed by this existing standard).
[0005] Transmit power control (TPC) under IEEE 802.11h for 5 GHz band WLANs is primarily motivated by different regulatory Tx power allowances in the 5 GHz band assignments in Europe, but is also required by the FCC in the US. Different regulatory power requirements for the 5 GHz band include:
Lower U-NII (5.25-5.35 GHz, 4 channels) 40 mW US, 200 mW Europe Middle U-NII (5.35-5.45 GHz, 4 channels) 200 mW US and Europe (5.47-5.725 GHz, 11 channels) Europe-only, 1000 mW Upper-U-NII (5.725-5.825 GHz, 5 channels) US-only, 800 mW
[0010] The maximum admissible Tx power setting for any STA in the BSS or IBSS is the Power Constraint information element (IE) subtracted from the Regulatory Max Power value contained in the Country (IE). The Country IE (802.11d) is contained in BEACON and PROBE RESPONSE frames. Similarly, 802.11h puts the Power Constraint IE into BEACON and PROBES RESPONSE frames.
[0011] TPC under IEEE 802.11h adds a Power Capability IE to ASSOCIATION REQUESTS (RE-ASSOCIATION REQUESTS) sent from the STA to the AP (or STA in IBSS). This Power Capability IE is an indication of the possible minimum and maximum Tx power settings of the transmitting STA to the receiving STA.
[0012] Association attempts by STAs are to be refused by the AP or other STAs in an IBSS if the range indicated in their Power Capability IE does not allow operation with the current BSS regulatory settings. The AP is the only authority in the BSS that can change the admissible power setting for the BSS. In an IBSS, the STA that starts the IBSS is the one that sets admissible power settings and other STAs that subsequently broadcast the BEACON frame are required to propagate this initial power setting.
[0013] In the BSS case, the admissible power settings (regulatory in Country IE and offset in Power Constraint IE) can change during the lifetime of the BSS. Range control and interference reduction are specifically cited in 802.11h as one purpose for this feature. However, it is preferred that these changes in the settings should not happen “too often”.
[0014] One of the problems is that even if every BEACON can be used to change the power settings, not all STAs (for example the ones in packet switched (PS) mode) listen to every BEACON frame. Therefore, maximum Tx power changes are semi-static in the sense that it requires at least several target beacon transmission times (TBTTs) (hundreds of milliseconds) to have a new Tx power setting adopted by all STAs in the BSS.
[0015] Officially, 802.11h TPC requires a STA to check the admissible Tx power setting any time it tires to access the channel. However, it is doubtful that all manufacturers have implemented an automatic update from the latest received BEACON frame into their MAC firmware. It is reasonable to assume that this happens only once in a while, in extreme cases only during association or re-association.
[0016] TPC under 802.11h also introduces a TPC REQUEST/REPORT action frame pair. This TPC REQUEST action frame is used by a STA to request Tx power settings and link margin from another STA. The reported Tx power in the TPC REPORT action frame is the one used for sending the TPC report. The link margin reported is the one observed by the receiver when the TPC REQUEST action frame was received.
[0017] The IEs contained in the TPC REPORT action frame can also be put into the BEACON and PROBE RESPONSES, originally intended to address some special problems with IBSS mode. However, the link margin field in this case is meaningless and simply set to zero. These new 802.11h TPC-relevant IEs and action frames are found in Class 1 frames (i.e. they can be sent from and received by non-authenticated and non-associated STAs).
[0018] For completeness, 802.11h TPC functionality for the 5 GHz band is extended “as-is” into 2.4 GHz by the 802.11k draft amendment.
[0019] In order to allow ease of deployment and ease of adoption to a new deployment environment, a means to adopt allowed Tx power settings for Mesh equipment is needed. In addition to these regulatory considerations, adaptive Tx power levels are highly desirable to maintain high throughput and guaranteed QoS levels in a Mesh network.
[0020] The Tx and Rx power level settings of the participating nodes in a Mesh have a large impact on perceived communication and interference range. Perceived communication range is the distance over which a certain data rate can be sustained in a point-to-point or point-to-multipoint transmission). The perceived interference range is the distance over which a transmission can still disturb or degrade other ongoing transmissions from other nodes in the Mesh on a channel (or even on adjacent channels), even though the transmission itself cannot be reliably decoded any more.
[0021] Usually, the least possible Tx power setting in an MP conditioned on maintaining a given sustained data rate for a given Mesh link is the best approach to minimize co-channel and adjacent channel interference to other nodes in the Mesh. On the other hand, maximum possible Tx power level settings allow higher net data transmit rates because this directly impacts the SNR as seen by the intended receiver. This implies that MPs face conflicting needs and preferences in terms of which Tx and Rx power level settings to use. The ideal Tx power level setting for a particular MP is therefore a trade-off between maximizing individual data rates on particular links (higher data rates with higher Tx power settings) and maximizing overall Mesh performance (better performance with less interference and more spatial reuse on the same channel).
[0022] Rx power level settings, such as clear channel assessment (CCA) detection thresholds and minimum Rx sensitivity, impact the link budget and, as such, the SNR observed in the receiver. The Rx power level settings also impact the likelihood of failed channel access or collisions in carrier sense multiple access (CSMA)-based schemes such as 802.11 WLANs.
[0023] However, the level of interference perceived by the different nodes of a wireless Mesh system can vary widely both geographically and in time. This is because of the dynamic radio environment and real-time time-varying characteristics of transmissions in a Mesh, such as load per link or path, occupied channel time, etc.
[0024] Therefore, a means for dynamically controlling Tx and Rx power levels of Mesh nodes during the Mesh network lifetime is desirable in order to keep Mesh throughput and QoS high and at guaranteed levels. Also, channel changes motivated because of regulatory requirements need to be addressed in a wireless Mesh network.
[0025] While traditional WLANs (802.11a,b,g,j,n) do not provide any means today to allow for an adoption of Tx power settings other than at initial start-up, an amendment (802.11h) was made to Wireless LAN Medium Access Control (MAC) and Physical Layer (PHY) specifications in order to satisfy regulatory requirements for operation in the 5 GHz band in Europe. IEEE 802.11h TPC only allows WLAN systems in the 5 GHz band to set Tx power settings during the initial association of incoming STAs and to some extent during the lifetime of the WLAN network (Infrastructure mode or AdHoc mode). However, the 802.11h amendment does not address the specific needs and constraints of Mesh systems. This case was simply not foreseen.
[0026] In particular, no means exist to ensure a selective Tx power change of a particular link within a Mesh. Moreover, only maximum admissible Tx power settings can be communicated. However, just as important as maximum admissible Tx power settings are, so too are the minimum power settings in order to guarantee establishment of links and to minimize probability of channel access collisions.
[0027] Variable Tx power settings would improve the radio efficiency of Mesh networks, but a method for achieving this feature is not provided by existing technology. Furthermore, a method for Tx power control needs to be devised to allow Mesh networks to meet certain regulatory requirements in the sense of 802.11h TPC similar to WLANs today operating in legacy infrastructure (such as in a BSS case) and AdHoc mode (such as in an IBSS case).
SUMMARY
[0028] A method and apparatus controls transmit and receive power level of a mesh point (MP) operating in a mesh wireless communication network of a plurality of MPs. Power capability information of a new MP is sent to at least one existing MP in the mesh network. The existing MP accepts the new MP as a member of the mesh network and sends allowed power setting information to the new MP. The new MP adjusts its power level in accordance with the allowed power setting information.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 shows block diagram of a conventional wireless LAN.
[0030] FIG. 2 shows a block diagram of a simple Mesh infrastructure.
[0031] FIGS. 3A and 3B show signaling diagrams of a power capability information exchange between a Mesh point and a power master Mesh point.
[0032] FIGS. 3C and 3D show signaling diagrams of a distributed power capability information exchange between Mesh points.
[0033] FIGS. 4A and 4B show signaling diagrams of Mesh allowed power settings information retrieval from a power master Mesh point.
[0034] FIGS. 4C and 4D show signaling diagrams of Mesh allowed power settings information retrieval from other Mesh points.
[0035] FIG. 5 shows a signal diagram for transmit power control according to the present invention.
[0036] FIG. 6 shows a signal diagram for adjustment of MP transmit power settings in response to received allowed power setting information.
[0037] FIG. 7 shows a signal diagram of a power master selection procedure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] Although the features and elements of the present invention are described in the preferred embodiments in particular combinations, each feature or element can be used alone (without the other features and elements of the preferred embodiments) or in various combinations with or without other features and elements of the present invention.
[0039] Hereafter, a mesh point includes but is not limited to a wireless transmit/receive unit (WTRU), user equipment, mobile station, fixed or mobile subscriber unit, pager, or any other type of device capable of operating in a wireless environment. When referred to hereafter, an access point includes but is not limited to a base station, Node-B, site controller, access point or any other type of interfacing device in a wireless environment.
[0040] The term “Mesh neighbor” herein refers to the immediate neighbors of a particular Mesh point, (i.e., the ones in radio range). It also refers to other Mesh nodes that the MP can reach when its signaling messages are forwarded through the Mesh over multiple hops by other MPs. It can also include network entities beyond the immediate reach of the wireless Mesh, such as nodes residing in the wired backhaul network connected with the Mesh.
[0041] The present invention provides signaling procedures and mechanisms that will provide the means by which Mesh systems can adjust Tx and Rx power levels for regulatory and radio management purposes at system start-up, when an MP joins the Mesh network and during the lifetime of the Mesh network. The invention addresses a distributed scenario (i.e., the MPs are engaged in “peer-to-peer” signaling), as well as a master-slave scenario, in which the relationship between MPs is one of master and slave. In the latter scenario, a Power Master (PM) is a master MP that is responsible for dictating the power settings in the Mesh, both the overall regulatory settings and the individual power settings per Mesh Point and per link.
[0042] The present invention includes methods and apparatus with means for:
a) Signaling by which MPs exchange power-setting relevant capability information such as maximum and minimum power settings; b) Signaling by which MPs learn about allowed power settings in the Mesh; c) An MP reacting to different or conflicting allowed power setting information messages and configuration parameters; d) Power adjustments in the Mesh to meet regulatory requirements and to dynamically adjust power settings; and e) Electing a given Mesh node as PM.
[0048] FIGS. 3A and 3B show signaling diagrams of a power capability information exchange between an MP 101 and a PM in a master-slave arrangement. The power capability information preferably includes, but is not limited to any of the items as shown in Table 1, including any combination thereof.
[0000]
TABLE 1
Power Capability Information
Type
Description
Tx power step sizes
Minimum and maximum Tx power and adjustment
step size settings that the MP supports
Rx power step sizes
Minimum and maximum Rx power and adjustment
step size settings, sensitivity levels and CCA
thresholds settings that the MP supports
Mode
The operational modes (e.g., 802.11a, b, g, n, j, etc.)
the MP is able to support
Bandwidth
The operational bandwidth that the MP is able to
support (e.g., 802.11n supports bandwidths of
10/20/40 MHz and 802.11j supports 10 or 20 MHz
bandwidths)
Freq. Bands
The number of bands and sub-bands on which the
MP is capable of simultaneous operation (e.g., 2.4
GHz, 5 GHz, 5 GHz Lower U-NII, 5 GHZ Middle U-
NII)
[0049] In FIG. 3A , an MP 101 reports its power capability information 301 to the PM in an un-solicited manner, such as part of a broadcast/multicast-type frame for example. In FIG. 3B , MP 1 reports its power capability information 303 in a solicited manner as a response-type frame in response to a power capability request 302 (e.g., the exchanged signals 302 , 303 may be in the form of a directed unicast request/response-type frame exchange between the MP 101 and the PM. Although FIGS. 3A and 3B show power capability information signaling between the MP 101 and the PM, such signaling may also be exchanged between MP 101 and other neighboring MPs. FIGS. 3C and 3D show such a distributed scenario of power capability information exchanged between the MP 101 and an MP 102 similar to that shown in FIGS. 3A and 3B .
[0050] According to the present invention, solicited (request/report-type) reporting and un-solicited reporting of power capability information 301 , 303 by MPs can be sent as a piggy-backed IE on top of a Mesh unicast, multicast or broadcast management or control frame. Alternatively, the reporting of power capabilities can be sent as a separate Mesh unicast, multicast or broadcast management or control frame.
[0051] As an example of a Mesh management frame embodiment, the MP power capability information 301 , 303 may be included as an additional IE in a Mesh ASSOCIATION frame or a Mesh AUTHENTICATION frame (e.g., frame exchanges with other MPs for the purpose of becoming part of the Mesh network). Alternatively, the power capability signaling information 301 , 303 is included as an additional IE within a Mesh BEACON frame or a Mesh PROBE RESPONSE frame, which may also be used in exchanges for the purpose of discovering the presence of a Mesh network or synchronizing general Mesh parameters such as timer values. Another alternative is to include the power capability information 301 , 303 as an IE in an Association or Re-Association Response frame. Another alternative is to include the power capability information 301 , 303 as part of a directed special purpose per-link or multi-hop Mesh POWER CAPABILITY frame.
[0052] FIGS. 4A and 4B show a signaling diagram by which an MP learns of allowed power settings for the Mesh, which is useful for dealing with the regulatory need for MPs not to exceed certain maximum admissible power settings during communication. The allowed power setting information preferably includes (but is not limited to) any of the items as shown in Table 2, including any combination thereof.
[0000]
TABLE 2
Allowed Power Setting Information
Type
Description
PM Info
PM address or PM identifier
Mode
Regulatory domain within which the Mesh network
currently operates (e.g., 802.11b, g, n, j, etc.)
Freq. Bands
frequency bands and sub-bands within which the
Mesh network currently operates
Tx Power
minimum, instantaneous, and maximum allowed
Tx power settings
Rx Power
minimum, instantaneous, and maximum allowed
Rx power settings
CCA
minimum, instantaneous, and maximum allowed
CCA threshold settings
Timing
validity timers or time-out values
Measurement
measurement intervals and configuration
Timing
validity timers or time-out values
Silence
silence periods
Offset
temporary offset values for any of the above plus
associated life-time values
[0053] A master-slave scenario is depicted in FIGS. 4A and 4B , in which a slave MP 101 obtains this information from the master PM. In FIG. 4A , MP 101 obtains its allowed power setting information 401 from the PM in an un-solicited manner, such as part of a broadcast/multicast-type frame for example. In FIG. 4B , MP 1 obtains its allowed power setting information 403 in a solicited manner as a response-type frame in response to a power capability request 402 (e.g., the exchanged signals 402 , 403 may be in the form of a directed unicast request/response-type frame exchange between the MP 101 and the PM. Although FIGS. 4A and 4B show allowed power setting information signaling between MP 101 and the PM, such signaling may also be exchanged similarly in a distributed scenario between the MP 101 and other neighboring MPs. FIGS. 4C and 4D show such a distributed scenario of power capability information exchanged between the MP 101 and an MP 102 similar to that shown in FIGS. 4A and 4B .
[0054] According to the present invention, solicited (request/report-type) and un-solicited receiving of allowed power setting information 401 , 403 can be sent as a piggy-backed IE on top of a Mesh unicast, multicast or broadcast management or control frame. Alternatively, the allowed power setting information 401 , 403 can be sent as a separate Mesh unicast, multicast or broadcast management or control frame.
[0055] As an example of a Mesh management frame embodiment, the signaling of allowed power setting information 401 , 403 in the Mesh may be included as part of a Mesh BEACON frame or a Mesh PROBE RESPONSE frames (e.g. signaling frames and exchanges for the purpose of discovering the presence of a Mesh network or synchronizing general Mesh parameters such as timer values). Alternatively, the MP power allowed power setting information 401 , 403 is part of Mesh ASSOCIATION or Mesh AUTHENTICATION frames (e.g. frame exchanges with other MPs for the purpose of becoming part of the Mesh network). In another alternative, the allowed power setting information is part of a directed special purpose per-link or multi-hop Mesh ALLOWED POWER SETTING frame.
[0056] Allowed power setting information 401 , 403 can be signaled for any of the following, either alone or in combination: the entire Mesh (e.g. valid for all nodes in the Mesh); a particular Mesh link or path (e.g. valid for a set of Mesh nodes); a particular Mesh node (e.g. valid for all radio channels of a MP); a particular radio interface of a Mesh node (e.g. settable per-link and per-neighbor of a MP).
[0057] Allowed power setting information 401 , 403 can be signaled as absolute values, relative values relating to some pre-determined absolute value, or a combination of absolute and relative values (e.g. max admissible Tx power=regulatory max−temporary offset).
[0058] Turning to FIG. 5 , a distributed scenario is now described in reference to an MP 501 , in which there is no PM and it is possible that the MP 501 receives different allowed power setting information from two or more MPs, shown as an MP 502 and an MP 503 . With no PM in the distributed scenario, the MP 501 needs to determine which allowed power setting information it will use when setting its own Tx power settings and when signaling its allowed power setting information to the other MPs, MP 502 and MP 503 . The signaling procedure shown in FIG. 5 resolves a situation in which the MP 501 determines which allowed power setting information to use while resolving a conflict with mismatched allowed power setting information received from other MPs.
[0059] The MP 501 configures its own allowed power setting information APSI_own, while receiving APSI_i which represents the allowed power setting information signaled from MP_i with index i=2 and 3 for the example shown in FIG. 5 . The APSI_i values can be further represented by a vector APSI_vector, which represents the ensemble of the APSI_i values MP 501 receives from the other MPs.
[0060] An example of an allowed power setting information IE includes a Maximum Allowed Tx Power Setting (MATPS). For the sake of simplicity, the following method illustration includes only the MATPS IE. From a set of inputs MATPS_own 504 and MATPS_vector values 505 , 506 , the MP 501 needs to determine which MATPS will be used when setting its own Tx Power settings and when signaling allowed power setting information to other MPs. This can be achieved by implementing a decision-making function F in MP 501 .
[0061] For example, assume MP 501 receives MATPS_vector which comprises two vector value settings 505 , 506 : MATPS_ 1 =20 dBM from MP 502 and MATPS_ 2 =10 dBm from MP 503 . Also assume that MP 501 's own MATPS setting is configured to be MATPS_own=15 dBm. In the preferred implementation, the function F will determine the minimum MATPS value from all its inputs (i.e., min(10,20,15)=10 dBM) and the MP 501 will use an operational MATPS value when setting its Tx Power and it will signal it as part of the allowed power setting information that the MP 501 signals to other MPs, including MP 1 and MP 2 . Accordingly, the operational MATPS 507 in terms of function F can be expressed as follows:
[0000]
MATPS_operational
=
F
(
MATPS_own
,
MATPS_vector
)
=
min
(
MATPS_own
,
MATPS_vector
)
.
Equation
(
1
)
[0000] Similarly, other operational power settings can be selected using a suitable function F.
[0062] In an alternative embodiment, the MP 501 uses the value MATPS_operational determined by Equation(1) while determining its Tx Power, but MP 501 signals the MATPS_own value as its allowed power setting information to the other MPs, MP 502 and MP 503 .
[0063] FIG. 6 shows a signaling method for an MP 601 entering a Mesh 600 in which the Tx Power is adjusted to meet regulatory requirements. While the Tx Power setting adjustment is described in reference to MP 601 , the same Tx Power setting adjustment procedure applies to each MP in the Mesh 600 . The Tx power can be similarly controlled for a subset of MPs. The Mesh 600 comprises MP 602 -MPN at the time that the MP 601 seeks entry. One or more of the MPs MP 602 -MPN may be a PM. At initial joining 610 , at switch-on, MP 601 sends its Tx Power capability information 611 to MP 602 -MPN as described above for FIGS. 3A-3D . As aforementioned, a preferred way to send the Tx power capability information is as part of ASSOCIATION or AUTHENTICATION (or Re-ASSOCIATION or Re-AUTHENTICATION) frames. The Tx Power Capability information 611 may be performed periodically or in a solicited or in an un-solicited manner. At step 612 , the MP 601 becomes part of the Mesh. The MP 601 receives allowed power settings information 613 which is sent periodically in the Mesh or in an un-solicited manner or in a solicited manner by the Mesh neighbors MP 602 -MPN, during the process of discovery or joining the Mesh network. The allowed power setting information is exchanged as described above for FIGS. 4A-4D . As aforementioned, a preferred way of such signaling is to use Mesh BEACON or Mesh PROBE RESPONSE frames. At step 614 , the MP 601 reads the received allowed power settings information 613 and adjusts its Tx power settings. The MP 601 may or may not acknowledge its Tx power setting adjustment to the other MPs MP 602 -MPN.
[0064] The MP 601 sends its own allowed power setting information 615 to MP 602 -MPN. Likewise, the MP 601 receives Tx Power setting changes from MP 602 -MPN, triggered by changes in their Tx Power settings. Several optional and complementary signaling extensions are possible (not shown in FIG. 6 ) to support adjustment of power settings in the Mesh. For example, the MP 601 can request reporting of measurements from its MP neighbors MP 602 -MPN regarding power settings, perceived SNR and link margin values, perceived interference power and channel busy times.
[0065] According to the present invention, a selection procedure is performed by the Mesh MPs for negotiating and selecting a Mesh PM. The preferred PM selection and re-selection procedure includes one or more of the following:
a) The first MP to belong in the Mesh automatically becomes PM. b) An MP at switch-on determines if one of its neighbors is a PM. The PM can be identified by means of L2 or L3 broadcast, multicast or dedicated signaling received by the MP as part of the set-up procedures, (e.g. authentication, Mesh BEACON reception, capability exchanges and so on). c) The PM can be pre-set, (i.e. fixed for the lifetime of the Mesh) or time-limited, (i.e., after a certain pre-determined amount of time or tied to the occurrence of certain conditions, the PM selection procedure is re-initiated) d) In one advantageous realization, the PM coincides with the Mesh Portal and Mesh Portal identifiers therefore automatically point to the PM. e) The MPs with the most links to neighbors becomes the PM. f) The MPs determine the PM by means of a random number draw. g) The MPs determine the PM as a function of the number of hops from the Mesh Portal or from a certain agreed-upon MP. h) Any combination of the above.
[0074] FIG. 7 shows a signaling diagram for identifying the Mesh PM according to the preferred methods described above. A PM Request Information Element (IE) is included as part of a broadcast/multicast/unicast signaling frame in signal 711 sent through the Mesh by MP 701 indicating to neighbor MPs MP 702 -MPN that a PM selection is required. This IE contains the address of the originating MP and other parameters, such as time-out values, selection criteria, default identifier for the proposed PM, reply-to address, and so on. A PM Response IE part of a broadcast/multicast/unicast signaling frame in signals 712 is sent through the Mesh containing the selection criteria response from the neighbor MPs MP 702 -MPN. A comparison procedure 713 is initiated in the MP 701 where the selection criteria responses 712 1 . . . 712 N from the different neighbor MPs are evaluated. The PM selection decision is made based on which MP meets the requirements in terms of the chosen selection criteria, (e.g., highest random number draw or similar). The MP 701 broadcasts its final selection for PM to the Mesh in signal 713 .
[0075] Alternatively, the MP 701 acts as the Mesh Portal and sets all of the Tx Power control settings for the Mesh and subsequently joining MPs are mandated to propagate these Tx Power control settings to other Mesh MPs.
[0076] The signaling messages and information exchanged between MPs or between MPs and the PM for the above described methods are preferably implemented as Layer L2 (e.g. MAC layer) signaling frames or IEs. As such, the physical implementation is a processor entity within each MP, such as MP 101 MP 102 and the PM shown in FIGS. 3A-3D , 4 A- 4 D; MP 501 , MP 502 , MP 503 as shown in FIG. 5 ; MP 601 , MP 602 -MPN as shown in FIG. 6 ; and MP 701 , MP 702 -MPN as shown in FIG. 7 . The processor entity may include for example, Layer L2 hardware or software in medium access control (MAC) or station management entity (SME). The layer L2 software, for example may be part of operation and maintenance (O&M) routines in MPs; or a combination thereof. Alternatively, the signaling is implemented as Layer L3 or above signaling packets or IEs, (e.g. encapsulated into IP packets, or into TCP/IP packets and so on). As such, the physical implementation would include Layer L3 hardware or software, such as IP or simple network management protocol (SNMP) entities. Another alternative includes a combination of Layer L2 and L3 signaling thereof.
[0077] All signaling messages and information exchanged as aforementioned can be either direct-link (e.g., MP-MP signaling frames) or multi-hop frame signaling (e.g., MP sending a message to another MP via intermediate forwarding MPs). Furthermore, signaling can take place between MPs and other nodes in the wired backhaul.
[0078] All methods described above can be subject to or are complemented by configuration settings in the individual MPs and can provide statistics and feedback to Mesh-internal or external network monitoring and control entities (e.g., using remote IT administrator network monitoring software) that can exercise control on MPs operational characteristics. These configuration settings and reportable statistics can be set in or reported from individual (or groups) of MPs by any of the following formats or a combination thereof:
a) databases in the physical layer (PHY), medium access control (MAC) or system management entity (SME), advantageously realized (but not limited to) in the form of management information bases (MIBs); b) signaling messages between L2 MAC or SME to above protocol entities, advantageously realized in the form of APIs; or c) primitives exchanged between SME, MAC, PHY and other protocol entities in a MP implementation.
[0082] The above described configuration settings that can be used by external management entities on the MP (or groups of MPs) can contain any of the following:
a) Admissible Tx, Rx and CCA value setting and ranges; b) Admissible mode settings (e.g. 11a,b,g,j,n and so on); c) Admissible band and sub-band settings (e.g. 2.4, 4.9, 5 GHz, U-NII lower, middle and upper band and so on); d) Mesh TPC feature on or off; e) Addresses and identifiers for PM; f) Timer values (e.g. channel dwell and measurement intervals) for TPC; g) Transmit Power change command for the MP; or h) Any combination thereof.
[0091] Reportable statistics in the MP that can be used by external management entities may include, but is not limited to any of the following, or a combination thereof:
a) Current Tx power control settings, modes, bandwidth, number of simultaneous channels (or combination thereof) of MP and neighbor MPs (as far as known); or b) Channel statistics such as the value and type of measurements performed and so on. | A method and apparatus for controlling transmit and receive power level of a mesh point (MP) operating in a mesh wireless communication network of a plurality of MPs. Power capability information of a new MP is sent to at least one existing MP in the mesh network. The existing MP accepts the new MP as a member of the mesh network and sends allowed power setting information to the new MP. The new MP adjusts its power level in accordance with the allowed power setting information. | 7 |
FIELD OF THE INVENTION
This invention relates to the construction and design of windows or doors. It presents a frame system for slidably retaining sashes in self-storing windows.
BACKGROUND OF THE INVENTION
Conventional self-storing storm windows are generally of two types. In the first type, some of the sashes are attached to the supporting frame, and a sliding sash is guided by removable guides. This requires the use of tools if the sashes are to be removed.
The other type has multiple sashes riding in multiple fixed tracks. In order to facilitate removal of the sashes for cleaning, opposed sets of tracks have one track deeper than the other. A sash can be shifted into the deeper track until its opposite edge clears the other track, and can then be removed. With sashes removable in this way, there is no security against unauthorized entry through the window, since the sashes can be removed from either side. This type of structure is disclosed in U.S. Pat. Nos. 2,910,740 and 3,636,661. In addition, when one track is deeper than the other to allow installation or removal of sashes, there is an air space between the base of the deeper track and the adjacent edge of the sash. This is undesirable in a window, since it allows infiltration of air and water.
To facilitate removal of all sashes and still prevent unauthorized entry from outside, another design utilizes retractable pins mounted on the sides of the sashes. The pins, not the sash itself, ride in the tracks. With the pins retracted from the inside, the sashes can be be removed. This design, however, allows a considerable amount of air and water infiltration between the sashes and the tracks.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a self-storing window assembly;
FIG. 2 is an enlarged fragmentary perspective view of the lower right-hand corner of the assembly in FIG. 1;
FIG. 3 is a cross-sectional view of the channel member;
FIG. 4 is a cross-sectional view of the channel retainer;
FIG. 5 is an inner elevational view of the window of FIG. 1;
FIG. 6 is an outer elevational view of the window of FIG. 1;
FIG. 7 is a cross-sectional view along line 7--7 in FIG. 5;
FIG. 8 is a cross-sectional view along line 8--8 in FIG. 5;
FIG. 9 is a cross-sectional view along line 9--9 in FIG. 5;
FIG. 10 is a cross-sectional view along line 10--10 in FIG. 5;
FIG. 11 is a cross-sectional view along line 11--11 in FIG. 5;
FIG. 12 is a cross-sectional view showing the frame assembly attached to a support frame;
FIG. 13 is a fragmentary exploded view of the frame assembly and support frame of FIG. 12;
FIGS. 14 through FIG. 26 are a series of paired schematic elevation and perspective views showing disassembly of the window of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In compliance with the constitutional purpose of the Patent Law "to promote the progress of science and useful arts" (Article 1, Section 8), applicant submits the following disclosure of the invention.
The present invention arose out of the need for a self-storing window assembly, useable either as a primary window or as a storm window, from which all sashes could easily be removed for cleaning. The window assembly also had to prevent air and water infiltration when the sashes were in their closed position.
In addition there was also a need for a self-storing window which was secure against unauthorized entry from the outside. Other requirements were that it be easy to install, require low maintenance and be cost-competitive with other designs. It also provides a single track extrusion and uniform frame components usable at all sides and ends of the assembled window. This design also permits the same window assembly to be used in either a horizontal or vertical orientation.
The present frame system utilizes a channel member 12 generally illustrated in FIGS. 3, 12 and 13. It has a transverse base 14. Three substantially parallel walls 15 project perpendicularly to one side of base 14, presenting an inner U-shaped track 16 and a parallel, outer U-shaped track 17. When the channel members 12 are installed in a window, the outer tracks 17 are positioned away from the interior of the structure and the inner tracks 16 are positioned toward the interior of the structure. The inner track 16 and outer track 17 are each adapted to receive one or more track fillers 22, as shown in FIGS. 12 and 13.
The inner surfaces of channel member walls 15, as illustrated in FIGS. 3 and 13, have elongated paired interior shoulders 18 which are parallel with and spaced outwardly from the channel member base 14. The interior shoulders 18 have two functions. The first is to provide a support for track fillers 22 when they are positioned within the tracks 16 and 17. The second function is to provide a raceway between channel member base 14 and track fillers 22. The raceway allows a portion of a connecting device, such as a bolt or a screw, to protrude through channel member base 14 without interfering with the overlying track fillers 22.
In the embodiment illustrated, the inner surfaces of walls 15 also have longitudinal ridges 20, parallel with the channel member base 14, and spaced outward from the channel member shoulders 18. The purpose of the longitudinal ridges 20 is to frictionally retain track fillers 22 in position when they are installed in tracks 16 and 17. While longitudinal ridges 20 are shown in the preferred embodiment, any suitable means of frictionally retaining the track fillers 22 in the tracks 16 and 17 may be utilized.
As illustrated in the preferred embodiment shown in FIG. 3, the edges 21 of the walls 15 are slightly tapered to facilitate positioning of track fillers 22 or the window sash within the tracks 16 and 17.
The channel member 12 is preferably constructed of a strong extruded plastic, relatively rigid, but having some resiliency. However, it can also be made from any inexpensive lightweight material which is relatively rigid but has some resiliency, such as aluminum.
Each track filler 22 comprises a transverse base 23 connecting two substantially parallel walls 24, forming a U-shaped configuration. The edges of the walls 24 are turned inwardly, forming two elongated edge flanges 26. Flanges 26 are parallel to the track filler base, and are turned at substantially a 90 degree angle with respect to the track filler walls 24.
Each track filler 22 has opposed outer surfaces 25 complementary to the open tracks 16 and 17. The track fillers are adapted to be removably positioned within a track of a channel member 12. The outer surfaces 25 of the walls 24 have one or more parallel elongated ridges 27 which are parallel with the track filler base 23. The ridges 27 are adapted to resiliently interlock with the channel member ridges 20 when the track filler 22 is positioned in tracks 16 and 17. While the preferred embodiment as illustrated shows the parallel track ridges 27, any suitable means of frictionally retaining the track fillers 22 in the tracks 16 and 17 may be utilized.
As illustrated in FIG. 13, the track filler base 23 has a number of holes 28 formed through it. The holes 28 allow the track filler 22 to be grasped by a hook or other tool (not shown) for removal from the tracks 16 and 17. They are also used in cooperation with conventional sliding barrel or pin latches 29 to position or lock a sash relative to the window frame.
As illustrated in FIGS. 12 and 13, the track fillers 22 may be positioned in tracks 16 and 17 either with the base 23 bearing against the interior shoulders 18, or with the flanges 26 resting on shoulders 18. In either case, the track filler bases 23 or flanges 26 provide a smooth, tightly-fitting surface about the perimeter of the installed sashes.
The track fillers 22 are preferably made from a strong, relatively rigid plastic extrusion having some resiliency. However, track fillers 22 may be of any material which has similar properties, such as aluminum. Aluminum track fillers are of particular benefit in that they are stronger and provide more support for carrying the weight of a sash resting vertically on them parallel to the elongated track fillers. The ability to support such weight is particularly useful in designing vertically sliding self-storing window assembies.
In a modified configuration (not shown) the track filler is the same as illustrated in FIG. 12, with the exception that there are no track filler flanges 26 along the exterior sides of the track filler walls 24. Instead, the track filler walls 24 are not quite perpendicular to the track filler base 23, and the outer edges of walls 24 are spaced apart a distance slightly greater than the width of track filler base 23. This alternate shape of the track fillers 22 provides a frictional fit between the track filler 22 and the walls defining tracks 16 and 17. Frictional force is provided by the resiliency of the track filler walls, which attempt to expand when constricted in tracks 16 and 17.
The orientation of the support frame 30 as shown is not necessary to the practice of this invention. The support frame 30 could be installed either horizontally as shown, or vertically with the second sash 44 being a sliding sash being installed either on the left side or the right side in the horizontal orientation or on top or on the bottom in a vertical orientation.
As used herein, the word sash means a frame surrounding a panel. The panel can be made of any material suitable for use in a window, such as glass, plastic, screen or fabric, among others.
The window assembly as described herein can be used either as a primary window or as a storm window. It can be installed on doors as well as windows, and can be either vertical or horizontal.
FIG. 12 and FIG. 13 illustrate the use of channel members 12 and track fillers 22 in conjunction with a first embodiment of a surrounding channel retainer 60. Its cross-section is detailed in FIG. 4 The outside surfaces of channel member walls 15 have elongated exterior shoulders 13. These shoulders 13 are adapted to interlock within complementary grooves 63 in the channel retainer walls 62. The channel retainer 60 comprises a base 61 having two substantially parallel walls 62 projecting perpendicularly to one side of base 61. The base 61 and walls 62 have inner surfaces forming a U-shaped open configuration adapted to receive channel members 12.
The channel retainer 60 also has a flange 64 that is perpendicular to the base 61 and extends in a direction opposite to the walls 62. As shown, the flange 64 is located to one side of a centerline extending along the channel retainer base 61. The flange 64 is used to attach channel retainer 60 to the support frame member 71. If desired retainer 60 and channel member 12 can be an integral unit, and can be further combined with an integral support frame structure as well.
Each channel member 12 is designed to be positioned within the channel members 12 with its base 14 engaging the channel retainer base 61. Channel member 12 is removably locked in retainer 60 by engagement of shoulders 13 and grooves 63 (See FIG. 12). Channel member 12 could also be fixed within retainer 60 by other means, such as an adhesive, mechanical fasteners or screws.
In the embodiment shown in FIGS. 12 and 13, a support frame member 71 has an elongated slot 72 adapted to receive the channel retainer flange 64 about the window periphery. To prevent any possibility of the removal of channel retainer 60 from frame member 71, screws or bolts would normally be driven perpendicularly through slot 72 and flange 64.
To present a more secure window assembly, channel retainer 60 can be installed parallel to and spaced apart from an exterior peripheral flange 73 that extends about frame member 71, forming a U-shaped guideway adapted to receive the ends of rigid cross members or a grill 70. The addition of cross members or a grill 70 provides additional physical security to the window or door assembly to prevent unauthorized entry through it.
The channel retainer 60, as pictured in FIGS. 12 and 13, is installed on support frame member 71 with the wider portion of the channel retainer base 61 overlapping support frame member 71. If a grill is desired, the channel retainer 60 can be installed with the wider portion of channel retainer base 61 extending outward from support frame member 71. The more narrow portion of channel retainer base 61 would then overlap support frame member 71. This arrangement provides the required space between channel retainer wall 62 and flange 73 for installation of cross members or grill 70. Alternatively, the channel retainer 60 can be installed on a support frame which is of reduced thickness. In that case, channel retainer wall 62 can be positioned against flange 73, eliminating the grill support guideway, or the retainer 60 can be reversed to present a guideway.
FIGS. 1, 2 and 5-11 show a typical self-storing window assembly 10. This configuration consists of a rectangular support frame 30, which comprises two parallel side members 31 joined at their ends by two perpendicular end members 32. Around the inner edge of the support frame 30 is a mounting flange 33, which is utilized to attach the window frame 30 to the structure on which it is mounted. Any type of conventional fastening means, such as screws or bolts, may be used to attach the flange to the supporting building, door or window structure. The frame 30 also has an outside peripheral flange 34, around the window opening for confining the channel members that hold the sashes. Flange 34 prevents removal of the channel members from outside, as well as helping provide a weather tight seal between the channel members and the support frame 30. Its outermost edge is preferably overlapped by the flanges 13 on the channel members, which act as a protective drip cap, preventing rain or water from entering between the channel members and flange 34.
A group of four elongated channel members, having the details previously described, are installed in a rectangular configuration around the window opening defined by the frame members 31, 32. The channel members include two parallel side channel members 50 and two parallel end channel members 51 extending perpendicularly between their respective ends.
In the illustrated embodiment, the channel members 50 and 51 are held in place within the support frame 30 by a commercially available weather resistant adhesive material. As an alternative, the channel members could also be fastened to the frame 30 by any type of fastening device such as screws or bolts. If desired, the surrounding frame members can interlock directly with shoulders 13 to hold the channel members in place.
The complete self-storing window assembly 10 has a first sash 38, a second sash 44 and a third sash 54 installed. The first sash 38 and third sash 54 are positioned in the outer tracks 17 of the channel members. Second sash 44 is positioned in the inner tracks 16 of the channel members. Additional sashes can be added when required.
In a typical self-storing window assembly as illustrated, sashes 38 and 44 will normally include rectangular panes of glass. Sash 54 will normally include a taut panel of ventilating screen material. Other panel materials can be substituted as desired. Sashes 38 and 54 are usually stationary. Sash 54 typically includes a bracket 48 at one end to facilitate its handling for removal or replacement purposes (see FIGS. 6 and 9). Sash 44 also has a bracket 49 at one end to assist a user in shifting the sash along the supporting channels (see FIGS. 5 and 10). As mentioned earlier, transverse barrel latches 29 are included along the outer end edge of sash 44 for selectively locking the movable sash relative to the surrounding window structure.
The first sash 38 has side edges 42 engaged between a first set of track fillers 65 located respectively within the outer tracks of the side channel members 50 at opposed sides of the support frame 30. The sash 38 has first and second parallel end edges 39 and 40 which are perpendicular to the side channel members 50. The first end edge 39 of sash 38 is positioned within the outer track of one of the end channel members 51. It abuts an end track filler 52 fixed within the track (see FIG. 8)
The second sash 44 has side edges 47 engaged between a second set of track fillers 66 located respectively within the inner tracks of the side channel members 50 at opposed sides of the support frame 30. The sash 44 has first and second parallel end edges 45 and 46 which are perpendicular to the side channel members 50. The first end edge 45 of sash 44 is positioned within the inner track of the remaining one of the end channel members 51. It abuts an end track filler 53 (see FIG. 10). The second end edge 46 of sash 44 overlaps the second end edge 40 of sash 38.
A third set of track fillers 67 is located respectively within the outer tracks of the side channel members 50 at opposed sides of the support frame 30 (see FIG. 11). The third set of track fillers 67 overlies a portion of the first set of track fillers 65. They are in engagement with the second end edge 40 of the sash 38 and extend along channel members 50 to abut end fillers 58 in the outer track of the remaining one of said end channel members 51. The track fillers 67 seal sash 54 along its sides and prevent sliding movement of sash 38 relative to support frame 30. Their lengths equal the length of sash 54.
The third sash 54 has side edges 57 engaged respectively between the third set of track fillers 67 at opposed sides of frame 30. Sash 54 has first and second parallel end edges 55 and 56 which are perpendicular to the side channel members 50. The first end edge 55 of sash 54 is engaged with the second end edge 40 of sash 38 (see FIG. 9). The second end edge 56 of sash 54 abuts an end track filler 58 within the outer track of the remaining one of end channel members 51 (see FIG. 10).
With the third set of track fillers 67 installed in side channel members 50, the first sash 38 is held in a fixed position and cannot be moved along channel members 50. This is necessary if the support frame 30 is installed vertically with the first sash 38 normally in an upper raised position.
The first sash 38 has a screen retention lip 41 adjacent its end edge 55. Lip 41 overlaps the first edge 55 of third sash 54 to retain sashes 38 and 54 in alignment. This overlap also prevents removal of the sash 54 from the window exterior.
FIGS. 1 and 5 through 11 show the assembled window components in a normal closed condition. The first and second sashes 38 and 44 (normally containing panes of glass) extend across the window opening and overlap one another at its center. The third sash 54 (normally contains a screen) is located outward from sash 44. It is normally stationary. Sash 54 can be exposed, for ventilation purposes, by sliding sash 44 to the left from its position shown in FIG. 5.
FIGS. 14 through 25 schematically illustrate the removal of sashes from a complete self-storing window 30. In FIGS. 14 and 15, the first sash 38 and second sash 44 are both positioned to the left, with the third sash 54 exposed on the right. One segment 68 of the second set of track fillers 66, having a length slightly greater than the width of second sash 44, is then removed from the inner track of one of the side channel members 50. This provides space within the track to permit sash 44 to be shifted laterally in the window frame after being moved to the right.
In FIGS. 16 and 17 the sash 44 has been moved to the right along the inner tracks 16 of the two side channel members 50. It has been shifted upwardly into the space created by removal of track filler segment 68. The second sash 44 can now be lifted in an upward direction until its opposite edge clears the inner track of the opposite side channel member 50. The second sash 44 can then be swung inwardly and away from the lower side channel member 50 for removal from the window assembly.
FIGS. 18 and 19 show the window assembly with second sash 44 removed. The first end edge 55 of third sash 54 is no longer overlapped by sash 44 and can be swung in an inward direction as shown. Sash 54 can now be removed from the window assembly.
In FIGS. 20 and 21 sash 54 has been removed. This provides access to the third set of track fillers 67. They can now be removed from the outer track of side channel members 50 as shown.
With the third set of track fillers 67 no longer overlying the first set of track fillers 65, one segment 69 of the first set of track fillers 65 can be removed. This segment having a length slightly greater than the width of first sash 38 is removed from the outer track of one of the side channel member 50. This provides space within the track to permit sash 38 to be shifted upwardly after being moved to the right. The removal of this filler segment 69 from the outer tracks is carried out in the manner seen in FIGS. 22 and 23.
In FIGS. 24 and 25 sash 38 has been moved to the right and shifted upwardly into the space created by removal of segment 69 of the first set of track fillers 65. The first sash 38 can now be lifted in an upward direction until its opposite edge clears the outer track of the opposite side channel member 50. The sash 38 can then be swung inwardly away from the lower side channel member 50 and removed from the window assembly.
With sash 38 removed, disassembly is complete. The steps described above are done in a reverse sequence to re-assemble the window.
The above-described frame system is unique in that it effectively surrounds and seals a self-storing window assembly by use of two extrusions--one for the channel members and one for the track fillers. Most prior designs for such windows required different channel configurations at both sides and at both ends of the window. The use of channel members having an identical cross-sectional shape about the entire frame provides economy in manufacturing costs and a substantial reduction in the inventory needs of a fabricator. Similarly, the track filler profile is extremely versatile, and a common filler extrusion can be used to provide the guiding and interlocking functions described in detail above. Assembly and fabrication of a window is relatively easy, and the resulting window is both functional and visually attractive.
In compliance with the statute, the invention has been described in language more or less specific as to structural features. It is to be understood, however, that the invention is not limited to the specific features shown, since the means and construction herein disclosed comprise a preferred form of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims, appropriately interpreted in accordance with the doctrine of equivalents. | An improved window frame system for slidably retaining sashes in self-storing windows. The frame system comprises four channel members disposed about an opening, having tracks for receiving sashes. A plurality of filler strips are removably positioned in the tracks. The sashes are engaged in the tracks by the filler strips. By removing segments of the filler strips the sashes can be removed from the windows. | 4 |
RELATED APPLICATIONS
This application is the U.S. National Phase under 35 U.S.C. § 371 of International Application No. PCT/AU2004/001765, filed on Dec. 15, 2004, which in turn claims the benefit of Australian Application No. 2003906932, filed on Dec. 15, 2003, the disclosures of which Applications are incorporated by reference herein.
FIELD OF THE INVENTION
This invention relates to hydraulic motors/pumps, otherwise known as hydrostatic drives or hydraulic machines.
BACKGROUND TO THE INVENTION
Hydraulic pumps/motors have applications in many industries, including the material handling, mining and manufacturing industries.
A hydraulic motor/pump can be operated in one of two ways. In one mode of operation, the input medium is pressurised hydraulic fluid, and the output is rotational motion. The process can be reversed such that rotational motion is supplied to the hydraulic motor/pump. In this second mode of operation, the hydraulic fluid is pumped from the motor/pump.
An advantage of hydraulic motors/pumps is that they typically have an excellent overall efficiency, among many other desirable characteristics.
However, many hydraulic motors/pumps suffer from a distinct disadvantage. There exists a torque-speed trade off, such that as the motor speed increases the output torque decreases, and vice versa.
Prior art hydraulic motors/pumps typically have an eccentric disc which is connected to an output shaft. A set of hydraulic cylinder and piston assemblies are positioned in a radial (also known as a “star” or “fan”) arrangement about the axis of rotation of the output shaft. Typically there are five such hydraulic cylinder assemblies.
The pistons intermittently exert a force to the edge of the eccentric disc in a coordinated fashion such that the disc is rotated. After exerting a force, the retraction of each piston is effected by the eccentric disc.
To vary the torque of the motor (in the driving mode of operation) some such motors have been fitted with a small piston between the output shaft and the centre of the eccentric disc. The eccentricity of the disc is varied by changing the length of small piston.
Similarly in a pumping mode of operation, the fluid flow rate and/or the output fluid pressure can be altered by changing the length of the small piston.
One disadvantage of such prior art hydraulic motors/pumps is that when the output shaft speed exceeds the fluid flow capabilities of the hydraulic cylinders, the pistons can dissociate from the eccentric disc. This can result in complete failure of the hydraulic motor/pump.
A further disadvantage of the prior art devices having a variable eccentric disc is that the possible range of eccentricity is limited. Typically a zero eccentricity situation is not possible.
A still further disadvantage is that the small piston can allow small unwanted perturbations of the eccentricity. These perturbations are the result of the fluid properties and the system elasticity.
With a high overall efficiency obtainable from hydraulic motors/pumps, there is a need for such a device which can simultaneously produces high torque at high speed.
SUMMARY OF THE INVENTION
According to the present invention there is provided a hydraulic machine which can exchange hydraulic fluid pressure with rotational motion of an output means, the hydraulic machine having a radial arrangement of a plurality of hydraulic piston and cylinder assemblies about at least one crankshaft coupled to the output means, the hydraulic cylinder and piston assemblies being longitudinally spaced along the crankshaft; and means for varying the eccentricity of the crankshaft.
Preferably, each piston is connected to the at least one crankshaft by a connecting rod.
Preferably, a spherical bearing is disposed between each connecting rod and the respective crankshaft.
Preferably, the eccentricity of the at least one crankshaft can be varied such that the stroke length of the pistons can be varied between zero and the maximum stroke length.
Preferably, the means for varying the eccentricity of the at least one crankshaft includes, located at each end of the at least one crankshaft:
an inner cylinder with a hollow eccentric cylindrical core within which the respective crankshaft is received such that the longitudinal axes of the inner cylinder and crankshaft are parallel and offset,
an outer cylinder with a hollow eccentric cylindrical core within which the inner cylinder is received such that longitudinal axes of the outer cylinder and the inner cylinder are parallel and offset,
a cylindrical main bearing with a concentric hollow cylindrical core within which the outer cylinder is received, and
a drive means,
wherein the drive means can be operated to simultaneously rotate the outer and inner cylinders to change the distance between the longitudinal axes of the main bearing and the crankshaft at both ends of the respective crankshaft.
Preferably, the drive means includes, at each end of at least one crankshaft:
a ring gear with teeth on both the inner and outer surfaces of the ring,
a set of teeth around an end portion of each of the inner and outer cylinders, and
a gear train to transfer rotation from the ring gear to the inner and outer cylinders,
wherein the ring gear is supported by the respective main bearing, and the main bearing has a cut out portion through which the gear train extends to engage the ring gear.
Preferably, the main bearings have teeth on the outer surface, and the ring gears are disposed next to the teeth on the respective main bearing, and the drive means further includes:
a shaft with a helix formed on the shaft surface, and pinion gears which engage the teeth on each of the main bearings such that the shaft rotates with the main bearings;
at least one nut with an internal helix which engages the helix on the shaft, and at least one projection which is radial with respect to the shaft;
at least one hollow cylindrical outer sheath through which the shaft extends, the at least one sheath having two thin pinion gears at each end of the outer sheath, wherein each thin pinion gear engages a ring gear of the drive means, the at least one outer sheath having at least one longitudinal slot through which the at least one projection extends.
Preferably, the drive means is operated by moving the nut longitudinally along the shaft, the outer sheath can be rotated with respect to the shaft.
More preferably, moving the nut longitudinally advances or retards the ring gears with respect to the main bearings.
Preferably, both the inner and outer cylinders each have a counter weight.
Preferably, the hydraulic machine further includes at least one lay shaft having, for each of the main bearings, a pinion gear to engage the teeth on the respective main bearing.
Thus, the torque applied to each of the main bearings is transferred through the at least one lay shaft rather than being transferred through the crankshafts.
Preferably, the heads of the hydraulic cylinder and piston assemblies are supported by the housing such that the hydraulic cylinder and piston assemblies can oscillate as the respective crankshaft rotates.
Preferably, the head of each hydraulic cylinder and piston assembly is supported between a pair of thrust blocks which are supported by the housing.
Preferably, the heads of the hydraulic cylinder and piston assemblies have, at least partially, a spherical shape. More preferably, each pair of thrust blocks have a complimentary shape to the heads of the hydraulic cylinders.
Preferably, there are equal angles between the hydraulic cylinder and piston assemblies attached to each of the at least one crankshaft.
More preferably, there are five hydraulic cylinder and piston assemblies disposed at 72° intervals about the at least one crankshaft.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention can be more easily understood, an embodiment will now be described, by way of example only, with reference to the accompanying drawings, in which:
FIG. 1 : is a plan view of the housing of a hydraulic machine according to an embodiment of the present invention;
FIG. 2 : is a plan view of the hydraulic machine shown in FIG. 1 with the housing removed;
FIG. 3 : is a view of the hydraulic machine shown in FIG. 2 ;
FIG. 4 : is an end view of the hydraulic machine shown in FIG. 3 with the output flange removed;
FIG. 5 : is a sectional view of the hydraulic machine through the section B-B in FIG. 1 ;
FIG. 6 : is a sectional view of the hydraulic machine through the section A-A in FIG. 5 ;
FIG. 7 : is an axiomatic view of a crankshaft and cylinder unit and thrust block of the hydraulic machine;
FIG. 8 : is a side view of the crankshaft and cylinder unit and thrust block of FIG. 7 ;
FIG. 9 : is an end view of the crankshaft, connecting rod, cylinder unit and thrust block of FIG. 7 ;
FIG. 10 : is a sectional view of the crankshaft, connecting rod, cylinder unit and thrust block through the section A-A of FIG. 8 ;
FIG. 11 : is a sectional view of the crankshaft, connecting rod, cylinder unit and thrust block through the section B-B of FIG. 10 ;
FIG. 12 : is an axiomatic view of a crank assembly of the hydraulic machine;
FIG. 13 : is a view of the crank assembly of FIG. 12 , with a pair of lay shafts and a helical shaft;
FIG. 14 : is a view of the crank assembly of FIG. 13 , with outer sheaths;
FIG. 15 : is a view of the stroke adjustment assembly in FIG. 13 ;
FIG. 16 : is an end view of the inner and outer eccentrics and gear train of FIG. 15 ;
FIG. 17 : is an exploded view of the inner and outer eccentrics and the gear train of the hydraulic machine;
FIG. 18 : is a view of the assembled inner and outer eccentrics and the gear train, of FIG. 17 ;
FIG. 19 : is an end view of the inner eccentric ring; and
FIG. 20 : is an end view of the outer eccentric ring.
DETAILED DESCRIPTION
FIGS. 1 to 6 illustrate a hydraulic machine 1 according to an embodiment of the present invention. The hydraulic machine 1 is encased in a housing 10 . The hydraulic machine 1 has an power coupling 5 which can be connected to a complimentary power coupling to transfer rotational motion to or from the machine 1 about an axis of rotation (not shown).
FIG. 2 shows the hydraulic machine 1 with the housing 10 removed. The hydraulic machine 1 has two crankshafts 15 , about each of which a bank 20 of five cylinder assemblies 50 are radially arranged. Thus, the hydraulic machine 1 in this embodiment has ten cylinder assemblies 50 .
The hydraulic machine 1 can have any integer number of banks 20 . Thus, the total number of cylinder assemblies 50 in a hydraulic machine 1 according to the invention is a multiple of the number of cylinder assemblies 50 per bank 20 ; such as five, ten, fifteen cylinder assemblies.
FIGS. 3 to 5 are views of the hydraulic machine 1 as seen looking along the axis of rotation.
As can be seen in FIGS. 3 and 4 , the five cylinder assemblies 50 of each bank 20 are arranged equiangularly about the axis of rotation. Thus when measured with respect to the axis of rotation, the angle between each adjacent pair of cylinder assemblies 50 is 72°.
FIGS. 2 and 6 show the hydraulic machine 1 in plan view such that the axis of rotation is in the plane of the page. Each cylinder assembly 50 is directly attached to its respective crankshafts 15 by a connecting rod 55 . As there is a connecting rod 55 for each cylinder assembly 50 , the cylinder assemblies 50 in each bank 20 are longitudinally offset with respect to the axis of rotation. Accordingly, the connecting rods 55 in each bank 20 are arranged in a side-by-side fashion along the respective crankshaft 15 .
FIG. 5 shows a sectional view of the hydraulic machine 1 as seen along the line B-B in FIG. 1 . Thus, FIG. 5 shows an end view of a bank 20 of a hydraulic machine 1 .
FIGS. 7 to 11 show various views of a cylinder assembly 50 , and a crankshaft 15 . The cylinder assembly 50 is one of the five cylinder assemblies in a bank 20 .
Each cylinder assembly 50 is supported by an outer thrust block 60 , and an inner thrust block 65 . The thrust blocks 60 , 65 are attached to the housing 10 . The head 70 of each cylinder assembly 50 has a ball shape. The thrust blocks 60 ; 65 locate the head 70 , while still allowing the cylinder head 70 to oscillate as the crankshaft 15 position changes.
A spherical bearing 75 is retained between a connecting rod 55 and the rod cap 56 . The spherical bearing 75 surrounds the crankshaft 15 , providing free relative rotational motion of the crankshaft 15 with respect to the connecting rod 55 . The rod cap 56 is attached to the connecting rod 55 by two big end bolts 80 .
By this arrangement, the piston 85 of each cylinder assembly 50 is positively attached to the crankshaft 15 by the connecting rod 55 and rod cap 56 arrangement. Thus, the speed range of the hydraulic motor is limited only by the flow characteristics of the hydraulic fluid.
Hydraulic fluid is supplied and removed from the cylinder head 70 via two fluid ports 95 .
FIG. 10 shows a cross section through a cylinder assembly 50 . The piston 85 is directly attached to the connecting rod 55 .
A gudgeon pin with a sufficient cross sectional area to handle the high forces cannot be arranged within cylinder since the cylinder bore is too narrow. Thus, to provide the angular movement required by the connecting rod 55 , the cylinder head 70 has been designed with a ball shape.
The cylinder head 70 is retained between the outer and inner thrust blocks 60 , 65 . The surfaces 62 , 67 of the thrust blocks 60 , 65 are concave to complement the ball shape of the cylinder head 70 . The cylinder head 70 is free to oscillate about an axis parallel to the longitudinal axis of the crankshaft 15 .
FIG. 11 shows a cross-section through the crankshaft 15 and the cylinder assembly 50 along the line B-B of FIG. 9 . Hydraulic fluid is introduced to, and expelled from, the cylinder assembly 50 via fluid ports 95 .
FIG. 12 shows an power coupling 5 and a pair of crank assemblies 25 . One crank assembly 25 is provided for each bank 20 . A pair of stroke adjustment mechanisms 100 are also provided for each bank 20 . The pair of stroke adjustment mechanisms 100 operate collaboratively to adjust the throw of the respective crankshaft 15 . By adjusting the throw of the crankshafts 15 , the hydraulic machine is provided with variable displacement. In other words, the swept volume can be increased or decreased by changing the stroke length of the cylinder assemblies 50 . Thus, the hydraulic machine 1 has a stepless ratio transmission throughout the entire speed range.
Two main bearings 105 (one at each end of the crankshaft 15 ) contain the stroke adjustment mechanisms 100 . Consequently, the main bearings 105 cannot be used to transmit torque.
To transmit output or input torque (depending on the mode of operation of the hydraulic machine 1 ), it is necessary to collect the torque at each main bearing 105 . This is achieved using lay shafts 110 (see FIG. 13 ). In the preferred embodiment, two lay shafts 110 are used.
The lay shafts 110 have pinion gears 115 , each of which engage a bull gear 120 attached to each of the main bearings 105 . The lay shafts 110 collect the torque from the bull gears 120 , and also serve to maintain the synchronisation between the bull gears 120 .
In order to control the stroke length of the pistons 85 , a helical shaft 125 is coupled to the bull gears 120 . The helical shaft 125 is not used to transmit torque, but remains in synchronisation with the bull gears 120 .
For each bank 20 of cylinder assemblies 50 , a helix 130 is formed on the helical shaft 125 , and a helical nut 135 is fitted. The helical nuts 135 have projections 140 . An outer sheath 145 is also provided for each bank 20 (see FIG. 14 ). Each outer sheath 145 has a thin pinion gear 150 at each end. The outer sheaths 145 surround the helical shaft 125 .
The projections 140 engage slots 155 in the outer sheaths 145 . As a helical nut 135 rotates as it is displaced longitudinally along the helical shaft 125 . Hence, such longitudinal movement of the helical nut 135 causes the associated outer sheath 145 to rotate.
Each pinion gears 150 engages a ring gear 160 located adjacent to the bull gears 120 , on the same side as the crankshaft 15 . Each ring gear 160 is rotatable on its main bearing 105 . As the helical nut 135 is moved longitudinally along the helical shaft 125 , the two ring gears 160 of the respective bank 20 are rotated. This mechanism provides means to rotate the ring gears 160 while the hydraulic machine 1 is operating at any speed or load.
The ring gears 160 drive the stroke adjustment mechanisms 100 . Thus, longitudinal movement of the helical nuts 135 provide means to drive the stroke adjustment mechanisms 100 .
A stroke adjustment mechanism 100 is shown in FIGS. 15 to 20 .
The main bearing 105 is a cylinder with the hollow cylindrical portion eccentrically positioned within the bearing 105 . A pair of eccentric rings 190 , 195 provide the actual stroke variation.
An outer eccentric ring 190 in the shape of a cylinder body with a hollow cylindrical portion. The diameter of the cylinder body of the outer eccentric ring 190 is geometrically dimensioned such that it is rotatably contained within the bore of the hollow portion of the main bearing 105 .
A portion of the first end of the outer eccentric ring 190 is provided with a set of gear teeth 195 . The other end is provided with a counter balance 200 .
An inner eccentric ring 205 in the shape of a cylinder body with a hollow cylindrical portion. The diameter of the cylinder body of the inner eccentric ring 205 is geometrically dimensioned such that it is rotatably contained within the bore of the hollow portion of the outer eccentric ring 190 .
A portion of the first end of the inner eccentric ring 20 S is provided with a set of gear teeth 210 . The other end is provided with a counter balance 215 .
Each end of the crankshaft 15 is retained within the hollow portion of an inner eccentric ring 205 . The throw of the crankshaft 15 is varied by moving the crankshaft 15 radially with respect to the respective main bearing 105 . This radial movement is achieved by simultaneously rotating the outer eccentric ring 190 in a first direction and rotating the inner eccentric ring 205 in the opposite direction. The speed of rotation of the eccentric rings 190 , 205 is the same.
There is a set of gear teeth 165 formed on the inner surface of each ring gear 160 . The teeth 165 engage the teeth of the first primary gear 175 of a gear train 170 . The first primary gear 175 engages the teeth 195 on the outer eccentric ring 190 .
A second primary gear 180 is attached to the side of the first primary gear 175 . The second primary gear 180 rotates with the first primary gear 175 . A secondary gear 185 is positioned between the second primary gear 180 and the teeth 210 on the inner eccentric ring 205 .
A gear train bearing 220 secures the gear train 170 in place. The main bearing 105 has a cut out section 106 through which the gear train 170 extends.
To ensure that the stroke adjustment mechanism 100 remains rotationally balanced, the counter balances 200 , 215 rotate with the respective eccentric rings 190 , 205 . The counter balances 200 , 215 cancel themselves out at zero stroke length, and work together at full stroke. The stroke adjustment mechanism 100 , and thus the hydraulic machine 1 are always balanced.
FIG. 16 shows a wire frame view of the main bearing 105 , the outer and inner eccentric rings 190 , 205 and the gear train 170 . The counter balances 200 , 215 are shown by the broken lines.
FIG. 17 is an exploded view of the stroke adjustment mechanism 100 .
FIGS. 18 to 20 illustrate the outer and inner eccentric rings 190 , 205 . FIG. 18 also shows the gear train 170 .
When operating the hydraulic machine 1 as a motor, the five cylinder assemblies 50 in the respective bank 20 sequentially apply a force to the crankshaft 15 , such that rotational motion is imparted to the crankshaft 15 . The rotational motion is transferred through a bull gear 120 to the lay shafts 110 .
When operating the hydraulic machine 1 as a pump, the power coupling 5 is rotated. The cylinders assemblies 50 are driven by the rotation of the crankshaft 15 . Thus, hydraulic fluid is pumped from the machine 1 .
It will be understood by persons skilled in the art of the invention that many modifications may be made without departing from the scope of the invention.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. | A hydraulic machine which can exchange hydraulic fluid pressure with rotational motion of an input/output means, having a radial arrangement of a plurality of hydraulic piston and cylinder assemblies about a crankshaft, the hydraulic cylinder and piston assemblies being longitudinally spaced along the crankshaft; and a means for varying eccentricity of the crankshaft whereby reciprocal motion of the pistons within the respective hydraulic cylinders is consequential to rotational motion of the crankshaft about the longitudinal axis of the crankshaft. | 5 |
INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS
Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57.
This application claims priority to Ecuadorean Patent Application No. SP2013-12745 filed on Jun. 28, 2013, the entire contents of which are hereby incorporated by reference and should be considered a part of this specification.
BACKGROUND
1. Field
The present application is directed to a system for collecting an endometrial tissue sample, and more particularly to a non-invasive endometrial sample collector.
2. Description of the Related Art
There are several existing procedures for obtaining samples of endometrial tissue. One such procedure involves the sampling of the endometrium with a small plastic device that is introduced in the uterine cavity and through the uterine cervix in order to obtain the tissue sample. This procedure is usually performed in a doctor's office, without anesthesia.
Another existing procedure for obtaining an endometrial tissue sample involves cervical dilation and curettage (D&C). The D&C procedure requires insertion of instruments (e.g., curette or sharp curettage, suction curettage, electric vacuum aspiration) in the uterine cavity and through the uterine cervix to remove endometrial tissue samples, such as by scraping and scooping the endometrial tissue sample. This procedure is performed in a hospital, under anesthesia. The procedure is often performed blindly by the doctor (e.g., without the use of any imaging technique such as ultrasound or hysteroscopy)
Still another existing procedure for obtaining an endometrial tissue sample involves a hysteroscopy. This procedure involves introducing an optical system (e.g., endoscope) within the uterine cavity and through the uterine cervix to directly observe the endometrium. The endoscope can have operative channels through which instruments (e.g., biopsy instruments, resectoscope) can be deployed to obtain a sample of the endometrial tissue under the visual guidance provided by the optical system. Such a procedure can be performed at a hospital or surgical centers, or a clinic, and can be performed under local anesthesia. Hysteroscopies are more expensive procedures (from the patient's and doctor's point of view) since they require expensive equipment and trained specialists.
All of the above described existing procedures for obtaining endometrial tissue samples have numerous disadvantages and potential risks to the patient, including: the risk of infection (e.g., due to the introduction of instruments into the vaginal cavity); the risk of perforating the endometrium and uterine wall (e.g., and possibly damage other organs, such as the intestines); severe bleeding (even in the absence of perforation of the endometrium); endometrial lesions by scarring, leading to infertility (i.e., Asherman's Syndrome); the risk of interrupting an existing but undiagnosed pregnancy; the risk of side effects from antibiotics or pain medication; the risks associated with anesthesia; pain and/or discomfort to the patient; interruption of sexual activity following the procedure; interruption of work and/or social activity for the patient following the procedure; and the risk of allergic reactions to drugs (e.g., antibiotics, analgesic, anesthesia, etc.), iodine (used for cleaning the uterine cervix and vagina during the procedure), latex (e.g., surgical gloves). Other drawbacks of existing procedures include the amount of time the procedures take, the elevated cost of the procedures and the complications they cause in the patient's lives (e.g., anxiety, interruption of work, family interactions and sexual activity).
SUMMARY
Accordingly, there is a need for an improved system and method for obtaining an endometrial tissue sample that does not suffer from the drawbacks associated with existing procedures, such as those described above.
In accordance with an aspect of the invention, an endometrial sample collector is provided. The collector comprises an outer body of absorbent material configured for insertion into a vaginal cavity of a patient such that a distal end of the body is positioned proximate a uterine cervix of the patient. The collector also comprises an internal collection assembly disposed within the outer body of absorbent material. The internal collection assembly comprises a funnel having an opening at the distal end of the outer body configured to face the uterine cervix when the outer body is positioned in the vaginal cavity, and a reservoir in fluid communication with the funnel. During a menstruation cycle of the patient when endometrial tissue cells are shed within menstrual fluid that passes through the uterine cervix, at least a portion of said menstrual fluid is directed to the reservoir via the funnel under the force of gravity.
In accordance with an aspect of the invention, an endometrial sample collector is provided. The collector comprises an outer body of absorbent material configured for insertion into a vaginal cavity of a patient such that a distal end of the body is positioned proximate a uterine cervix of the patient. The collector also comprises an internal collection assembly disposed within the outer body of absorbent material. The internal collection assembly comprises a funnel having an opening at the distal end of the outer body configured to face the uterine cervix when the outer body is positioned in the vaginal cavity, a conduit in fluid communication with the funnel, and a reservoir in fluid communication with the conduit. During a menstruation cycle of the patient when endometrial tissue cells are shed within menstrual fluid that passes through the uterine cervix, at least a portion of said menstrual fluid is directed to the reservoir via the funnel and the conduit under the force of gravity.
In accordance with an aspect of the invention, a method for passively collecting an endometrial tissue sample is provided. The method comprises inserting a sample collector into a vaginal cavity of a patient so that a distal end of the collector is positioned proximate a uterine cervix of the patient. The method also comprises collecting an endometrial sample in the sample collector during a menstrual cycle of the patient or during any type of normal or abnormal bleeding solely under the force of gravity. The method also comprises sending the sample collector with the collected sample to a laboratory for evaluation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic perspective top view of an endometrial sample collector.
FIG. 2 is a schematic perspective top view of the endometrial sample collector of FIG. 1 , showing internal components of the collector in phantom.
FIG. 3 is a schematic bottom view of the endometrial sample collector of FIG. 1 .
FIG. 4 is a schematic front view of the endometrial sample collector.
FIG. 5 is a schematic perspective top view of one embodiment of a collection assembly of the endometrial sample collector.
FIG. 6A is a schematic perspective top view of one embodiment of a collection assembly of the endometrial sample collector.
FIG. 6B is a schematic perspective top view of one embodiment of a collection assembly of the endometrial sample collector.
FIG. 6C is a schematic perspective top view of one embodiment of a collection assembly of the endometrial sample collector.
FIG. 6D is a schematic perspective top view of one embodiment of a collection assembly of the endometrial sample collector.
FIG. 7A is a schematic top view of the collection assembly of FIG. 6A .
FIG. 7B is a schematic top view of the collection assembly of FIGS. 6B , 6 C and 6 D.
FIG. 8 is a block diagram illustrating a method of collecting an endometrial tissue sample.
DETAILED DESCRIPTION
FIGS. 1-4 show and endometrial sample collector 100 that extends between a proximal end 2 and a distal end 3 and includes and outer body 10 and an internal collection assembly 50 . The outer body 10 is of an absorbent material (e.g., cotton, rayon, sponge material, absorbent polymer), such as the material used in typical tampons, and has absorption channels 11 through which fluid passes toward the internal collection assembly 50 . The outer body 10 of absorbent material advantageously facilitates patient comfort during collection of an endometrial sample in the manner discussed further below. The sample collector 100 can have a thread or cord 20 attached to it to aid in the removal of the collector 100 . As shown in FIG. 1 , the thread or cord 20 is in the form of a loop. However, the thread or cord 20 can optionally be a single string that extends to a free end (e.g., not a loop).
The endometrial sample collector 100 has a length L between the proximal end 2 to the distal end 3 of between about 4 cm and about 6 cm, and has a width W of between about 1 cm and about 3 cm. However, the endometrial sample collector can have other suitable dimensions.
The inner collection assembly 50 can be wrapped by the outer body 10 . The collection assembly has a cup or funnel 52 with an open end at the distal end 3 of the collector 100 that receives the sample therein. The funnel 52 is in fluid communication with a conduit 54 , which is itself in communication with a reservoir 56 , such that the conduit 54 is interposed between the funnel 52 and the reservoir 56 . The reservoir 56 can be at least partially filled with a fluid 4 that preserves the endometrial sample once received. The funnel 52 , conduit 54 and reservoir 56 can be separate components that are coupled together to form the collection assembly 50 . Optionally, the funnel 52 , conduit 54 and reservoir 56 can be made as a single monolithic piece (e.g., via an injection molding process). In other variations, the funnel can be augmented to have, or can be replaced with, a mesh or screen or permeable layer (e.g., foam layer) through which the sample fluid can pass to the reservoir 56 . The funnel 52 , conduit 54 and reservoir 56 can be made of a bio-compatible material, such as a plastic material, or other suitable material. The conduit 54 can optionally be excluded and the funnel 52 be in fluid communication with the reservoir 56 .
As discussed above, the fluid 4 in the reservoir 56 facilitates preservation of the collected endometrial sample. In one embodiment, the fluid 4 can be sterile saline. In another embodiment, the fluid 4 can be a solution made from a 1 L amount of distilled water in combination with the following composition: 0.9 gm/L Sodium Thioglycollate, 10.0 gm/L Sodium Glycerophosphate, 0.1 gm/L Calcium Chloride, and 3.0 gm/L Agar. The solution has a pH of 7.4±0.2. In some embodiments, the composition can optionally include 0.002 gm/L of methylene blue.
As shown in FIG. 5 , the collection assembly 50 can have a length L 2 that is substantially equal to the length L of the collector 100 . In one embodiment, the length L 2 is about 6 cm. The funnel 52 has a width W 1 (e.g., a diameter), and the reservoir 56 has a width W 2 , with the conduit 54 having a width smaller than the widths W 1 , W 2 of the funnel 52 and reservoir 56 . Optionally, the width of the conduit 54 can be generally equal to the widths W 1 , W 2 of the funnel 52 and reservoir 56 . The width W 1 of the funnel 52 can optionally be substantially equal to the width W 2 of the reservoir 56 . Optionally, the widths W 1 , W 2 (e.g., diameters) of the funnel 52 and reservoir 56 can be about 2 cm. As shown in FIG. 5 , the reservoir 56 has a generally spherical shape. However, the reservoir 56 can have other suitable shapes (e.g., oval).
FIGS. 6A-6D show various embodiments of the collection assembly 50 , in which the funnel 52 and reservoir 56 are the same, but where the conduit 54 is different for each embodiment.
In FIG. 6A , the conduit 54 A has a cross-shaped cross-section (see FIG. 7A ) that defines channels 54 A 2 between adjacent fins 54 A 2 of the conduit 54 A. The channels 54 A 2 can extend along the length of the conduit 54 A and can receive fluid axially from the funnel 52 as well as radially through the outer body 10 of absorbent material. The channels 54 A 2 can direct the sample fluid to the reservoir 56 .
In FIG. 6B , the conduit 54 B has a plurality of openings 54 B 1 distributed on a surface of the conduit 54 B (e.g., in spiral form) that are in fluid communication with an inner flow channel 54 B 2 of the conduit 54 B. Fluid can pass axially through the flow channel 54 B 2 from the funnel 52 to the reservoir 56 (see FIG. 7B ). Fluid can also pass transversely from the outer body 10 of absorbent material, through the openings 54 B 1 and into the flow channel 54 B 2 , which then directs the fluid to the reservoir 56 .
In FIG. 6C , the conduit 54 C has a plurality of openings 54 C 1 distributed on a surface of the conduit 54 C (e.g., in linear form) that are in fluid communication with an inner flow channel 54 C 2 of the conduit 54 C. Fluid can pass axially through the flow channel 54 C 2 from the funnel 52 to the reservoir 56 (see FIG. 7B ). Fluid can also pass transversely from the outer body 10 of absorbent material, through the openings 54 C 1 and into the flow channel 54 C 2 , which then directs the fluid to the reservoir 56 .
In FIG. 6D , the conduit 54 D is a tube that without any openings on its outer surface and has an internal flow channel 54 D 2 that directs fluid from the funnel 52 to the reservoir 56 , as shown in FIG. 7B .
FIG. 8 is a block diagram illustrating a method 200 of collecting an endometrial tissue sample using the sample collector 100 . The sample collector 200 is first inserted 210 (e.g., by the patient) into the vaginal cavity, in a similar manner as a tampon, so that the distal end 3 of the collector is proximate the uterine cervix and so that the funnel 52 faces the uterine cervix. Optionally, the distal end 3 is placed in contact with the uterine cervix. During menstruation, menstrual fluid, which will include endometrial tissue that is shed during the menstrual cycle and passes through the uterine cervix, is collected 220 by the collector 100 in the manner discussed above. For example, menstrual fluid can be collected in the funnel 52 and directed via the conduit 54 A, 54 B, 54 C, 54 D to the reservoir 56 , where the endometrial cells in the sample can be preserved in the preservation liquid 4 . Additionally, menstrual fluid absorbed by the outer body 10 of absorbent material can be directed transversely through channels (e.g., 54 A 1 ) or openings (e.g., 54 B 1 , 54 C 1 ) in a surface of the conduit 54 A, 54 B, 54 C, which can then also be directed to the reservoir 56 . Advantageously, the endometrial sample collector 100 passively collects the endometrial tissue sample using gravity and without the use of an external actuation force (e.g., without an aspiration or vacuum force, without a mechanical force such as scraping, etc.). Once the sample has been collected, the collector 100 can be can packaged in a container (e.g., plastic receptacle) and be sent 230 to a laboratory for evaluation. For example, the sample collector 100 can include user instructions directing the user on how to collect the sample, and how to package the sample for shipping to the laboratory, and optionally instructions on where to ship the collected sample.
Advantageously, the endometrial sample collector 100 and its use allows the patient to collect the sample without having to visit a doctor's office, clinic or hospital, and therefore without disruption to their normal daily activities. Additionally, the use of the collector 100 is non-invasive and does note expose the patient to the potential risks noted above with existing procedures (e.g., risk of infection, risk of perforation of the endometrium, pain and discomfort, bleeding, allergic reaction to medication, risks associated with anesthesia). Further, the sample collector 100 is as easy to use for patients as existing tampons. Additionally, the sample collector 100 can be used in patients with intact hymens (e.g., virgin women), patients that refuse gynecological exams or who live in remote areas far away from healthcare facilities, or patients who have problems adopting the correct gynecological position due to problems in their pelvic articulations, which is often the case following menopause. Further, the sample collector 100 allows the collection of endometrial tissue samples at much lower cost than existing procedures because, for example, doctor's fees (e.g., gynecologist, anesthesiologist), hospital fees, and disposable instruments and devices are avoided.
While certain embodiments of the inventions have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the systems and methods described herein may be made without departing from the spirit of the disclosure. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure. Accordingly, the scope of the present inventions is defined only by reference to the appended claims.
Features, materials, characteristics, or groups described in conjunction with a particular aspect, embodiment, or example are to be understood to be applicable to any other aspect, embodiment or example described in this section or elsewhere in this specification unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The protection is not restricted to the details of any foregoing embodiments. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
Furthermore, certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as a subcombination or variation of a sub combination.
Moreover, while operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Further, the operations may be rearranged or reordered in other implementations. Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the processes illustrated and/or disclosed may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be removed, others may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products.
For purposes of this disclosure, certain aspects, advantages, and novel features are described herein. Not necessarily all such advantages may be achieved in accordance with any particular embodiment. Thus, for example, those skilled in the art will recognize that the disclosure may be embodied or carried out in a manner that achieves one advantage or a group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.
Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements, and/or steps are included or are to be performed in any particular embodiment.
Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.
Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount. As another example, in certain embodiments, the terms “generally parallel” and “substantially parallel” refer to a value, amount, or characteristic that departs from exactly parallel by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, or 0.1 degree.
The scope of the present disclosure is not intended to be limited by the specific disclosures of preferred embodiments in this section or elsewhere in this specification, and may be defined by claims as presented in this section or elsewhere in this specification or as presented in the future. The language of the claims is to be interpreted broadly based on the language employed in the claims and not limited to the examples described in the present specification or during the prosecution of the application, which examples are to be construed as non-exclusive. | A non-invasive endometrial sample collector has an outer body of absorbent material configured for insertion into a vaginal cavity of a patient such that a distal end of the body is positioned proximate a uterine cervix of the patient. The collector has an internal collection assembly disposed within the outer body of absorbent material. The internal collection assembly includes a funnel having an opening at the distal end of the outer body configured to face the uterine cervix when the outer body is positioned in the vaginal cavity, and a reservoir in fluid communication with the funnel. During a menstruation cycle of the patient when endometrial tissue cells are shed within menstrual fluid that passes through the uterine cervix, or during any type of normal or abnormal bleeding episode, at least a portion of said fluid is directed to the reservoir via the funnel under the force of gravity. | 0 |
This application is a continuation-in-part of U.S. Ser. No. 08/760,331 filed Dec. 4, 1996.
BACKGROUND OF THE INVENTION
In the art of papermaking, chemical materials exist for improving the strength of paper when wetted with water or aqueous solutions, including body fluids such as urine, blood, mucus, menses, lymph and other body exudates. These materials are known in the art as "wet strength agents" and are commercially available from a wide variety of sources.
The substantivity or effectiveness of many cationic wet strength agents is limited by low retention of the wet strength agent on the cellulose fiber. Much of the applied chemical may not be retained on the fiber, but remains in solution or is washed off after application, for there are relatively few anionic sites on the cellulose surface to attract the charged wet strength agent, and in some cases there may be a large number of anionic sites on colloidal particles or other particles in the fiber suspension which may adsorb a large portion of the wet strength agent, limiting its effectiveness in increasing wet strength. Likewise, the presence of anionic additives or agents in the pulp has a deleterious effect on the efficiency of cationic wet strength agents. This adverse effect can be reduced by adding "cationic promoters" or other cationic additives to the stock, as is known in the art of papermaking, to help neutralize excess anionic sites on colloidal particles or "anionic trash" in the suspension, to allow more of a subsequently added cationic wet strength resin to attach to the fiber surface and not to be preferentially absorbed onto non-fiber components. Such additives can, for example, be cationic promoters such as polyethyleneimine with a cationic charge of about 0.75 to 3.5 milliequivalents/gram, quaternized polyamines, such as polydiallyidimethylammonium chloride, or cationic starch. Commonly used cationic resins include polyquaternary amines and are available from Cytec Industries under the trade names CYPRO 514, 515, 516. Cationic promoters are added to the stock in advance of the wet strength resins to ensure adequate mixing and adequate contact with the fibers. When used, the cationic resins are generally used in an amount of about 1 to 10 pounds per ton or 0.05 to 0.5%. The cationic promoter can be used at 0 to 0.5 wt %; typically the resins are used in an amount of about 0.02 to 0.3 wt % and preferably 0.1 to 0.2 wt %. The manufacturer of the promoter will typically recommend a pH for its use. The Cypro resins, for example, are effective over a pH of about 4 to 9.
However, the use of cationic promoters does not increase the number of anionic sites on the fiber surface itself, and may decrease the number of such sites, such that the intrinsic potential of the cationic wet strength agent to increase wet strength is still limited by inadequate attachment sites on the cellulose surface. What is needed, therefore, is an improved means of increasing the wet strength performance of paper prepared with cationic wet strength agents through the addition of anionic sites on the cellulose fiber. (The extent of anionic sites on the cellulose can be measured in terms of the carboxyl group content of cellulose, which is typically measured to be about 2 to 5 milliequivalent per 100 grams of cellulose, or higher.)
While the use of fiber reactive agents to enhance the efficiency of wet strength agents is not known, fiber reactive agents are known in the art, particularly for treatment of textiles. In particular, anionic fiber reactive dyes are well known in the art. By reactive dyes are meant the customary dyes that form a covalent bond with cellulose, e.g. those listed under the heading "Reactive dyes" in the Colour Index, Vol. 3, 3rd Edition (1971), on pages 3391-3560, and in Vol. 6, revised 3rd Edition (1975), on pages 6268-6345. Fiber reactive dyes contain functional groups with react with the hydroxyl groups of cellulose to form covalent bonds, and further contain anionic groups such as sulfonic groups. Monochlorotriazinyl reactive dyes are one exemplary class. Other fiber-reactive groups may be, for example monofluorotriazinyl, dichlorotriazinyl, dichloroquinoxalinyl, trichloropyrimidyl, difluorochloropyrimidyl, the α-bromoacrylamide group or the β-oxyethylsulphuric acid ester group, as disclosed in U.S. Pat. No. 4,155,707 issued to Franceschini et al., May 22, 1979, herein incorporated by reference. Many commercial dyes are stilbene derivatives and particularly are derivatives of 4,4'-diaminostilbene-2,2'-disulfonic acid, sometimes known as flavonic acid. Other fiber reactive dyes of importance are disclosed in U.S. Pat. No. 5,432,266 issued Jul. 11, 1995 to Herd and Roschger; U.S. Pat. No. 4,402,703 issued Sep. 6, 1983 to Panto and Kaswell; all of which are herein incorporated by reference.
In addition to fiber reactive dyes, fiber reactive fluorescent whitening agents and optical brighteners are known which employ reactive groups such as the chloro- or fluoro-s-triazinyl radical or a 5-chloro-2,6-difluoro-4-pyrimidinyl or 5-chloro-6-fluoro-4-pyrimidinyl radical; and other moieties known in the art of fiber reactive dyes, coupled with UV absorbing structures such as stilbene derivatives. Fluorescent whitening agents do not absorb light strongly in the visible spectrum, being substantially colorless in visible light, but do absorb ultraviolet light (e.g., in the wavelength range of about 300 to about 400 nm) and re-emit the energy absorbed as visible light, typically blue, thus increasing the apparent brightness of the material and helping to overcome a possibly yellow appearance. If excessive doses of fluorescent whitening agents are used, the material may no longer appear white but may have a blue, purple, or green tinge. Typical fluorescent whitening agents are derived from stilbene compounds, cumarins, benzocumarins, pyrazines, pyrazolines, oxazines, dibenzoxazolyl or dibenzimidazolyl compounds and naphthalimides, with stilbene among the most common. Exemplary fluorescent whitening agents are disclosed in U.S. Pat. No. 3,951,588, issued Apr. 20, 1976 to Perrin et al.; U.S. Pat. No. 4,140,852, "Triazinyl Styryl-Benzoxazole Fluorescent Dyestuffs," issued Feb. 20, 1979 to Eckstein and Harnisch; U.S. Pat. No. 3,951,588, "Process for Dyeing and Printing or Optical Brightening of Cellulose," issued Apr. 20, 1976; U.S. Pat. No. 4,228,071; "Triazine Containing Fiber-Reactive Disazo Dyestuffs," issued Oct. 14, 1980 to Riat and Seltz; U.S. Pat. No. 4,134,724, issued Jan. 16, 1979 to Thompson et al.; and U.S. Pat. No. 4,141,890 issued Feb. 27, 1979 to Hegar and Back, all of which are herein incorporated by reference.
While many optical brighteners or whitening compounds used in the art of papermaking have anionic groups that might be able to form bonds with cationic wet strength additives, fiber-reactive whitening compounds have not been used in a manner that can provide improved wet strength in paper or improved retention of wet strength compounds. Indeed, when possible interactions between whitening compounds and wet strength agents have been considered, it has been taught that the whitener should be added to the pulp after the wet strength agent has been added, as in German Patent No. DE 1,283,083, published Nov. 14, 1968 by H. E. Gottgens and H. Tretter of Bayer AG, in which case no improved retention of the wet strength agent by means of increased anionic sites on the fiber can be expected. Further, it has been taught that cationic polymer additives hinder the brightening effect of fluorescent whitening additives and can increase the apparent yellowness of a sheet by quenching fluorescence (B. W. Crouse and G. H. Snow, "Fluorescent Whitening Agents in the Paper Industry," Tappi J., Vol. 64, No. 7, July 1981, pp. 87-89). The possibility of negative interactions between cationic agents and fluorescent whitening agents was also recognized by H. Geenen in "Possibilities for Improving Paper Brightness," Wochenblatt Papierfabr., vol. 114, no. 2, end January 1986, pp. 41-42.
Reactive optical brighteners and fluorescent whitening agents are now rarely if ever used in the paper industry because of the tendency to hydrolyze when added to aqueous suspensions and because of other problems associated with the reactivity of the compounds. Indeed, as of 1998, it appears that no supplier of dyes and dyestuffs produces commercially available fiber reactive optical brighteners for use in the paper industry. Thus, the potential benefits of fiber reactive optical brighteners for papermaking properties appear not to have been recognized.
While fiber reactive forms may not be in use in the paper industry, non-reactive fluorescent whitening agents and optical brighteners are widely used. While the major uses are probably for improving the brightness of coated and uncoated printing and writing papers, one possible use is in the prevention of photoyellowing of high-yield fibers, particularly TMP and BCTMP. The lignin compounds in high-yield pulps can rapidly degrade to produce a yellow color upon exposure to UV light. The yellowing of newspaper, which usually comprises TMP or groundwood, is well known, but there are many other products for which yellowing is problematic. Paper towels and bath tissue, for example, can become yellow due to the ultraviolet component of ordinary fluorescent lights while sitting on the shelf of a grocery store.
In theory, if a compound absorbs UV energy, it may prevent the UV energy from causing reactions in the lignin that lead to yellowing. Ideally, the UV absorbing agent should be able to continually absorb UV energy and re-emit a portion of it as fluorescence rather than decomposing rapidly due to the energy absorbed. For this reason, fluorescent whitening agents appear to have promise in shielding high-yield pulps from the yellowing caused by UV light, and in hiding the yellowish tinge of such pulps through the addition of blue light from the fluorescence. While stilbene structures in high-yield pulp contribute to yellowing, especially in pulps bleached with peroxides (see "Reactive Structures in Wood and High-Yield Pulps; Daylight-Induced Oxidation of Stilbene Structures in the Solid State," by L. M. Zhang and G. Gellerstedt, Acta Chem. Scand. 48, no. 6: 490-497, June 1994), stilbene derivatives that function as UV absorbers may be able to reduce yellowing of high-yield paper by shielding lignin from UV. However, for durable materials or products intended for long-term use or long shelf lives, there is the risk that stilbene additives themselves will lead to yellowing with time, typically due to oxidative reduction of the double bond in the stilbene group. The decomposition of the stilbene derivative can lead to production of yellow chromophores or other undesired products. (Thioglycolic acid is known to cause some degree of photostabilisation of natural stilbene compounds in high-yield pulps, but poses other difficulties associated with sulfur compounds and with cost.) For this reason, it may be desirable for some products to avoid the use of stilbene derivatives altogether. For example, products comprising high brightness fibers such as bleached kraft fibers may be unsuited for the use of fluorescent whitening agents or stilbene derivatives in particular, if such compounds may degrade to give yellow chromophores. Further, in some countries, optical brighteners or fluorescent whitening agents are not permitted in paper packaging which may contact food. Further still, for some products and materials it is desirable that the hue or shade or white not be affected by the presence of UV light (i.e., the degree of whiteness or brightness is similar for both incandescent and fluorescent lights or incandescent light and sunlight). In such cases, the paper web should be substantially free of fluorescent whitening agents such that the web does not fluoresce in UV light. Thus, fluorescent whitening agents may not be desirable for all grades, but may be suited for high-yield grades, especially for disposable products where short-term protection from photoyellowing is needed.
Thus, in terms of fluorescent whitening agents, some applications may benefit from a synergistic use of fluorescent whitening agents that also promote improvements in non-optical properties of the web such as wet strength, while other applications may not be benefited by use of fluorescent whitening agents.
Therefore, an object of the present invention is to increase the number of anionic sites on the surface of papermaking fibers by pretreating the fibers, thus increasing the substantivity of subsequently added cationic wet strength agents that form covalent bonds with the cellulose. A further object of the present invention is to provide a means of increasing both the wet strength and the brightness of a web, particularly a web comprising high-yield papermaking fibers. A further object of the present invention is substantially increasing the wet strength of paper that can be achieved with a given dose of wet strength agent.
SUMMARY OF THE INVENTION
It has now been discovered that the wet strength of paper can be increased by adding certain fiber reactive anionic compounds to the papermaking furnish prior to the addition of cationic wet strength agents. The fiber reactive anionic compounds can be a fluorescent whitening agent, or not.
More specifically, in one aspect the invention resides in a method for making wet strength paper comprising the steps of:
a) providing an aqueous slurry of cellulosic papermaking fibers;
b) adding a substantially colorless reactive anionic compound to said aqueous slurry, said reactive anionic compound having the formula:
W--R--Y--X--B
wherein:
W is sulfonyl or carboxyl or salts thereof;
R is an aliphatic, an aromatic, an inertly or essentially inertly substituted aromatic, a cyclic, a heterocyclic, or an inertly or essentially inertly substituted heterocyclic radical;
Y is NH or ##STR1## X is a moiety suitable for forming a covalent bond to a hydroxyl group on cellulose, selected from the group consisting of monohalotriazine, dihalotriazine, trihalopyrimidine, dihalopyridazinone, dihaloquinoxaline, dihalophtalazine, halobenzothiazole, acrylamide, vinylsulfone, β-sulfatoethylsylfonamide, β-chloroethylsulfone, and methylol;
B is hydrogen, a group of the formula Y--R (wherein Y and R are defined as above), or a group of the formula Y--R--W (wherein Y, R, and W are defined as above);
c) adjusting the pH and temperature of said aqueous slurry to promote reaction of the reactive anionic compound with the cellulosic fibers;
d) adding a cationic wet strength agent and water to said aqueous slurry to create a papermaking furnish;
e) depositing said papermaking furnish on a foraminous surface to form an embryonic web; and
f) drying the web.
In another aspect, the invention resides in a method for making wet strength paper comprising the steps of:
a) providing an aqueous slurry of cellulosic papermaking fibers;
b) adding a substantially colorless reactive anionic compound to said aqueous slurry, said reactive anionic compound having the formula:
W--R--Y--X--B
wherein:
W is sulfonyl or carboxyl or salts thereof;
R is an aliphatic, an aromatic, an inertly or essentially inertly substituted aromatic, a cyclic, a heterocyclic, or an inertly or essentially inertly substituted heterocyclic radical;
Y is a linking group selected from --NH--, --SO 2 --, --CO-- and --CONH--;
X is a fiber reactive group capable of forming a covalent bond to a hydroxyl group on cellulose;
B is hydrogen, a group of the formula Y--R (wherein Y and R are defined as above), or a group of the formula Y--R--W (wherein Y, R, and W are defined as above);
c) adjusting the pH and temperature of said aqueous slurry to promote reaction of the reactive anionic compound with the cellulosic fibers;
d) adding a cationic wet strength agent and water to said aqueous slurry to create a papermaking furnish;
e) depositing said papermaking furnish on a foraminous surface to form an embryonic web; and
(f) drying the web.
In another aspect, the invention resides in a method for producing wet strength paper having improved optical properties, comprising the steps of:
a) providing an aqueous slurry of cellulosic papermaking fibers;
b) adding an anionic fiber reactive fluorescent whitening agent to said slurry;
c) adjusting the pH and temperature of said aqueous slurry to promote reaction of the anionic fiber reactive fluorescent whitening agent with the cellulosic fibers such that a substantial portion of the anionic fiber reactive fluorescent whitening agent becomes covalently bonded to said cellulosic papermaking fibers;
d) adding water and a cationic wet strength agent to said aqueous slurry to create a dilute papermaking furnish, such that a substantial portion of said cationic wet strength agent can form ionic bonds with said anionic fiber reactive fluorescent whitening agent covalently bonded to the cellulosic papermaking fibers;
e) depositing said papermaking furnish on a foraminous surface to form an embryonic web; and
f) drying the web.
In another aspect, the invention resides in a wet-strength paper web comprising:
a) cellulosic papermaking fibers;
b) from about 0.02 to about 1.5 dry weight percent, based on dry fiber, of a cationic wet strength additive; and
c) from about 0.01 to about 4 dry weight percent, based on dry fiber, of a reactive anionic compound, said reactive anionic compound being substantially colorless in both visible and UV light and having the formula:
W--R--Y--X--B
wherein:
W is sulfonyl or carboxyl or salts thereof;
R is an aliphatic, an aromatic, an inertly or essentially inertly substituted aromatic, a cyclic, a heterocyclic, or an inertly or essentially inertly substituted heterocyclic radical;
Y is --OH-- or --CONH--;
X is a fiber-reactive group suitable for forming a covalent bond to a hydroxyl group on cellulose; and
B is hydrogen, a group of the formula Y--R (wherein Y and R are defined as above), or a group of the formula Y--R--W (wherein Y, R, and W are defined as above).
In a further aspect, the invention resides in a method of preparing paper with relatively high wet strength and low dry strength by first increasing anionic sites on the cellulose fibers with a fiber reactive anionic compound as described above, followed by addition of a chemical debonder agent and a cationic wet strength agent. The debonder agent can be applied to the fibers while the fibers are in solution, followed by addition of the cationic wet strength agent, whereafter the paper is formed, dewatered, and dried. Alternatively, the debonder agent may be applied to a dried or partially dried paper web that has been prepared with a fiber reactive anionic compound and a cationic wet strength agent. In either case, the debonder agent interferes with hydrogen bond formation, reducing the dry strength of the paper, while having relatively little effect on covalent bond formation. The result is a paper with an increased wet:dry tensile strength ratio. Such paper can have reduced stiffness and improved softness due to the reduced extent of hydrogen bonding, while still having high wet strength. The reactive anionic compound, however, can also lead to improved dry strength of the paper, especially if it contains two or more reactive groups, but also by virtue of increasing the efficiency of the wet strength additive. Improved strength without refining the fibers can permit harsher creping or other mechanical softening treatments for a bulkier, softer material. Thus, the invention also resides in a method of improving multiple material properties of a tissue web, including wet strength, through the synergistic use of anionic fiber reactive additives and cationic wet strength agents, followed by mechanical softening such as creping.
In contrast to the most common methods of adding dyestuffs to cellulose, the methods of the present invention do not require a salting step wherein sodium chloride or other salts are added in high concentration to the liquid phase to force the dye to affix to the fiber or precipitate on the fiber due to the common ion effect. In particular, the method of affixing the reactive anionic compound (analogous to a "colorless dye") to cellulosic fibers at elevated consistency can be done with no need for salt addition, with no need for a subsequent washing step to remove the salt or byproducts of the reaction, and with very little process water in general. Thus, in contrast to conventional textile dyeing technology, the present invention modifies the fibers in a way that reduces water usage and water pollution (particularly pollution due to salt content in the water). Therefore, in another aspect, the present invention can provide a process for improving the wet strength of paper through the use of colorless fiber reactive compounds via a method that is free of at least one of a salting step and a washing step after addition of the reactive anionic compound and prior to depositing the furnish on a foraminous surface.
When practicing a method of this invention, the wet strength that can be achieved with a given quantity of wet strength resin can be increased by a factor of about 20 percent or greater, more specifically about 40 percent or greater, more specifically about 50 percent or greater, and most specifically about 70 percent or greater. In addition, methods of this invention can achieve wet tensile strength values in substantially unrefined paper of about 1500 grams per inch (g/in) or greater, preferably about 2000 g/in or greater, and most preferably about 2300 g/in or greater, based on a 60 gsm Tappi handsheet. Also, wet:dry strength ratios can be attained which are about 0.2 or greater, more specifically about 0.3 or greater, more specifically about 0.4 or greater, more specifically about 0.5 or greater, and still more specifically from about 0.2 to about 0.5.
Creped or throughdried tissue webs made according to the present invention can be particularly useful as disposable consumer products and industrial or commercial products. Examples include paper towels, bath tissue, facial tissue, wet wipes, absorbent pads, intake webs in absorbent articles such as diapers, bed pads, meat and poultry pads, feminine care pads, and the like. Uncreped through-air dried webs having high wet strength and preferably having a basis weight from about 10 gsm to about 80 gsm, alternatively from about 20 to about 40 gsm, may be particularly useful as wet resilient, high bulk materials for absorbent articles and other uses, as illustrated by way of example in commonly owned copending U.S. application, Ser. No. 08/614,420, "Wet Resilient Webs and Disposable Articles Made Therewith," by F.-J. Chen et al., herein incorporated by reference.
Certain embodiments of the invention are directed to the additional optical properties of the web that are affected by the presence of reactive anionic compounds bound to cellulose in wet strength paper. In one embodiment of the invention, the reactive anionic compound does not fluoresce in ultraviolet light and preferably does not absorb strongly in UV or visible light, being colorless or substantially colorless in UV and visible light. Alternatively, for some pulps, a reactive anionic compound which strongly absorbs UV light may be desirable. Thus in a separate embodiment, the reactive anionic compound can comprise a UV absorbing group which can serve to shield lignin from photoyellowing in high-yield paper, or can contain a fluorescent group which can improve the optical brightness of the paper in UV-containing light, as well as decrease the apparent yellowness of the paper by increasing the intensity of the blue component of light leaving the paper.
DEFINITION OF TERMS AND TEST PROCEDURES
As used herein, "colorless" in terms of a chemical compound means that the compound does not absorb light strongly in the visible spectrum. Thus, a colorless compound, when applied to a white sheet of paper, will not alter the human visual perception that the sheet is white (as opposed to red or blue or some other visible color) when under ordinary white incandescent light, substantially regardless of concentration. More specifically such a compound can be said to be "colorless in visible light" (synonymous with simply "colorless" as used herein). If a colorless compound also does not absorb ultraviolet light strongly (particularly in the wavelength range of about 330 to about 380 nm), then, as used herein, that compound is "colorless in UV and visible light," though humans are not gifted with the ability to distinguish color in the UV spectrum. Fluorescent whitening agents are not "colorless in UV and visible light" because of their strong absorption of UV light, even though such compounds appear substantially colorless to the human eye when applied to paper.
"Papermaking fibers," as used herein, include all known cellulosic fibers or fiber mixes comprising cellulosic fibers. Fibers suitable for making the webs of this invention comprise any natural or synthetic cellulosic fibers including, but not limited to: nonwoody fibers, such as cotton liners and other cotton fibers or cotton derivatives, abaca, kenaf, sabai grass, flax, esparto grass, straw, jute hemp, bagasse, milkweed floss fibers, and pineapple leaf fibers; and woody fibers such as those obtained from deciduous and coniferous trees, including softwood fibers, such as northern and southern softwood kraft fibers; hardwood fibers, such as eucalyptus, maple, birch, aspen, or the like. Woody fibers may be prepared in high-yield or low-yield forms and may be pulped in any known method, include kraft, sulfite, groundwood, thermomechanical pulp (TMP), chemithermomechanical pulp (CTMP) and bleached chemithermomechanical pulp (BCTMP). High brightness pulps, including chemically bleached pulps, are especially preferred for tissue making, but unbleached or semi-bleached pulps may also be used. Recycled fibers are included within the scope of the present invention. Any known pulping and bleaching methods may be used.
Synthetic cellulose fiber types include rayon in all its varieties and other fibers derived from viscose or chemically modified cellulose. Chemically treated natural cellulosic fibers may be used such as mercerized pulps, chemically stiffened or crosslinked fibers, sulfonated fibers, and the like. Suitable papermaking fibers may also include recycled fibers, virgin fibers, or mixes thereof.
As used herein, "high yield Pulp fibers" are those papermaking fibers of pulps produced by pulping processes providing a yield of about 65 percent or greater, more specifically about 75 percent or greater, and still more specifically from about 75 to about 95 percent. Yield is the resulting amount of processed fiber expressed as a percentage of the initial wood mass. High yield pulps include bleached chemithermomechanical pulp (BCTMP), chemithermomechanical pulp (CTMP) pressure/pressure thermomechanical pulp (PTMP), thermomechanical pulp (TMP), thermomechanical chemical pulp (TMCP), high yield sulfite pulps, and high yield Kraft pulps, all of which contain fibers having high levels of lignin. Characteristic high-yield fibers can have lignin content by mass of about 1 percent or greater, more specifically about 3 percent or greater, still more specifically from about 2 percent to about 25 percent. Likewise, high yield fibers can have a kappa number greater than 20 or greater than 30, for example. The preferred high yield pulp fibers, after being prepared by pulping and optional bleaching steps and prior to being formed into dry bales or webs, in one embodiment can also be characterized by being comprised of comparatively whole, relatively undamaged fibers, high freeness (250 Canadian Standard Freeness (CSF) or greater, more specifically 350 CSF or greater, and still more specifically 400 CSF or greater), and low fines content (less than 25 percent, more specifically less than 20 percent, still more specifically less that 15 percent, and still more specifically less than 10 percent by the Britt jar test). In one embodiment, the high-yield fibers are preferably predominately softwood, more preferably northern softwood.
As used herein, the term "cellulosic" is meant to include any material having cellulose as a major constituent, and specifically, comprising at least 50 percent by weight cellulose cellulose or a cellulose derivative. Thus, the term includes cotton, typical wood pulps, cellulose acetate, cellulose triacetate, rayon, thermomechanical wood pulp, chemical wood pulp, debonded chemical wood pulp, milkweed, and the like.
As used herein, a "wet strength agent" is any material that when added to a paper web or sheet results in providing the sheet with a wet geometric tensile strength to dry geometric tensile strength ratio in excess of 0.1. Typically these materials are termed either as "permanent" wet strength agents or as "temporary" wet strength agents. For the purposes of differentiating permanent from temporary wet strength, permanent wet strength agents are defined as those resins which, when incorporated into paper or tissue products, will provide a product that retains 50 percent or more of its original wet strength after exposure to water (i.e., saturation into deionized water at 73° F.) for a period of at least five minutes. Temporary wet strength agents are those which show less than 50% of their original wet strength after exposure to water for five minutes. Both classes of material find application in the present invention. The present invention is particularly concerned with wet strength resins that are cationic and especially polycationic polymers. "Water retention value" (WRV) is a measure that can be used to characterize some fibers useful for purposes of this invention. WRV is measured by dispersing 0.5 grams of fibers in deionized water, soaking overnight, then centrifuging the fibers in a 1.9 inch ter tube with a 100 mesh screen at the bottom at 1000 G for 20 minutes. The samples are weighed, then dried at 105° C. for two hours and then weighed again. WRV is (wet weight--dry weight)/dry weight. Fibers useful for purposes of this invention can have a WRV of about 0.7 or greater, more specifically from about 1 to about 2. High yield pulp fibers typically have a WRV of about 1 or greater.
As used herein, "Absorbent Capacity" refers to the amount of distilled water that an initially 1-inch cube of densified absorbent fibrous material can absorb while in contact with a pool of room-temperature water and still retain after being removed from contact with liquid water and held on a metal screen and allowed to drip for 30 seconds. Absorbent capacity is expressed as grams of water held per gram of dry fiber. Densified pads of the present invention have water retention values of about 5 g/g or greater, preferably about 7 g/g or greater, more preferably from about 8 g/g to about 15 g/g, and most preferably about 9 g/g or greater.
As used herein, "bulk" and "density," unless otherwise specified, are based on oven-dry mass of a sample and a thickness measurement made at a load of 0.05 psi with a three-inch diameter circular platen. Thickness measurements of samples are made in a Tappi conditioned room (50% RH and 73° F.) after conditioning for at least four hours. Samples should be essentially flat and uniform under the area of the contacting platen. Bulk is expressed as volume per mass of fiber in cc/g and density is the inverse, g/cc.
As used herein, the "wet:dry ratio" is the ratio of the geometric mean wet tensile strength divided by the geometric mean dry tensile strength. Geometric mean tensile strength (GMT) is the square root of the product of the machine direction tensile strength and the cross-machine direction tensile strength of the web. Tensile strengths are measured with standard Instron test devices having a 5-inch jaw span using 1-inch wide strips of tissue, conditioned at 50% relative humidity and 72° F. for at least 24 hours, with the tensile test run at a crosshead speed of 1 in/min.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a characteristic fiber reactive anionic compound after reaction with a hydroxyl group on a cellulose fiber, wherein the anionic moiety of the fiber reactive anionic compound is engaged in an ionic bond with a cationic site of a cationic wet strength agent.
FIGS. 2 through 4 are bar graphs showing the physical properties of 60 gsm handsheets made according to Example 1 at various levels of added fiber reactive anionic compound (RAC) and Kymene. FIG. 2 depicts measured wet tensile strength in grams of force per inch; FIG. 3 depicts results for dry tensile strength; FIG. 4 depicts wet TEA (total energy absorbed), and FIG. 5 depicts dry TEA.
DETAILED DESCRIPTION OF THE INVENTION
One aspect of the present invention is a multistep process for improving the wet strength and other physical properties of paper through the novel use of anionic fiber reactive agents. The anionic fiber reactive agents bond covalently to the hydroxyl groups of cellulose, providing new anionic sites to attract and retain subsequently added cationic polymers, particularly polycationic wet strength resins. Before describing the steps of the present invention, suitable fiber reactive compounds will be disclosed.
SUITABLE FIBER REACTIVE ANIONIC COMPOUNDS
Most generally, any known fiber reactive compound can be used provided it has the following properties:
a) It must be substantially colorless to permit its use in a wide range of paper products, such as white tissue. In one embodiment, it is also substantially colorless in ultraviolet and visible light. In another embodiment, it is substantially colorless in visible light but absorbs UV light strongly. In yet another embodiment, it is substantially colorless but fluoresces in UV light, as do fluorescent whitening agents (also known as optical brighteners).
b) It must contain anionic groups, such as sulfonyl or carboxyl groups, capable of forming ionic bonds with a polycationic polymer, particularly a polymer containing quaternary ammonium groups or other cationic groups typical of wet strength resins. The ionic bonds with cationic groups of a polymer help to form bridges between the fiber and the wet strength agent to hold the polymer on the fiber, thus increasing the effectiveness of a given dose of a cationic polymer, particularly a wet strength agent, in a papermaking furnish.
c) It must contain at least one fiber reactive group capable of forming covalent bonds with the hydroxyl groups of cellulose.
d) Preferably it is substantially water soluble, or at least soluble enough to permit effective reaction with cellulose in an aqueous slurry of papermaking fibers having a consistency of about 2 percent by weight or greater.
Such fiber reactive anionic compounds can be fiber reactive "dyes" modified to be without chromophore groups (i.e., colorless or substantially colorless) and further modified, if necessary, to ensure the presence of at least one anionic moiety such as a sulfonic or carboxylic group.
Specific examples of suitable reactive anionic compounds are given by the formula:
W--R--Y--X--B (1)
wherein W is an anionic moiety, particularly sulfonyl or carboxyl or salts thereof;
R is a bridging group such as an aliphatic, an aromatic, an inertly or essentially inertly substituted aromatic, an aminoaryl such as a diaminostilbene group, a cyclic, a heterocyclic, optionally a heterocyclic comprising at least one 5- or 6-membered ring having 2 or 3 nitrogens, or an inertly or essentially inertly substituted heterocyclic radical; the bridging group being characterized by low absorption of visible light (i.e., not contributing to a colored appearance in visible white light), and preferably being resistant to attack or cleavage at 70° C. over a pH range of 6 to 8, preferably 6 to 9, more preferably 5 to 9, and most preferably 4 to 10;
Y is a linking group such as --NH-- (preferably), --SO 2 --, --CO--, --C--; or --CONH--, which is: ##STR2## X is a fiber reactive group suitable for forming a covalent bond on cellulose such as an ether-type linkage to a hydroxyl group on cellulose, selected according to principles and examples disclosed hereafter; and
B is either hydrogen, a group of the formula Y--R (wherein Y and R are defined as above), or a group of the formula Y--R--W (wherein Y, R, and W are defined as above).
A particular commercially available example of a suitable fiber reactive anionic compound, discovered to be useful for the present invention, is the nylon dye retardant Sandospace S produced by Clariant Corp., Charlotte, N.C. While the formula of Sandospace S is proprietary, chemical analysis and partial information from the supplier confirms that it has a chlorinated triazine group, aromatic structures, and sulfonic groups.
In one embodiment, the fiber reactive group X is selected from the group consisting of monohalotriazine, dihalotriazine, trihalopyrimidine, dihalopyridazinone, dihaloquinoxaline, dihalophtalazine, halobenzothiazole, haloacrylamide, vinylsulfone, β-sulfatoethyl-sulfonamide, β-haloethylsulfone, and methylol, with dihalotriazine believed to be particularly advantageous because of an ability to allow reaction with the fiber to occur at lower temperatures than monohalotriazine and related compounds; and with chlorine as the preferred halogen. In another preferred embodiment, the fiber reactive moiety or group is a halo-substituted six-membered heterocyclic radical with two or three ring nitrogen atoms, said group being capable of reacting with the hydroxyl groups of cellulose, wherein said fiber reactive group is bonded to the rest of the compound via an --NH-- linkage (i.e., group Y is --NH--).
Hegar and Back in U.S. Pat. No. 4,141,890, issued Feb. 27, 1979, herein incorporated by reference, list a variety of acylating agents containing a fibre-reactive radical, which may be used in the production of fiber reactive dyestuff. Such acylating agents can also be of value in the production of colorless fiber reactive groups according to the present invention using techniques known to those skilled in the art through reaction to join the acylating agent to a bridging group or other molecular components connected to anionic groups. These acylating agents include: chloroacetyl chloride or bromoacetyl chloride, beta-chloropropionyl or beta-bromopropionyl chloride, alpha, beta-dichloropropionyl or alpha, beta-dibromopropionyl chloride, chloromaleic anhydride, carbyl sulphate, acrylyl chloride, beta-chloroacrylyl or beta-bromoacrylyl chloride, alpha-chloroacrylyl or alpha-bromoacrylyl chloride, alpha, beta-dichloroacrylyl or alpha, beta-dibromoacrylyl chloride, trichloroacrylyl chloride, chlorocrotonyl chloride, propiolic acid chloride, 3,5-dinitro-4-chlorobenzene-sulphonic acid chloride or -carboxylic acid chloride, 3-nitro-4-chlorobenzene-sulphonic acid chloride or -carboxylic acid chloride, 2,2,3,3-tetrafluorocyclobutane-1-carboxylic acid chloride, beta-chloroethylsulphonyl-endomethylene-cyclohexanecarboxyl ic acid chloride, acrylsulphonyl-endomethylene-cyclohexanecarboxylic acid chloride and above all heterocyclic acid halides and their derivatives, such as the 2-chlorobenzoxazolecarboxylic acid chlorides, 2-chlorobenzthiazolecarboxylic or -sulphonic acid chlorides and above all the following compounds possessing at least 2 nitrogen atoms as hetero-atoms of a 6-membered heterocyclic structure: 4,5-dichloro-1-phenylpyridazonecarboxylic or -sulphonic acid chloride, 4,5-dichloropyridazonepropionic acid chloride, 1,4-dichlorophthalazine carboxylic or -sulphonic acid chloride, 2,3-dichloroquinoxalinecarboxylic or -sulphonic acid chloride, 2,4-dichloroquinazolinecarboxylic or -sulphonic acid chloride, 2-methanesulphonyl-4-chloro-6-methylpyrimidine, tetrachloropyridazine, 2,4-bis-methanesulphonyl-6-methylpyrimidine, 2,4,6-tri- or 2,4,5,6-tetrachloropyrimidine, 2,4,6-tri- or 2,4,5,6-tetrabromopyrimidine, 2-methanesulphonyl-4,5-dichloro-6-methylpyrimidine, 2,4-dichloropyrimidine-5-sulphonic acid, 5-nitro- or 5-cyano-2,4,6-trichloropyrimidine,2,6-bis-methanesulphonylpyridine-4-carboxylic acid chloride, 2,4-dichloro-5 -chloromethyl-6-methyl-pyrimidine, 2,4-dibromo-5-bromomethyl-6-methylpyrimidine, 2,4-dichloro-5-chloromethylpyrimidine, 2,4-dibromo-5-bromomethylpyrimidine, 2,5,6-trichloro-4-methylpyrimidine, 2,6-dichloro-4-trichloromethylpyrimidine or especially 2,4-dimethylsulphonyl-5-chloro-6-methylpyrimidine, 2,4,6-trimethylsulphonyl-1,3,5-triazine, 2,4-dichloropyrimidine, 3,6-dichloropyridazine, 3,6-dichloropyridazine-5-carboxylic acid chloride, 2,6-dichloro- or 2,6-dibromo-4-carboethoxypyrimidine, 2,4,5-trichloropyrimidine, 2,4-dichloropyrimidine-6-carboxylic acid chloride, 2,4-dichloropyrimidine-5-carboxylic acid chloride, 2,6-dichloro- or 2,6-dibromopyrimidine-4- or -5-carboxylic acid amides or -sulphonic acid amides or -4- or -5-sulphonic acid chloride, 2,4,5,6-tetrachloropyridazine, 5-bromo-2,4,6-trichloropyrimidine, 5-acetyl-2,4,6-trichloropyrimidine, 5-nitro-6-methyl-2,4 -dichloropyrimidine, 2-chlorobenzthiazole-6-carboxylic acid chloride, 2-chlorobenzthiazole-6-sulphonic acid chloride, 5-nitro-6-methyl-2,4-dichloropyrimidine, 2,4,6-trichloro-5-chloropyrimidine, 2,4,5,6-tetrafluoropyrimidine, 4,6-difluoro-5-chloropyrimidine, 2,4,6-trifluoro-5-chloropyrimidine, 2,4,5-trifluoropyrimidine, 2,4,6-trichloro-(-tribromo- or -trifluoro)-1,3,5 -triazines, as well as 4,6-dichloro(dibromo- or -difluoro)-1,3,5 -triazines which are substituted in the 2-position by an aryl or alkyl radical, for example a phenyl, methyl or ethyl radical, or by the radical of an aliphatic or aromatic mercapto compound bonded via the sulphur atom, or by the radical of an aliphatic or aromatic hydroxy compound bonded via the oxygen atom, or, in particular, by an NH 2 group or by the radical of an aliphatic, heterocyclic or aromatic amino compound bonded via the nitrogen atom. As such compounds, the radicals of which can be bonded in the 2-position to the triazine nucleus by reaction with trihalotriazines, the following may for example be mentioned: aliphatic or aromatic mercapto or hydroxy compounds, such as thioalcohols, thioglycolic acid, thiophenols, alkoxyalkanols, methyl alcohol, ethyl alcohol or isopropyl alcohol, glycolic acid, phenol, chlorophenols or nitrophenols, phenolcarboxylic and phenolsulphonic acids, naphthols, naphtholsulphonic acids and the like, but in particular ammonia and compounds containing amino groups which can be acylated, such as hydroxylamine, hydrazine, phenylhydrazine, phenylhydrazinesulphonic acids, glycolmonoalkyl ethers, methylamine, ethylamine, isopropylamine, methoxyethylamine, methoxypropylamine, dimethylamine, diethylamine, methylphenylamine, ethylenephenylamine, chloroethylamine, ethanolamines, propanolamines, benzylamine, cyclohexylamine, morpholine, piperidine, piperazine aminocarbonic acid esters, aminoacetic acid ester, aminoethane-sulphonic acid, N-methylaminoethanesulphonic acid, and aromatic amines, such as aniline, N-methylaniline, toluidines, xylidines, chloroanilines, p- or m-aminocetanilide, aminophenols, anisidine, phenetidine and, in particular, anilines containing acid groups, sulphanilic acid, methanilic acid, orthanilic acid, anilinedisulphonic acid, aminobenzylsulphonic acid, anilinemethanesulphonic acid, aminobenzenedicarboxylic acids, naphthylaminomonosulphonic, -disulphonic and -trisulphonic acids, aminobenzoic acid, such as 2-hydroxy-5-aminobenzoic acid, and also stilbene compounds such as those used in fluorescent whitening agents.
In addition to the fiber-reactive radicals which can be introduced to a colorless compound by acylation, further such radicals which may be mentioned are, for example, the vinylsulphone, the beta-sulphato- or thiosulphatoethylsulphone, beta-thiosulphatopropionylamide, the beta-thiosulphatoethylsulphonylamide or the sulphonic acid-N, beta-sulphatoethylamide groups, which are introduced into the reactive anionic compound in another way, for example by ester formation or thioester formation.
Among examples of compounds which contain a fiber-reactive radical that cannot be introduced by acylation, and in which the fiber-reactive radical is therefore preferably not bonded via an amino group, but is bonded directly to a benzene radical or aryl group, the sulpho esters of the following sulphones may, in particular, be mentioned: 1-amino-2-methoxy-5-(beta-hydroxyethyl)-phenylsulphone, 1-aminobenzene-3- or 4-beta-hydroxyethylsulphone, 1-amino-2-methyl-benzene-5-beta-hydroxyethylsulphone, 1-amino4-(beta-hydroxyethylsulphonylpropionylaminomethyl)-benzene, 1-amino-4-(beta-hydroxyethylsulphonylamino)-benzene, as well as reactive compounds which can be obtained via the appropriate methylols by Einhorn's method, for example 1-amino-4-chloroacetylaminomethyl-benzene or 1-amino-3-chloroacetylaminomethyl-benzene-6-sulphonic acid.
Condensation with the acid halides or anhydrides, or with the heterocyclic halogen compounds, is advantageously carried out in the presence of acid acceptors, for example sodium carbonate. It is to be understood that preparation of the fiber reactive compounds of Hegar and Back is to be carried out in such a manner that an unsaturated bond or at least a replaceable halogen atom still remains in the final product to permit formation of a covalent bond with the hydroxyl group of cellulose under suitable conditions of pH, concentration, and temperature.
Formula (1) above provides one class of suitable structures. Related structures within the scope of this invention can have multiple sulfonyl or carbonyl groups attached to various locations of the molecule, including on segments of the bridging group or even directly attached to part of the fiber reactive group. Multiple fiber reactive groups may also be attached to one or more bridging groups, allowing the reactive anionic compound to attach to multiple adjoining sites on a cellulose surface. Species according to formula (1) which can complex with metal ions are also within the scope of the present invention, provided that the resulting compound in its dry state on cellulose reamins substantially colorless.
Examples of halo-triazine derivatives of use in the present invention include known halo-1,3,5-s-triazinyl-diamino-stilbene-disulfonic acid derivatives used as fluorescent whitening agents or as ultraviolet absorbers. Chlorotriazinyl intermediates of commercially available non-reactive fluorescent whitening agents, particularly those derived from cyanuric acid and diaminostilbene, are likely to be useful fiber reactive compounds which may also be of value in preventing photoyellowing of high-yield fibers. One commercial fiber-reactive triazinyl ultraviolet absorber (but not a fluorescent whitening agent) is RAYOSAN CO Liquid, produced by Clariant Corp. (Charlotte, N.C.). RAYOSAN, like many other fiber-reactive compounds, requires a temperature above about 160° F. and a pH of about 9.5 or higher for efficient reaction of the fiber reactive radical with hydroxy groups on cellulose, according to the manufacturer. RAYOSAN CO does not appear to effectively absorb the UV frequency range typical of fluorescent lights, and thus is not a preferred fiber reactive compound for preventing yellowing from such lights, but may be of value for other purposes.
Examples of pyridone derivatives of use in the present invention include those of the formula ##STR3## related to the compounds taught in U.S. Pat. No. 4,092,308, issued May 30, 1978 to Hegar, herein incorporated by reference. At least one of R 1 , R 2 , and R 3 contains a fiber reactive group such as a chlorotriazine or any of the other suitable fiber reactive groups previously disclosed, in which case the fiber reactive containing radical R 1 , R 2 , or R 3 can be represented as --Y--X--B, wherein Y,X, and B have meanings previously defined. When not a fiber reactive containing radical, then R 1 represents a hydrogen atom, an alkyl or aryl radical, R 2 and R 3 represent independently a hydrogen or halogen atom, a cyano, carboxylic amide, alkylsulphonyl, arylsulphonyl, nitro, nitroso, amino, or acylamino group, or --NH--Z where Z is a heterocyclic or aromatic radical which can be derived from a compound of the anthraquinone, benzene, naphthalene, nitroaryl, phthalocyanine, or stilbene series or the like. The fiber reactive groups that can be one or more of R 1 , R 2 , and R 3 contain a linking group such as --NH-- or --CONH-- connected to a reactive radical of the classes previously disclosed.
The compounds of the formula (2) can exist in a number of tautomeric forms. In order to simplify the description the compounds in the formulae are illustrated in only one of these tautomeric forms, but it must be expressly emphasized that throughout this specification, especially in the claims, the description refers to compounds in any of these tautomeric forms.
In particular, the term "pyridone" is intended to include also the compounds in question which are substituted at the nitrogen atoms of the pyridone ring by a hydrogen atom as well as the corresponding tautomeric 2,6-dihydroxypyridones.
In addition to the sulphomethyl group, the pyridone compounds according to the invention preferably contain additional water-solubilizing groups such as sulphonic acid groups, carboxyl groups, or quaternized amino groups. The compounds can contain one or more than one reactive radical, for example, a halotriazine radical, in the molecule. In addition to being substituted by water-solubilizing groups, the compounds can be substituted in the normal way, by still further atoms or groups of atoms, and in particular in the radicals R 1 , R 2 and R 3 , for example by halogen atoms or hydroxy, amino, alkyl, aryl, alkoxy, aryloxy, acylamino, cyano, acyl, carbalkoxy, acyloxy or nitro groups, and the like.
Examples of pyrimidine derivatives of value for the present invention would include colorless forms of the fiber-reactive compounds disclosed in U.S. Pat. No. 4,007,164, "Azo Dyestuffs Containing 6-Fluoro-Pyrimidinyl 4-Reactive Group," issued Feb. 8, 1977 to Bien and Klauke, herein incorporated by reference. Removal of the azo groups or preparation of such compounds without addition of azo groups may be necessary to achieve a substantially colorless species. For the purpose of the present invention, the analogs to Bien and Klauke's compounds can be represented by the formula: ##STR4## wherein R 4 is fluoro; R 5 is hydrogen, optionally alkyl, alkenyl, aralkyl, aryl, haloalkyl or haloallyl; R 6 is hydrogen or a substituent as defined hereafter; Q is a linking member, e.g. SO 2 or --CO--; n is the number 0 or 1; R 7 is hydrogen or lower alkyl; W is an anionic group as defined above; and R 8 is a bridge group such as R in formula (1) preferably containing an aromatic ring linked to the N adjacent R 8 as shown either directly or via a further bridge or linking member, such as --SO 2 -- or --CO--, as in the case of amide groupings, or via an alkylene group, an alkylene-CO--, an arylene-, arylene-SO 2 --, arylene-CO-- group or a triazine or diazine ring or an arylene-amidosulphonyl group. If such further linking members contain heterocyclic ring systems, as is the case with triazinyl or pryimidinyl radicals, these, too, may contain reactive atoms or groupings, such as halogen atoms or other substituents. Examples of substituents R 6 on the pyrimidine ring are: halogen, such as Cl, Br and F; alkyl radicals, such as --CH 3 and --C 2 H 5 ; substituted alkyl radicals, such as mono-, di- or trichloro- or tribromomethyl, trifluoromethyl radicals; alkenyl radicals, such as vinyl or halovinyl and allyl radicals; --NO 2 , --CN, carboxylic acid, carboxylic acid ester and optionally N-substituted carboxylic acid or sulphonic acid amide groups, sulphonic acid and sulphonic acid ester groups; alkyl-sulphonyl, aralkyl-sulphonyl or aryl-sulphonyl groups.
Adapting known reactive azo dyes for colorless fiber-reactive compounds obviously can be done by cleaving the azo group or by altering synthesis by not performing the normal step of coupling a diazonium salt with an electron-rich nucleophile, presuming that the nucleophile also contains or can be provided with the fiber reactive group and anionic compounds.
According to Hegar and Back in U.S. Pat. No. 4,141,890, previously incorporated by reference, groupings capable of being reactive with the hydroxyl groups of cellulose to form a covalent chemical bond include low molecular alkanoyl or alkylsulphonyl radical substituted by a removable atom or a removable group, a low molecular alkenoyl or alkenesulphonyl radical optionally substituted by a removable atom or a removable group, a carboxylic or heterocyclic radical containing 4-, 5- or 6-membered rings which is substituted by a removable atom or a removable group and is bonded via a carbonyl or sulphonyl group, or a triazine or pyrimidine radical substituted by a removable atom or a removable group and directly bonded via a carbon atom, or such a grouping contains such a radical.
Other reactive radicals can be used, including those disclosed in the article "Dyes, Reactive" in Vol. 8 of the Kirk-Othmer Encyclopedia of Chemical Technology, Vol. 8, pp. 374-390, including chlorobenzothiazole or reactive acrylamide as used in BASF Primazin dyes. The fiber-reactive radical may also be a radical of the formula --N(R 9 )--Z, wherein R 9 represents a low molecular alkyl radical or preferably a hydrogen atom, and Z represents a dihalotriazine radical or a monohalotriazine radical. By low molecular alkyl radicals are meant in this context alkyl radicals with up to 4 carbon atoms, e.g. the methyl, ethyl, propyl, isopropyl, or butyl radical.
In U.S. Pat. No. 4,134,724 issued Jan. 16, 1979 to Thompson et al., herein incorporated by reference, discloses fiber reactive groups which may also be of value in the present invention, including ethylene sulfonimide and cyclic ethylene- immonium type species.
In a preferred embodiment, the reactive anionic compound is substantially water soluble and has a molecular weight of about 5,000 or less, more specifically about 3000 or less, more specifically about 1500 or less, and most specifically from about 300 to about 1000. Preferably, the reactive anionic compound comprises at least two sulfonic groups. Preferably, the reactive anionic compound comprises at least two heterocyclic rings and alternatively at least three heterocyclic rings.
THE METHOD OF USING THE REACTIVE ANIONIC COMPOUND
The first step in the method of this invention is providing an aqueous slurry of papermaking fibers. Any papermaking fibers, as previously defined, or mixtures thereof may be used. Because of commercial availability, softwood and hardwood fibers are especially preferred. In one embodiment, the fibers may be predominantly hardwood, such as at least 50% hardwood or about 60% hardwood or greater or about 80% hardwood or greater or substantially 100% hardwood. Higher hardwood contents art desired for high opacity and softness, whereas high softwood is desirable for strength. In another embodiment, the fibers may be predominantly softwood, such as at least 50% softwood or about 60% softwood or greater or about 80% softwood or greater or substantially 100% softwood. For many tissue applications, high brightness is desired. Thus the papermaking fibers or the resulting tissue or paper of the present invention can have an ISO brightness of about 60 percent or greater, more specifically about 80 percent or greater, more specifically about 85 percent or greater, more specifically from about 75 percent to about 90 percent, more specifically from about 80 percent to about 90 percent, and more specifically still from about 83 percent to about 88 percent. Best strength improvements are obtained with fibers that are not highly sulfonated, for the sulfonic groups on the pulp may already provide adequate anionic sites for attachment of cationic polymers. Some sulfonated BCTMP pulps, for example, may not show significant strength improvements if abundant sulfonic groups are already on the fibers.
The slurry preferably has a fiber consistency of about 1 or 2 percent or greater, more specifically about 3 percent or greater, more specifically about 5 percent or greater, more specifically about 8 percent or greater, more specifically about 10 percent or greater, more specifically about 15 percent or greater, more specifically about 20 percent or greater, more specifically from about 5 percent to about 50 percent and most specifically from about 10 percent to about 30 percent.
The second step of the present invention is chemical pretreatment of the fibers by adding an effective amount of a fiber reactive anionic compound to the fiber slurry. The preferred amount of fiber reactive anionic compound added to the fiber slurry is from about 0.01 to about 4 weight percent (wt %) based on the dry fiber weight, preferably from about 0.05 to about 2 wt %, more preferably from about 0.08 to about 1.5 wt %, and most preferably from about 0.1 to about 1 wt %. (All weight percentages referred to herein are on a dry basis unless otherwise stated.)
Whereas treatment with fiber reactive dyes are typically carried out in dilute slurries, such as about 2 percent consistency, it has been surprisingly discovered that the reaction of the present invention can be successfully carried out with low amounts of liquid. Thus successful operation is possible for higher consistency fiber slurries, including the consistencies previously mentioned. The reduced use of water improves process efficiency and reduces water treatment burdens, and may reduce the tendency of fiber reactive compounds to hydrolyze. For high consistency treatment, it is desirable to employ high consistency mixers such as those recently known in the art of papermaking and bleaching. Hobart batch mixers, for example, may be useful in preparing the slurry at high or medium consistency. Useful continuous high consistency mixers are produced by Sunds Defibrator, Norcross, Ga., and other vendors. For best results, mixing should be done with adequate shear to thoroughly and uniformly mix the reagents with the fiber slurry. Elevated temperature, possibly assisted with steam injection into the pulp, may be beneficial.
When high-yield pulps are used, it may be desirable for the reactive anionic compound to comprise a UV absorbing group or to contain a fluorescent whitening group capable of absorbing UV light and fluorescing.
The third step is adjusting the pH and temperature of the slurry to effectively drive the reaction between the fiber reactive anionic compound and the fiber. Once applied to an aqueous fiber slurry, the reactive anionic compound added in the second step may not react significantly with the cellulose until the pH is adjusted and the temperature is sufficiently high. The vast majority of suitable fiber reactive groups require alkalization, although a few fiber reactive groups such as methylol require acidic conditions. Alkalization is typically necessary to raise the pH to about 6 or greater, preferably about 7 or greater, more preferably about 8 or greater, still more preferably from about 8 to about 11, and most preferably from about 8 to about 10, in order to drive the reaction toward completion. Alkaline agents such as sodium hydroxide, trisodium phosphate, sodium bicarbonate, and sodium carbonate, either singly or in combination, are preferred for their low cost, their chemical effectiveness, their general compatibility with tissue making operations, and their ease of handling and processing, but other alkaline compounds may be selected as well, including but not limited to calcium oxide, potassium hydroxide, potassium carbonate, and related compounds. If acidification is necessary, sulfuric acid or other acids known in the art may be used.
Adjustment of pH of the fibrous slurry can be done either before, during, or after addition of the reactive anionic compound to the fibers in the second step. Based on experimental results with alkalization, alkalization after addition of the reactive anionic compound is preferred because it results in higher yield and efficiency (higher substantivity of the wet strength agent, manifest by higher wet strength of paper at a given dosage of wet strength agent). Without limitation, it is believed that alkalization too early in the process can cause some hydrolysis of the reactive group of the reactive anionic compound, resulting in lower yield.
In an especially preferred embodiment of the invention, slightly more of an alkaline compound is added to the slurry than would be needed to neutralize the acidic byproduct of reaction between the reactive anionic compound and a hydroxyl group of the cellulose. For example, when the reactive group is monochloro-triazine, the acidic byproduct is hydrogen chloride. Adding sufficient sodium hydroxide in the post-alkalization treatment to more than neutralize the hydrogen chloride, assuming complete reaction, has proven to be effective in achieving the desired reaction and the desired wet strength properties. Thorough mixing of the slurry during alkalization is desirable. When using high-yield pulps, care must be taken to avoid excessive exposure of the fibers to high pH and high temperature, since accelerated thermal yellowing may occur. It may be desirable to reduce the pH, such as to about 9 or lower, or to about 8 or lower, or to about 7 or lower, once fixation of the fiber reactive compound has been achieved through alkalization and pH elevation. Normal industrial papermaking conditions for tissue drying generally will not cause significant thermal yellowing.
A few fiber reactive groups known in the art, particularly methylolated nitrogen groups (--NHCH 2 OH), should be applied under acidic conditions at elevated temperature. If such compounds are used, the step of pH adjustment would generally be acidification rather than alkalization. Reactions with methylol groups may require higher temperatures than are normally needed for most other fiber reactive groups, which can be harmful to fiber properties.
Simultaneously or subsequent to the pH adjustment, a temperature of from about 20° C. to about 150° C. is typically needed for practically rapid reaction rates with most fiber reactive species of use in the present invention, with a preferred temperature range of from about 20° C. to about 120° C., more preferably from about 20° C. to 100° C., more preferably still from about 40° C. to about 85° C., and most preferably from about 50° C. to about 80° C. Of course, the optimum temperature will depend on which fiber reactive anionic compound is used. If the slurry is below a suitable temperature range, temperature elevation may be achieved by contact heating through the use of a heat exchanger, heated vessel walls, steam injection, or any of the many means known in the art. For uniformity of reaction, good mixing of the slurry during heating is desirable. The adjustment of temperature need not be simultaneous with the addition of alkaline compounds or with the addition of fiber reactive anionic compound, but preferably will follow addition of the alkaline compound. The proper temperature should be maintained for a sufficient period of time to drive the reaction to a useful degree of completion.
If the reactive anionic compound comprises a group with fluorescent whitening functionality, various post-treatments may be needed after fiber reaction to achieve full fluorescent activity, as is known in the art. Adjustment of pH and washing or rinsing may be desirable. Such steps may be achieved during or as an inherent aspect of the subsequent steps given hereafter.
The fourth step is adding an effective amount of cationic wet strength agents and water to said aqueous slurry, creating a papermaking furnish. Mixtures of compatible wet strength resins, including those described previously, can be used in the practice of this invention. Additional compounds and fillers or solid components may be added simultaneously with the second step, or could even precede the second step, if desired, although better efficiency is obtained by performing the addition of cationic wet strength agents after chemical pretreatment of the fibers. Any amount of wet strength agent may be added, but for efficient use and reasonable cost it is desirable that about 30 pounds per ton or less (1.5 wt % or less) on a dry fiber basis be added, preferably from about 0.02 to about 1.5 wt %, more preferably from about 0.02 to about 1.0 wt %, and most preferably from about 0.05 to about 0.8 wt %. Any cationic wet strength agent suitable for papermaking may be used. For high wet resiliency tissue, agents preferably should be capable of cross-linking (auto-cross-linking or with cellulose) or be capable of forming covalent bonds with cellulose. In the usual case, the wet strength resins are water-soluble, cationic materials. That is to say, the resins are water-soluble at the time they are added to the papermaking furnish. It is quite possible, and even to be expected, that subsequent events such as cross-linking will render the resins insoluble in water. Further, some resins are soluble only under specific conditions, such as over a limited pH range. Wet strength resins are generally believed to undergo a cross-linking or other curing reactions after they have been deposited on, within, or among the papermaking fibers. Cross-linking or curing does not normally occur so long as substantial amounts of water are present.
Particular permanent wet strength agents that are of utility in the present invention are typically water soluble, cationic oligomeric or polymeric resins that are capable of either crosslinking with themselves (homocrosslinking) or with the cellulose or other constituent of the wood fiber. Such compounds have long been known in the art of papermaking. See, for example, U.S. Pat. Nos. 2,345,543 (1944), 2,926,116 (1965) and 2,926,154 (1960), all herein incorporated by reference. One class of such agents include polyamine-epichlorohydrin, polyamide epichlorohydrin or polyamide-amine epichlorohydrin resins, collectively termed "PAE resins." These materials have been described in patents issued to Keim (U.S. Pat. Nos. 3,700,623 and 3,772,076 herein incorporated by reference) and are sold by Hercules, Inc., Wilmington, Del., as Kymene, e.g., Kymene 557H. Related wet strength agents are sold by Georgia Pacific under the name Amres, e.g., Amres 8855. Other suitable materials are marketed by Henkel Chemical Co., Charlotte, N.C. Materials developed by Monsanto and marketed under the Santo Res label are base-activated polyamide-epichlorohydrin resins that can be used in the present invention. These materials are described in patents issued to Petrovich (U.S. Pat. No. 3,885,158; U.S. Pat. No. 3,899,388; U.S. Pat. No. 4,129,528 and U.S. Pat. No. 4,147,586) and van Eenam (U.S. Pat. No. 4,222,921) all herein incorporated by reference.
Although they are not as commonly used in consumer products, polyethylenimine resins are also suitable for immobilizing fiber-fiber bonds. Another class of permanent-type wet strength agents includes aminoplast resins (e.g., urea-formaldehyde and melamine-formaldehyde).
The permanent wet strength agent is typically added to the paper fiber in an amount of about 20 pounds per ton (1.0 wt %) or less. The exact amount will depend on the nature of the fibers and the amount of wet strength required in the product. As in the case of the temporary wet strength agent, these resins are generally recommended for use within a specific pH range depending upon the nature of the resin. For example, the Amres resins are typically used at a pH of about 4.5 to 9. Addition of wet strength resins to papermaking fibers is typically conducted at low fiber consistency, such as about 2 percent or less and preferably about 1 percent or less or about 0.5 percent consistency.
Temporary wet strength agents are also useful in the method of this invention. Suitable cationic temporary wet strength agents can be selected from agents known in the art such as dialdehyde starch, polyethylene imine, mannogalactan gum, glyoxal, and dialdehyde mannogalactan. Also useful are cationic glyoxylated vinylamide wet strength resins as described in U.S. Pat. No. 3,556,932 issued to Coscia et al. on Jan. 19, 1971, and in U.S. Pat. No. 5,466,337, "Repulpable Wet Strength Paper," issued to William B. Darlington and William G. Lanier on Nov. 14, 1995, herein incorporated by reference. Useful water-soluble cation resins include polyacrylamide resins such as those sold under the Parez trademark, such as Parez 631NC, by American Cyanamid Company of Stanford, Conn., generally described in the above-mentioned patent issued to Coscia et al. and in U.S. Pat. No. 3,556,933 issued to Williams et al. on Jan. 19, 1971. U.S. Pat. No. 4,605,702, Guerro et al., issued Aug. 12, 1986, discloses temporary wet strength resin made by reacting a vinylamide polymer with glyoxal, and then subjecting the polymer to an aqueous base treatment. The product is said to provide tissue paper which loses a part of its wet strength when soaked in water at neutral pH. U.S. Pat. No. 4,603,176, Bjorkquist and Schmidt, issued Jul. 29, 1986, discloses related temporary wet strength resins. Generally, the cationic temporary wet strength agent is provided by the manufacturer as an aqueous solution and is added to the pulp in an amount of from about 0.05 to about 0.4 wt % and more typically in an amount of from about 0.1 to about 0.2 wt %. Depending on the nature of the resin, the pH of the pulp is adjusted prior to adding the resin. The manufacturer of the resin will usually recommend a pH range for use with the resin. The Parez 631NC resin, for example, can be used at a pH of from about 4 to about 8.
The fifth step is depositing said papermaking furnish on a foraminous surface to form an embryonic web. This step may further comprise dewatering and other operations known in the art prior to drying of the web. Examples of known dewatering and other operations are given in U.S. Pat. No. 5,656,132, issued Aug. 12, 1997 to Farrington et al., herein incorporated by reference.
The sixth and final step is drying the web. Any of the techniques known to those skilled in the papermaking art for drying wet fibrous webs can be used. Typically, the web is dried by heat supplied by air moving around, over, or through the web; by contact with a heated surface; by infrared radiation; by exposure to superheated steam, or by a combination of such methods. The exact point at which the wet strength agent begins to cure during the drying of the wet fibrous web is an indistinct one. What is required in the present invention is that the fibrous web be substantially dried and that the wet strength bonds of whatever nature as provided by the wet strength resin begin to form. The extent of formation of these bonds must have proceeded to such an extent that subsequent process steps will not appreciably interfere with their ultimate completion and the corresponding wet strength development. In general, though not necessarily in all cases, it is desired that the temperature of said web be sufficiently elevated to effectively cure the wet strength agent (i.e., drying may or may not require high temperature curing). The wet:dry tensile strength ratio of the dried web can be at about 0.1 or greater, preferably about 0.2 or greater, more preferably about 0.3 or greater and more preferably still about 0.4 or greater when the process has been properly executed.
The final wet strength of the paper for a given dose of wet strength agent should be greater than is achieved by the use of the wet strength agent without addition of the reactive anionic compound. The increase can be about 10 percent or greater, more specifically about 20 percent or greater, and more specifically still about 30 percent or greater.
The present invention offers multiple advantages over prior art techniques for enhancing wet strength. The present invention requires no coloration or dying of the fibers, and requires no bleaching or discharging of chromophores to maintain a white sheet. The present invention requires no addition of NaCl or other chlorides to drive the reaction of the reactive anionic compound with the fiber. Further, the present invention does not require highly dilute fiber slurries in the fiber pretreatment step but has been demonstrated successfully at fiber consistencies as high as 30%. Further, the present invention does not rely on ionic bonds to enhance strength, but takes advantage of reactive wet strength agents that form covalent bonds with the cellulose surface, though ionic bonds do provide the initial attachment of the cationic polymer with the sulfonic groups of the reactive anionic compound.
The novel use of fiber reactive anionic compounds in the present invention can also be coupled with chemical debonder agents to make paper with relatively high wet strength and low dry strength. One or more fiber reactive anionic compounds are used with cationic wet strength resins to establish water-resistant covalent bonds, while chemical debonders are used to reduce the number of hydrogen bonds between fibers, thus reducing the dry strength of the paper. This is best done by first increasing anionic sites on the cellulose fibers with said fiber reactive anionic compound, according to steps one through three as previously described, followed by addition of a chemical debonder agent and a cationic wet strength agent. The debonder agent may be applied to the fibers after step three while the fibers are in solution, followed by addition of the cationic wet strength agent as in step four, whereafter the paper is formed, dewatered, and dried according to steps five and six above. In this case, wherein the debonder agent is added to the fibers while they are in slurry form, it is desirable that the cationic wet strength resin be added after the debonder agent has been added to the slurry. Otherwise, the cationic wet strength agent may occupy most anionic sites on the fibers and interfere with retention of the chemical debonder agent. Chemical debonder agents typically have a single cationic site, such as a quaternary ammonium salt, with fatty acid chains.
Alternatively, the debonder agent may be applied to the dried or partially dried paper web during step six through known means such as spraying, printing, coating, and the like. Preferably, the web has been dried enough to begin formation of covalent bonds in the web. The web should then be at a solids level (consistency) of preferably about 40 percent or greater, more preferably about 60 percent or greater, more preferably still about 70 percent or greater, most preferably about 80 percent or greater, and desirably from about 60 to about 90 percent. The debonder maybe applied at other times, but for best results it should be either between steps 3 and 4 or during step 6 of the process described above.
When properly applied, the debonder agent interferes with hydrogen bond formation between the fibers, thus reducing the dry strength of the paper, while having relatively little effect on covalent bond formation. The result is a paper with an increased wet:dry tensile strength ratio. Such paper can have reduced stiffness and improved softness due to the reduced extent of hydrogen bonding, while still having high wet strength.
Desirable chemical debonder agents have less than five cationic sites per molecule and preferably no more than one cationic site which can bond with the anionic sites on the cellulose fiber surface. Large numbers of cationic sites could interfere with the anionic sites provided by the fiber reactive anionic compound if the debonder is applied to the fibers before covalent bonds have formed. Examples of useful chemical debonder agents include fatty chain quaternary ammonium salts (QAS) such as Berocell 584, an ethoxylated QAS made by Eka Nobel, Inc. (Marietta, Ga.), or compounds made by Witco Corp., Melrose Park, Ill., including C-6027, an imidazoline QAS, Adogen 444, a cethyl trimethyl QAS, Varisoft 3690PG, an imidazoline QAS, or Arosurf PA 801, a blended QAS. Agents known as softeners in the art of tissue making are also likely to be suitable as chemical debonder agents. Relative to the dry mass of the fibers, debonder may be added at a level in the range of 0.1% to 2%, preferably 0.2% to 1.5%, and more preferably 0.5% to 1%.
Under the present invention, the increased substantivity of wet strength agents obviously will improved the wet strength of the paper or tissue so produced, but may also offer the potential for other improved physical properties as well. For example, improved fiber-fiber bonding caused by the wet strength resin and the reactive anionic compound itself can improve dry strength and other strength properties (particularly if the reactive anionic compound has a plurality of fiber reactive groups to permit inter-fiber bonds to form). Improved fiber bonding, especially improved wet strength, may be correlated with improved wet resiliency, as defined in Wendt et al., U.S. Pat. No. 5,672,248, issued Sep. 30, 1997, herein incorporated by reference. In tissue production, for example, it is known that improved tensile strength achieved by chemical bonds can be exploited to permit more intense creping of the web leading to improved bulk and potentially to improved softness.
To achieve good softness and opacity, it is desirable that the tissue web comprise substantial amounts of hardwood. For good strength, substantial amounts of softwood are desired. Both strength and softness are often achieved through layered tissues, such as those produced from stratified headboxes wherein at least one layer delivered by the headbox comprises softwood fibers while another layer comprises hardwood or other fiber types. Layered tissue structures produced by any means known in the art are within the scope of the present invention, including those disclosed by Edwards et al. in U.S. Pat. No. 5,494,554, issued Feb. 27, 1996, herein incorporated by reference.
Wet strength agents and reactive anionic compounds may be added to any layer independent from other layers in a tissue or paper web, but in a preferred embodiment they are added to the predominantly softwood component of a tissue web to enhance the physical properties of the strength layer. However, excellent results in physical property improvement have also been observed in predominantly hardwood fiber structures (bleached kraft hardwood, for example), particularly a dramatic increase in TEA (tensile energy absorbed in the dry state during tensile tests), suggesting that layered tissue production with reactive anionic compounds and wet strength agents in predominantly hardwood layers of a tissue could offer improvements in physical properties.
EXAMPLES
Example 1
100 gm of a dried bleached virgin northern softwood kraft pulp (Kimberly-Clark LL-19 pulp) was saturated with 1200 ml of water and dispersed into a slurry through agitation in a Hobart mixer. The slurry was dewatered to a fiber consistency of about 25%. This was repeated several times to obtain multiple batches of high consistency pulp. For each batch of pulp, between 1 and 4 grams of Sandospace S (Clariant Corp., Charlotte, N.C.) was prepared and diluted with 5 parts of water per part of reagent (thus, the amount of dilution water ranged from 5 to 20 grams of water). Each batch of fiber slurry, comprising 100 gm of fiber per batch, was then reloaded into the Hobart mixer and a Sandospace S solution, containing between 1 and 4 gm of Sandospace S was added during agitation of the pulp. The mixture was thoroughly blended at 25° C. for 25 minutes. Then NaHCO 3 was added to each batch at a dose of 0.5 gm of NaHCO 3 per gm of Sandospace S (for a range of 0.5 to 2 gm of NaHCO 3 ), with the NaHCO 3 having been first dispersed in 5-10 ml of water prior to addition to the mixture of fiber, water, and Sandospace S. Following addition of NaHCO 3 , the mixture was further blended in the Hobart mixer for 20 min at 25° C. Thereafter, the mixture was heated to 100° C. in an oven and maintained at said temperature for 2 hours without mixing. After cooling the slurry to 25° C., without post-washing of the slurry, the slurry was formed into 60 gsm handsheets using standard Tappi procedures. Kymene 557LX wet strength agent was added to the diluted handsheet slurry at a level of 1% Kymene on a dry fiber basis. The properties of these handsheets are shown in FIGS. 2-5. Sheet wet strength is shown to have increased substantially as the level of Sandospace S was increased, even though the amount of wet strength agent was constant. This demonstrates the ability of the fiber reactive anionic compound to improve the efficiency and substantivity of the Kymene, which is a cationic wet strength agent.
Untreated LL19 fiber handsheets with 1% Kymene had a wet strength of 1411 grams/in and a wet:dry tensile strength ratio of 24.6%. With pretreatment by the Sandospace S fiber reactive anionic compound, the same level of Kymene resulted in a wet strength of 2374 g/in and a wet:dry tensile strength ratio of 30.1% when 1% of the Sandospace S was applied. Results from tensile testing are shown in Table 1. Up to a 68% increase in wet strength was possible with fiber reactive anionic compound relative to the use of 1% Kymene alone. Comparing the TEA values of the "0/1" and "1/1" cases (a web with no RAC and 1% Kymene compared to a web with 1% RAC and 1% Kymene) in Table 1, it is evident that the addition of the reactive anionic compound to fibers with Kymene present dramatically increased TEA (nearly tripled for Wet TEA and more than doubled for Dry TEA) and significantly increased dry strength though not as dramatically as wet strength (thus, the wet:dry tensile ratio increases with the addition of RAC in a system that will later contain wet strength resins). TEA refers to the "tensile energy absorbed" during standard testing of mechanical properties and relates to product performance. A sheet that absorbs more tensile energy before failure in testing is less likely to fail in use and may seem more resilient.
TABLE 1__________________________________________________________________________Results from Example 1 (post-alkalization)% RAC/% Kymene(dry fiber basis) 0/0 0/1 1/1 2/1 3/1 4/1 5/1__________________________________________________________________________wet strength 236 1411 2374 2100 2242 2290 2348dry strength 4952 5723 7861 7147 7679 7361 8258Wet TEA 2.24 3.21 8.49 6.52 7.11 7.51 8.39Dry TEA 25.45 41.05 95 90.42 92 92.43 95.68__________________________________________________________________________
Example 2
All steps were conducted as in Example 1 except that the NaHCO 3 solution was added prior to the addition of the Sandospace S solution, resulting in pre-alkalization rather than post alkalkization. Up to a 46% increase in wet strength with fiber reactive anionic compound was possible relative to paper made with the Kymene alone. Note that at 1 % RAC (reactive anionic compound), a wet strength of 1606 g was achieved with pre-alkalization compared to 2374 g with post-alkalization.
TABLE 2__________________________________________________________________________Results from Example 2 (pre-alkalization)% RAC/% Kymene(dry fiber basis) 0/0 0/1 1/1 2/1 3/1 4/1 5/1__________________________________________________________________________wet strength 236 1594 1606 1872 2115 2334 2330dry strength 4953 5889 6934 7651 7609 7621 7632Wet TEA 2.24 6.28 9.03 11.29 12.8 14.13 14.4Dry TEA 25.45 33.25 64.72 79.64 75.1 74.2 75__________________________________________________________________________
Example 3
45 kg of a bleached northern softwood kraft pulp was pulped at 25° C. for 20 minutes in a high consistency pulper at a consistency of 8%. 3.6 kg (8% relative to the fiber mass) of Sandospace S paste, as received from Clariant Corp., was added to the slurry in the pulper and mixed for an additional 20 minutes. 0.9 kg of sodium carbonate powder was added to the slurry in the pulper and mixed for another 20 minutes. The slurry was then heated to 60° C. and maintained at that temperature for 2 hours and then dewatered with a centrifuge to 35% consistency. The fibers were then ready for use in papermaking without any washing.
The 35% consistency fibers were then diluted with water to make handsheets according to Tappi procedures for handsheet making. Then Berocell 584 liquid (Eka Nobel Corp., Marietta, Ga.) was added to the dilute slurry at a dose of 1 gram of Berocell liquid per 100 grams of fiber (1% Berocell on a dry fiber basis) and stirred for 20 minutes. Thereafter, 1% Kymene 557LX on a dry fiber basis was also added to the slurry and stirred for 20 minutes. Then 60 gsm handsheets were formed according to Tappi procedures and tested for dry and wet tensile strength properties.
The 60 gsm handsheets had a mean wet strength of 2160 g/inch and a mean dry strength of 4929 g/inch. The wet:dry tensile strength ratio for the handsheets of this example was 43.8%, in contrast to typical values of 30-35% for sheets with Kymene but without debonder, as in Example 1. A handsheet made according to this Example but without any added debonder had a wet:dry tensile strength ratio of 35.1%.
Example 4
Handsheets were prepared as described in Example 3, except that no debonder was added to the fibrous slurry. A 1% by weight aqueous solution of Berocell liquid was prepared and sprayed onto the dried handsheets using a common household hand sprayer. Spray was applied evenly to both sides of the handsheets until the added liquid mass was approximately 100% of the dry handsheet mass, resulting in a total application of 1% pure Berocell to the fibers on a dry fiber basis (1 gram of added Berocell per 100 grams of fiber). Then the handsheets were dried at 105° C. for 20 minutes and then cooled, conditioned, and tested for tensile strength. The mean wet strength was 2897 g/inch and the dry strength was 6551 g/inch, yielding a wet:dry tensile ratio of 44.3%.
It will be appreciated that the foregoing examples, given for purposes of illustration, are not to be construed as limiting the scope of this invention, which is defined by the following claims and all equivalents thereto. | The invention is a method for improving the efficiency of aqueous cationic wet strength additives by pretreating cellulose surfaces with reactive anionic compounds, thus providing the cellulose surface with additional anionic sites suitable for retaining a high proportion of said cationic wet strength additives on the cellulose. The wet strength additives on the cellulose surface are cured or reacted with the cellulose surface. The resulting fibrous material has unusually high wet strength with unusually low doses of cationic wet strength additive. The preferred reactive anionic compounds comprise compounds having a reactive group suitable for covalent bonding to hydroxyl groups on cellulose, and further having sulfonic or other anionic end groups capable of attracting cationic wet strength compounds in aqueous solution. The invention also includes means of preventing photoyellowing of high-yield fibers while simultaneously improving wet strength performance. | 3 |
RELATED APPLICATIONS
[0001] This Application is a Continuation application of International Application PCT/UA2011/000123, filed on Dec. 9, 2011, of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The method pertains to information technologies domain and can be used to collect and process data in the course of studies of respondents' behavior, prices, market trends, use of products and services, testing of concepts, products and services, promo campaigns and materials; studies of respondents' degree of satisfaction and lifestyles; public opinion polls, gathering of demographic and other data from private individuals through collection, automatic storage and automatic processing of data and data output by computer systems and electronic media.
BACKGROUND OF THE INVENTION
[0003] There exists a method to convey marketing and sociological studies, which includes a stage of collection and processing of information, received from respondents, through telecommunication means. This well-known method includes a preparatory stage of encouraging; during that preparatory stage, a technology system is first formed on the basis of a coordination center equipped with a powerful server to collect respondents” SMS messages; after that, within that system, a database of commodities and services is formed, with each item being assigned an individual code; after that, similar commodities are grouped into individual columns and a higher-level database is formed—the column database, each of those being assigned an individual code; after that, a database of information product customers (IPCs), registered in the coordination system, as well as databases, are formed, and, proceeding from those databases, a database of unique identification codes is created; those identification codes are later printed on each product packaging or are used to mark every service received; bilateral communication channels are established between respondents and the coordination system and the registered IPCs. In that process, information is collected by way of SMS messages with respective identification codes of products or services purchased, which are registered in the coordination system and an address static base of those messages is formed for each individual IPC, and those are placed on its personal web page (UA 11541, 15.12.2005).
[0004] A shortcoming of this known method is a complicated hierarchical structure and limited possibilities, which renders it unusable for a real-time method for collection and processing of multi-aspect data and respondents' feedback.
[0005] There also exists a method for marketing and sociological surveys (known as the TOUCHPOLL). The method encompasses collection and processing of information received from respondents; in that process, information is collected with the use of touch-screen devices displaying questions and multiple-choice answers, with each question and answer being assigned the respective display position coordinates, registered in the file, and a respondent's physical action in respect to the answer chosen on the device display is transformed into an electric signal, which is the coordinates of the respective answer option, and those coordinates are correlated with the coordinates of answers that are stored in the respective display coordinate file; in case the coordinates match, the question and the answer chosen are stored in memory, and all questions directed at the respondent and the answers chosen are registered in the database. After data collection has been completed, data are processed by one of the known methods for statistical data processing (UA 53603 A, 15.01.2003).
[0006] A shortcoming of this known method is its being unsuitable for real-time mode use, since the results of the survey are processed only after the information from all respondents has been collected.
[0007] A method, closest by its technical essence and the results obtained, is the method of public opinion polls among web audiences with the use of Internet, cell telephones or land-line telephones in various parts of the world. The poll results are published for unrestricted access, or for a limited number of persons only, on a web site, or are sent to the respondents' electronic mail addresses, to the respondents' mobile telephones or iPod-type devices, in the real-time mode and in a multilingual format to inform people living in various parts of the globe (US 2008154627, 26.06.2008).
[0008] A shortcoming of this known solution is the impossibility of functioning of the known method simultaneously for different audiences of respondents (web audience, electronic media audience and the audience in the studio).
SUMMARY OF THE INVENTION
[0009] The present invention is based on the objective to develop a method for The real-time method for collection and processing of multi-aspect data and respondents' feedback conducted simultaneously among different de-localized audiences of respondents (web audience, electronic media audience and the audience in the studio), in the real-time mode and with additional video- or television broadcasting.
[0010] The objective is reached through the fact that, in the real-time method for collection and processing of multi-aspect data and respondents' feedback, which includes collection of data from respondents, data processing and presentation of the results to an unlimited or limited number of people, in accordance with the present invention, data collection is carried out from various groups or respondents in delocalized audiences, including web audience, electronic media audience and the audience in the studio; to that effect, video- or television broadcasts are carried out with synchronization of signals coming in from respondents with the video and television signals coming to displays or the respondents' video terminals.
[0011] Data from the respondents are collected with the use of technical devices that have Internet connectivity.
[0012] Such technical devices may be a personal computer, a notebook computer, a tablet computer, a telephone, a smartphone, a communicator, etc.
[0013] Intermediate results are being demonstrated at the respondents' terminals for both the web audience and the electronic media audience.
[0014] The questions asked may be optionally specified, the order of questions may be changed or new questions added.
[0015] The proposed method makes it possible to collect multi-aspect data on the audience reaction to video streams being demonstrated (for example, a live broadcast of an event, a movie, a news report, etc.) in the real-time mode.
[0016] The present description uses the following definitions and terms:
[0017] Respondent: participant who takes part in the real-time method for collection and processing of multi-aspect data and respondents' feedback by means of technical devices with Internet or Intranet connectivity.
[0018] Web-audience: respondents who take part by means of technical devices with Internet or Intranet connectivity. Each participant works with the system through a personal computer, a tablet computer, a mobile device or any communicator, with Internet or Intranet connectivity.
[0019] Electronic media audience: respondents who take part by means of technical devices with Internet or Intranet connectivity and who receive visual information in the real-time mode at video terminals.
[0020] Audience in the studio: respondents who take part by means of technical devices with Intranet connectivity directly in the television studio.
[0021] Multi-aspect data: any data obtained from the audience in the course of the process. Examples of those data may be the audiences' attitude to what they witness on the screen, assessment of the broadcast quality, the audiences' forecasts for a certain event and video broadcast.
[0022] Data package—a data package means a unit of information received from each participant of web-audience at any moment of information collection. A data package includes: the IP-address of the device that a participant works with; data itself (assessment, question number, text message); time stamp when the package was sent.
[0023] Multi-iteration collection and processing—method of collection and processing data being conducted simultaneously. In the course of each iteration, changes may be made in the session, such as changes in the order of questions or adding of new questions.
[0024] Consider functioning of the real-time method for collection and processing of multi-aspect data and respondents' feedback survey among a television show audience. The audience opinion with the use of the system makes it possible to conduct a multi-iteration method with questions being clarified at each iteration and with demonstration of intermediate results both to the web-audience and to the electronic media audience.
[0025] Data are collected with the use of computers (personal, notebook, palm-top) or other technical means with Internet connectivity.
[0026] The participants, who registered earlier, log into the system using their account name and password. After doing that, they have the possibility to answer the questions, to ask questions, to browse intermediate results/In the course of the process there is a possibility to display the results on the screen in the studio and on the participants' monitors/video terminals. Also, the participants may ask questions or give answers or comment on the events in the real-time mode. Their questions and comments may be displayed on the monitors/video terminals.
[0027] In the course of the process a data package is formed, which is sent via the net to the central server in the system. A program that runs on the server collects the information that enters the database. Proceeding from that information, results of the session are formed. After the information and analysis of the reaction of the web-audience have been processed, the studio personnel may the questions for the subsequent iteration—in that manner feedback is implemented.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] For better understanding, the invention is illustrated by the following graphics:
[0029] FIG. 1 : General diagram of interaction with respondents.
[0030] The system consists of the following modules:
[0031] 1 . Mapping module
[0032] 2 . Feedback module
[0033] 3 . Visualization module
[0034] 4 . Module for interaction with the audience
[0035] 5 . Data export module
[0036] 6 . Session control module
[0037] 7 . Computer network
[0038] 8 . Server
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] The System Operation Algorithm
[0040] 1. A respondent logs into the system using their account data. After that, they are granted access to the Module for interaction with the audience ( 4 ).
[0041] 2. The system operator, via the Session control module ( 6 ), sends questions or information for assessment to the participants.
[0042] 3. Respondents, in their Module for interaction with the audience ( 4 ), have the question or the request to assess the video broadcast displayed in the question section.
[0043] 4. The answer section displays the multiple-choice answers or the assessment scale.
[0044] 5. In the course of the carrying out the method, the audience, via the Feedback module ( 2 ), can ask questions or comment the events.
[0045] 6. After a respondent has answered a question or made an assessment, the data package with the information about the answer is sent to the Server ( 8 ).
[0046] 7. Information is stored in the database on the Server ( 8 ).
[0047] 8. After the information has been stored in the database, the visualization module ( 3 ) displays the updated versions of the diagrams (that is, those are mapped on the basis of information received in the real-time mode).
[0048] 9. After the visualization operator has selected the most suitable diagram version, it is sent to the mapping module ( 1 ).
[0049] 10. The mapping module ( 1 ) displays the visual information on a projector or a video terminal.
[0050] 11. Over the entire session, each of the items can be repeated different number of times for different participants and for different questions.
[0051] 12. After a session has been completed, all data can be retrieved from the system through the Data export module ( 5 ).
[0052] Below description and intent of modules 1 through 8 are contained.
[0053] 1 . Mapping module
[0054] The Mapping module is used for the output of the data collection results to presentation means.
[0055] In case of a small group, presentation means may include:
a personal computer a tablet computer a palm-top computer a telephone a smartphone
[0061] In case of a television broadcast:
video terminal projector personal computer capable of displaying a television signal mobile devices capable of displaying a television signal
[0066] The Mapping module receives data for presentation and the format for their output from the Visualization module.
[0067] The Mapping module is based on PHP, JavaScript, jQuery, with the use of SVG (Scalable Vector Graphics) technology and Land Pooling.
[0068] The jQuery technology has been selected since it makes it possible to create complex animation effects by means of a browser. Its advantage over the Flash technology is in the absence of the need to install additional components. Besides, the Flash technology is not supported by the majority of mobile devices and tablets.
[0069] The SVG technology has been selected since vector is graphics can be scaled in a much better way. This allows for mapping of diagrams on various mapping devices with different height-to-width aspect ratios, without loss of quality.
[0070] 2 . Feedback module
[0071] The feedback module is responsible for interaction between the audience and the system respondents. That makes it possible to implement feedback and the system participants can receive information that is necessary for making adjustments in the course of data collection.
[0072] The feedback module is based on PHP, JavaScript and jQuery with application of the Long Pooling technology.
[0073] The Long Pooling technology was selected since it allows a server to send <> to the client without an additional request on part of the client. This improves the overall rate of response of the system.
[0074] 3 . Visualization module
[0075] Visualization module is responsible for the format of visualization of data obtained as a result of the system operation.
[0076] A respondent who works with this module can choose the presentation graphical form to be displayed.
[0077] The feedback module is based on PHP, JavaScript and jQuery with application of the Long Pooling technology.
[0078] The Long Pooling technology was selected since it allows a server to send <> to the client without an additional request on part of the client. This improves the overall rate of response of the system.
[0079] The jQuery technology was selected since it provides a convenient API to work with Ajax. This reduces the amount of the necessary code.
[0080] 4 . Module for interaction with the audience
[0081] This module makes it possible to receive data from the audience and to transmit those to the system central server.
[0082] This module is a web page consisting of the following parts:
[0083] the question area
the answer area, containing multiple-choice answers or a scale the video demonstration area the feedback area
[0087] The feedback module is based on PHP, JavaScript and jQuery with application of the Long Pooling technology.
[0088] The Long Pooling technology was selected since it allows a server to send to the client without an additional request on part of the client. This improves the overall rate of response of the system and the rate of interaction of the web audience with the system.
[0089] 5 . Data export module
[0090] It is responsible for export of data from the system. The data exported can be transferred for further processing to analysts, or to the data collection customer.
[0091] The data export module is based on PHP, MySQL, JavaScript.
[0092] Efficiency of PHP is an extremely important factor in programming for multi-user environments, with the web being one of those. Due to the simplicity of the code, scenarios are implemented at relatively high rates, since the language nature may be defined as an assembling interpreter (performing the scenario processing and mapping its result in a visual form). The scenario implementation rates are perfectly suited for applications of any level of complexity.
[0093] MySQL is one of the best suited DBMS (database management systems) to be used in the web environment. The main advantages of MySQL are as follows: multithreading, support of more than one simultaneous requests;
optimization of connections with adding of multiple data in one pass; fixed- and variable-length records; a flexible system of privileges and passwords; flexible support of numbers, various-length strings and data stamps; interface with the C and Pert languages and PHP;
[0099] 6 . Session control module
[0100] This module is responsible for directly collecting data from the audience.
[0101] The session control module is used for synchronous control of the process respondents' forms. This module makes it possible to manage information presented to the web-audience; to change the sequence of information output; to adjust the information presented, as may be necessary.
[0102] It is implemented in PHP and j Query.
[0103] 7 . Computer network
[0104] The computer network can be a channel for data transmission from the web-audience to the central server.
[0105] The computer network may mean:
Internet Intranet A wireless net based on Wi-Fi, Wi-MAX, Bluetooth
[0109] For the data transfer, the TCP/IP protocol is used.
[0110] 8 . Server
[0111] The server ensures data processing, visualization and storage.
[0112] The recommended server configuration is as follows:
Windows, Unix, Linux PHP 5.2 MySQL 5 Profiler 3.0 (as part of the Since TV package)
[0117] Hardware requirements (minimal):
Intel Xeon dual-core processor RAM-4Gb HDD-17core+DB+log (depending on the load) 1,000 Mb/s network card Number of active respondents—up to 5,000
[0123] Long Pooling
[0124] The Long Pooling technology was selected since it allows a server to send to the client without an additional request on part of the client. This improves the overall rate of response of the system and the rate of interaction of the web audience with the system.
[0125] The j Query technology was selected since it provides a convenient API to work with Ajax. This reduces the amount of the necessary code. Also, it was selected because it makes it possible to create complex animation effects by means of a browser. Its advantage over the Flash technology is in the absence of the need to install additional components. Besides, the Flash technology is not supported by the majority of mobile devices and tablets.
[0126] SVG
[0127] The SVG technology has been selected since vector is graphics can be scaled in a much better way. This allows for mapping of diagrams on various mapping devices with different height-to-width aspect ratios, without loss of quality.
[0128] PHP
[0129] Efficiency of PHP is an extremely important factor in programming for multi-user environments, with the web being one of those. Due to the simplicity of the code, scenarios are implemented at relatively high rates, since the language nature may be defined as an assembling interpreter (performing the scenario processing and mapping its result in a visual form). The scenario implementation rates are perfectly suited for applications of any level of complexity.
[0130] MySQL
[0131] MySQL is one of the best suited DBMS (database management systems) to be used in the web environment. The main advantages of MySQL are as follows:
multithreading, support of more than one simultaneous requests; optimization of connections with adding of multiple data in one pass; fixed- and variable-length records; a flexible system of privileges and passwords; flexible support of numbers, various-length strings and data stamps; interface with the C and Pert languages and PHP;
[0138] fast work and scalability;
compatibility with ANSI SQL; good support by hosting service providers
[0141] As an example, let us consider a public opinion during a football game.
[0142] Before, during and after the match, the audience can vote on different questions, such as:
What team will win the game? What will the final score be? Was the red card justified? What is the chance of scoring at this moment?
[0147] Who is the most active player?
[0148] In this case, we have three different groups of audiences:
audience in the studio—experts (5 to 50 persons) electronic-media audience—television viewers (unlimited numbers) web-audience—users who take an active part in the process (unlimited numbers)
[0152] Each of the groups can use the following technical means, in different combinations: notebook and desktop computers, tablet computers, handheld computers, smartphones, video terminals.
[0153] 1. One hour before the broadcast. Communication with the audience within the framework of the broadcast. Voting taking place. Voting results displayed on the audience terminals. Signal broadcast in video format. Program topic announcement. Its discussion in the question-answer format, with participation of a moderator and the guests to the program.
[0154] After the end—invitation to participation and viewing of the television program.
[0155] 2. During the broadcast. In the course of the program, observations by the audience members are constantly displayed on the video terminal (for example, a plasma television set) in the studio (feedback line mode); results of the audience voting may be selectively displayed, as well as assessment of reactions to observations by the host, guests and other program respondents, in the synchronous voting mode.
[0156] Simultaneously with the voting via Internet, results of voting on the similar questions by the direct participants in the program (experts) can be displayed on the video terminal in the studio. Upon the program host's request, those data are compared by the most interesting aspects. Synchronous communication with the audience in the studio (for example, 50 guests) and voting by the web audience and the electronic media audience on the issue. The signal is transmitted in the video format. Feedback line. The program ending. Invitation of the audience to viewing of the video broadcast on discussion of results of voting on the air. Invitation to the registered users to take on-the-air voting results with the audience. The most opposite opinions, the most consolidated opinions, the best program participant, the best forecast by a user. The most active participants of the web audience and he electronic media audience are invited to the television studio as experts for the next program and become participants in the broadcast. Discussion of the voting results received in the course of the broadcast from all audiences. The voting results are presented to the audiences. The signal is transmitted in the video format.
[0157] All results obtained from each group can be compared both in the course of the broadcasting and after it. | The real-time method for collection and processing of multi-aspect data and respondents' feedback includes data collection from respondents, data processing and presentation of the results to a wide or a limited group of persons; in that respect, data are collected from different groups of delocalized audiences, including the web audience, the electronic media audience and the audience in the studio; in that process, video- or television broadcasting is additionally carried out, with the signals coming from respondents being synchronized with the signals coming to respondents' monitors or video terminals. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
This invention is a continuation of U.S. patent application Ser. No. 10/348,050 filed Jan. 21, 2003 now U.S. Pat. No. 6,830,812.
BACKGROUND OF THE INVENTION
This invention relates generally to carbonaceous materials that have enhanced properties. More particularly, the present invention is related to carbon material that is made oxidation resistant to temperatures of 900° C. The oxidation resistant carbon materials have an electrically non-conducting surface with significantly enhanced surface hardeness.
Carbonaceous materials, such as carbon, graphite, carbon-carbon composites, glassy carbon, and the like have many uses. In particular they are useful at high-temperatures where they have excellent mechanical strength. The oxidation of carbonaceous materials in air or oxygen-containing environments at temperatures of 400 to 500° C. has limited its use in high-temperature applications. Otherwise, the easy machinability, low density, good strength, and other properties would lead to carbonaceous materials being the obvious choice.
Oxidation protection of carbonaceous materials has been directed to coatings and layers that are utilized to reduce the reaction of oxygen with the materials. Exemplary teachings are provided in U.S. Pat. Nos. 4,711,666 and 4,769,074. Often such layers contain silicon or aluminum to help form glasslike coatings during oxygen attack, whereby the glassy layer or glaze will reduce any additional oxidation of the substrate. An inherent concern with coatings is the thermal expansion mismatches between the substrate and coating that often cause delamination and complete coating spallation.
Another example of oxidation improvement for carbonaceous materials is U.S. Pat. No. 5,368,938, herein described is the reaction of carbon with gaseous boron oxide to form boron carbide. Still another method of oxidation protection for carbonaceous materials, described in U.S. Pat. No. 5,356,727, is based on “boron carbonitride” designated as CBN, or CBNO if it contains oxygen. CBN is produced by chemical vapor deposition at 700° C. with a mixture of hydrocarbons, boron trichloride and ammonia along with nitrogen or hydrogen carriers at a low as a small fraction of atmospheric pressure, such as a few hundred to a few thousand pascals. The CBN, as described therein, typically has a “metallic appearance” at 50 micrometers thickness.
Graphite has been coated with “pyrolytic boron nitride” to form boats for metal vaporization, as described in U.S. Pat. No. 4,264,803. In such cases, the boron nitride coating was deposited at 1750 to 2300° C. to a thickness of about 250 micrometers or 0.010 inches. It was found that the geometry of the boat cavity and nearly total encapsulation of the boat held the coating onto the substrate. The tendency of the coating of “pyrolytic boron nitride” to delaminate seems to be the main problem with this type of boat.
None of the known technologies for improving the oxidation resistance of carbonaceous materials produces a carbon material that is not a coated surface. Integral materials have been heretofore been thought to be difficult to prepare due to the differences in crystal lattice between dissimilar materials. Any blending of materials would generate a unique crystalline lattice which is dissimilar from either starting material. This typically leads to crystallographic defects and dislocations which can create additional, often uncontrollable and unpredictable, crystallographic phases.
BRIEF SUMMARY OF THE INVENTION
A particular feature of the present invention is the ability to form carbonaceous materials with a hardened exterior that is non-conducting.
Another feature is the ability to form a relatively soft carbonaceous item in a desired shape and configuration after which the item can be treated to form an oxidative resistant hard surface without altering the dimensions or structural components of the carbonaceous item.
These and other advantages, as would be realised to one of ordinary skill in the art, are provided in a carbon material produced by heating a carbonaceous material embedded in a boron nitride precursor.
Another embodiment is provided in a process for manufacturing a carbon material that has enhanced oxidation resistance and an electrically non-conducting surface. The process involves the steps of embedding a carbonaceous material in a boron nitride precursor and heating the embedded carbonaceous material to a temperature in the range of from about 1600° C. to about 2000° C. at one atmosphere pressure with flowing nitrogen.
Yet another embodiment is provided in a surface hardened carbonaceous tool prepared by a process comprising machining a carbonaceous blank into a tool precursor, embedding the tool precursor in a boron nitride precursor to form an envelope and heating the envelope to a temperature of 1600 to 2000° C. at one atmosphere of flowing nitrogen to form the carbonaceous tool.
DETAILED DESCRIPTION OF THE INVENTION
The inventors of the present application have developed, through diligent research, a process for forming an integral oxidation resistance region on the exterior of the carbon and the material formed thereby.
Essential to this invention is a means of heat-treating carbonaceous materials in a boron nitride production process. Boron nitride production processes are well known in the art, typically involving reaction of boric acid, borates, or boron oxides or the like with ammonia gas or with nitrogen containing compounds such as melamine, urea, dicyandiamide etc. that yield ammonia during heating in nitrogen atmosphere. These processes have been referred to in U.S. Pat. Nos. 4,562,050; 4,784,978; 4,749,556; 5,854,155. A filler, such as calcium phosphate, may be used, as well as additives such as carbon or boron to affect final purity of the boron nitride powder. However, these processes all involve heating to temperatures of around 1000° C. to produce a “turbostratic” boron nitride that then requires further heating to temperatures of 1600 to 2200° C. to obtain good crystallinity and to reduce residual boron oxide.
The present invention provides a new carbon material. This carbon material is likely a composition of B—N—O—C, resulting from the reaction of those phases present during boron nitride production with the carbonaceous material buried in the reaction mixture. The type of carbonaceous material can be carbon, carbon-carbon composite, glassy carbon, any type of graphite, or virtually any type of carbon material. The interaction of the reactive products of boron nitride precursors, such boron oxides and ammonia or melamine, typically results in incompletely reacted boron nitride that contains considerable oxygen and has varied stoichiometry and crystallinity along with unreacted boron oxide. In the presence of nitrogen, boron carbide does not form. Boron oxides vaporize at temperatures above 1300° C. By heat-treating the carbonaceous material in the reaction mixtures used for making boron nitride, a carbon material is produced with visually the same dimensions and no weight changes from its initial condition. The surface is light grayish-white in appearance. Machined dimensions are retained. Yet the initial carbonaceous material transforms into a distinctly different carbon material, with superior oxidation resistance and an electrically non-conductive surface. The final material is uniquely produced at one atmosphere pressure with flowing nitrogen.
According to the present invention, a new carbon material is provided that has many advantages over the prior art. The new carbon material exhibits almost no reaction with air to temperatures of 900° C. for many days. The material is distinctly not a coating but an integral surface treatment that is married to the substrate whereby the dimensions are essentially unchanged from their initial dimensions. Any carbonaceous material can be heat-treated in a standard boron nitride powder production process mixture in the presence of nitrogen gas at one atmosphere pressure. The converted surface has an affected depth of about 200 micrometers whereas the first 100 micrometers seem to have mostly changed. Visually the surface is light grayish-black.
The procedure is similar to metal heat-treating. Any shaped part or component of a carbonaceous material is placed in a powder mixture that is a precursor material for boron nitride. For example, boric acid is normally blended with melamine in a ratio of 2.5 pounds of melamine to 3.5 pounds of boric acid. The carbonaceous material is placed into the mixture so that it is completely covered with the mixture. A graphite boat or container is used to hold this material. Typically, it is heated from room temperature up to 1000° C. for approximately 2 hours immediately followed by heating to 1900° C. for 2 hours. During this period of heating in a nitrogen atmosphere, gases evolve. The gases are mostly ammonia but also include water, carbon monoxide, carbon dioxide, hydrogen, hydrogen cyanide, boron oxide(s), and other species.
The precursor material for boron nitride comprises a boron compound and a nitriding compound which, when heated together, react to form boron nitride. Preferred boron compounds include boric acid, borates, borax, boron oxides, orthoboric acid, metaboric acid, tetraboric acid, lithium borate, potassium borate, sodium perborate, boron trichloride and ammonium borate. It is most preferred that the boron compound be solid. Boron oxides are particularly preferred as the boron compound.
Preferred nitriding compounds include ammonia gas, ammonium chloride, urea, melamine, melam, melem, melon, dicyandiamide, ammelide, guanamines such as acetoguanamine, and nitrogen-compound containing salts such as guanidine hydrochloride, melamine hydrochloride, melamine phosphate or malamine oxalate. Melamine is a particularly preferred nitriding compound.
For graphite parts subjected to the above procedure, weight changes are minimal as are any visual changes in dimensions. Edge retention and shape retention are excellent. Graphite parts have been tested in an air furnace for oxidation to 10% weight loss. This is a standard measurement used to compare effectiveness with graphite oxidation improvements. Oxidation was essentially stopped at 750° C., with no observable weight change after 400 to 500 hours. At 900° C., weight loss reached 10% after 18 to 20 days.
By post-heating in air for 1000° C. for 1 hour up to 24 hours or so and then testing the oxidation at lower temperatures, such as 750° C., the oxidation resistance is enhanced. At 750° C., the time to reach 10% weight loss was approximately 2000 hours or 80 to 90 days.
Testing of the heat-treated carbon material in vacuum at 1500° C. showed no weight, dimensional, or visual changes. The surface remained electrically nonconductive in all cases.
The surface of the new carbon material is not soluble in water or methyl alcohol. While not restricted to any theory regarding the actual chemical composition of the surface and immediate interior the insolubility indicates that the inventive phase is different chemically from boron oxide/boric acid phases. The lack of vaporization at 1500° C. also indicates significant differences from boron-oxygen compounds. The oxidation stability in air greatly exceeds boron nitride. The visual appearance suggests that the new carbon material is probably likely a composition of B—N—O—C, which results from the reaction of those phases present in the boron nitride production processes reacting with the carbonaceous material that is buried in the reaction mixture.
Any type of carbonaceous material is similarly affected, whether it is carbon, carbon-carbon composite, glassy carbon, carbon or graphite felt, flexible graphite foil (grafoil) such as described in U.S. Pat. No. 3,404,061, or any type of graphite. It appears that the reactive phases from boron nitride production processes react with carbon to produce a carbon material that is unique and not yet characterized herein. The many phases of boron-nitrogen-oxygen-carbon that can be present in liquid, vapor, or gaseous states prohibit the determination of the mechanism of the production of this new carbon material. Since boron carbide does not form in the nitrogen atmosphere that is used for boron nitride production processes, that may drive the composition towards a boron-nitride-like phase. This would account for the observed light grayish-white color, definitely not metallic appearing. Visually, there is no change in the outer dimensions or shape which suggest, without limiting the scope herein, some type of substitution reaction within the crystal lattice of the carbon. Even screw threads are not affected by the heat-treatment and transformation to the new carbon material. The final carbon material does not act in any way like a coated part.
The observed properties of this new carbon material greatly enhance the potential utility of carbonaceous materials. The surface created with this invention is like a “deep-case” treatment for metals, where the treated surface is integrally bonded to the substrate, essentially married to the substrate and not acting as an independent layer or coating. The underlying carbon has the properties of normal carbon and thus has electrical conductivity that is characteristic of whatever species of carbon is utilized, enabling both electrically conductive and nonconductive surfaces to be available. The affected surface region from the heat-treatment is electrically nonconductive, but that layer can be machined down to leave material that has the characteristics of the un-heat-treated substrate carbonaceous material. For graphite, the substrate is highly electrically conductive.
It should be noted that the affected surface is much harder than normal graphite or carbon materials or normal hexagonal boron nitride. The surface is easily ground down with silicon carbide wheels, thus indicating it to be softer than silicon carbide.
Graphite electrodes used for steelmaking have significant consumption due to surface oxidation. This can be prevented with the carbon material of this invention. Electrical conductivity can be achieved by clamps that penetrate the surface to achieve electrical contact with the underlying electrically conductive graphite substrate which remains chemically unaltered in the present process.
Evaporation boats can be made that are usable in vacuum conditions to 1500° C. and above due to the stability of the surface of this carbon material. There are no problems with delamination since the surface is tightly bonded to the substrate, essentially as if there is no coating but just an extension of the material. Areas needing electrical conductivity, such as where clamping is desired, can be made electrically conductive by machining away the electrically nonconductive affected surface region to expose the electrically conductive graphite substrate.
For electrical-discharge machining (EDM) electrodes used for hole-drilling, the sides need to be electrically nonconductive while the cutting surface needs to be electrically conductive. This is also achieved by machining away the electrically nonconductive affected surface region to expose the electrically conductive graphite substrate.
For greatly extended life, pump components, injection tubes, paddles, stalk tubes, etc. used for nonferrous metal melting and casting can be made of this new carbon material. The enhanced oxidation resistance, hardness, and electrical nonconduction of the affected surface provide new usefulness for carbonaceous materials.
A flash evaporator was prepared in accordance with the invention described herein. The heating cycle was about 2 hours at 950° C. and about 2 hours at about 1900° C. The flash evaporator was cross-sectioned for visible inspection. The visible appearance indicated that the chemical transformation was about 200 to 300 micrometers into the carbon. Increasing the time, temperature and exposure is expected to increase the thickness of the converted layer.
A graphite sample was embedded in melamine and borix acid mix. The coupon was heated to 950° C. for 2 hours. The resulting product oxidized like normal graphite indicating that the reaction did not occur under these conditions.
Braided graphite, available as braided flexible graphite packing, was treated in accordance with the present invention. The material became less flexible yet the shape and appearance were substantially unchanged. Oxidation properties were consistent with the present invention.
A sample of 0.1 to 0.125 thick piece of grafoil was treated in accordance with the present invention. The oxidation properties were improved without loss of shape or size.
While preferred embodiments have been shown and described, it will be understood that it is not intended to limit the disclosure, but rather it is intended to cover all modifications and alternate methods falling within the spirit and the scope of the invention as defined in the appended claims.
The invention has been described with particular emphasis on the preferred embodiments. It would be realized from the teachings herein that other embodiments, alterations, and configurations could be employed without departing from the scope of the invention which is more specifically set forth in the claims which are appended hereto. | A carbon material is formed by heat-treating a carbonaceous material in a reaction mix of boron oxide or its precursors and ammonia-generating phases such as melamine or its like in a nitrogen atmosphere to temperatures of 1600 to 2000° C. The surface of the carbonaceous material is transformed into a carbon material that is resistant to oxidation to temperatures of 900° C., enabling machined components to be utilized for weeks at that temperature. The carbon material also is stable in inert or vacuum environments to temperatures in the range of 1500 to 2000° C., enabling its use as aluminum evaporative boats and the like. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is related to co-pending U.S. patent application Ser. No. 0/958,797 entitled “RECOVERY FROM DATA FETCH ERRORS IN HYPERVISOR CODE” filed Jun. 8, 2000. The content of the above-mentioned commonly assigned, co-pending U. S. Patent application is hereby incorporated herein by reference for all purposes.
BACKGROUND OF THE INVENTION
1. Technical Field:
The present invention relates generally to the field of computer architecture and, more specifically, to methods and systems for managing resources among multiple operating system images within a logically partitioned data processing system.
2. Description of Related Art:
A logical partitioning option (LPAR) within a data processing system (platform) allows multiple copies of a single operating system (OS) or multiple heterogeneous operating systems to be simultaneously run on a single data processing system platform. A partition, within which an operating system image runs, is assigned a non-overlapping sub-set of the platform's resources. These platform allocable resources include one or more architecturally distinct processors with their interrupt management area, regions of system memory, and I/O adapter bus slots. The partition's resources are represented by its own open firmware device tree to the OS image.
Each distinct OS or image of an OS running within the platform are protected from each other such that software errors on one logical partition cannot affect the correct operation of any of the other partitions. This is provided by allocating a disjoint set of platform resources to be directly managed by each OS image and by providing mechanisms for ensuring that the various images cannot control any resources that have not been allocated to it. Furthermore, software errors in the control of an OS's allocated resources are prevented from affecting the resources of any other image. Thus, each image of the OS (or each different OS) directly controls a distinct set of allocable resources within the platform.
One means for separating the partitions is managed by a firmware component, such as, for example, the hypervisor within an RS/6000 platform, a product of International Business Machines Corporation of Armonk, N.Y. Hardware errors that are fatal to this firmware component become fatal for the entire platform, thus, bringing down the entire system. One major hardware error that may affect the hypervisor is an instruction fetch unrecoverable memory error (IfetchUE). The Risc system 6000 memory, within the RS/6000, is single bit error correction code protected, that is, hardware is able to correct any single bit error by special redundancy codes. However, currently, multi-bit errors cannot be corrected, but may only be detected. Multi-bit errors, while rare, occur due to a variety of conditions. Therefore, a method, system, and apparatus for recovering and isolating errors affecting the hypervisor is desirable.
SUMMARY OF THE INVENTION
The present invention provides a method, system, and apparatus for recovering from an instruction fetch error. In one embodiment, a data processing system maintains a primary copy and an alternate copy of a set of instructions for a software component. The instructions for performing the processes of the software component are fetched from the primary copy for execution by a processor. A pair of pointers is maintained in each copy identifying the beginning of each copy. Responsive to a determination that an instruction fetch error has been received, a corresponding current instruction in the alternate copy is determined and the software component is restarted by fetching and executing instructions from the alternate copy starting with the corresponding current instruction. The corresponding current instruction is determined by subtracting the beginning address of the copy with the error from the address of the current instruction, then adding the beginning address of the alternate copy.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 depicts a pictorial representation of a distributed data processing system in which the present invention may be implemented;
FIG. 2, a block diagram of a data processing system in accordance with the present invention is illustrated;
FIG. 3 depicts a block diagram of a data processing system, which may be implemented as a logically partitioned server, in accordance with the present invention;
FIG. 4 depicts a block diagram of a logically partitioned platform in which the present invention may be implemented;
FIG. 5 depicts a block diagram illustrating a primary and alternate copy of hypervisor instructions in accordance with the present invention; and
FIG. 6 depicts a flowchart illustrating an exemplary method of recovering from instruction fetch errors is depicted in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the figures, and in particular with reference to FIG. 1, a pictorial representation of distributed data processing system is depicted in which the present invention may be implemented.
Distributed data processing system 100 is a network of computers in which the present invention may be implemented. Distributed data processing system 100 contains network 102 , which is the medium used to provide communications links between various devices and computers connected within distributed data processing system 100 . Network 102 may include permanent connections, such as wire or fiber optic cables, or temporary connections made through telephone connections.
In the depicted example, server 104 is connected to hardware system console 150 . Server 104 is also connected to network 102 , along with storage unit 106 . In addition, clients 108 , 110 and 112 are also connected to network 102 . These clients, 108 , 110 and 112 , may be, for example, personal computers or network computers. For purposes of this application, a network computer is any computer coupled to a network that receives a program or other application from another computer coupled to the network. In the depicted example, server 104 is a logically partitioned platform and provides data, such as boot files, operating system images and applications, to clients 108 - 112 . Hardware system console 150 may be a laptop computer and is used to display messages to an operator from each operating system image running on server 104 , as well as to send input information, received from the operator, to server 104 . Clients 108 , 110 and 112 are clients to server 104 . Distributed data processing system 100 may include additional servers, clients, and other devices not shown. Distributed data processing system 100 also includes printers 114 , 116 and 118 . A client, such as client 110 , may print directly to printer 114 . Clients, such as client 108 and client 112 , do not have directly attached printers. These clients may print to printer 116 , which is attached to server 104 , or to printer 118 , which is a network printer that does not require connection to a computer for printing documents. Client 110 , alternatively, may print to printer 116 or printer 118 , depending on the printer type and the document requirements.
In the depicted example, distributed data processing system 100 is the Internet, with network 102 representing a worldwide collection of networks and gateways that use the TCP/IP suite of protocols to communicate with one another. At the heart of the Internet is a backbone of high-speed data communication lines between major nodes or host computers consisting of thousands of commercial, government, education, and other computer systems that route data and messages. Of course, distributed data processing system 100 also may be implemented as a number of different types of networks, such as, for example, an intranet or a local area network.
FIG. 1 is intended as an example and not as an architectural limitation for the processes of the present invention.
With reference now to FIG. 2, a block diagram of a data processing system in accordance with the present invention is illustrated. Data processing system 200 is an example of a hardware system console, such as hardware system console 150 depicted in FIG. 1 . Data processing system 200 employs a peripheral component interconnect (PCI) local bus architecture. Although the depicted example employs a PCI bus, other bus architectures, such as Micro Channel and ISA, may be used. Processor 202 and main memory 204 are connected to PCI local bus 206 through PCI bridge 208 . PCI bridge 208 may also include an integrated memory controller and cache memory for processor 202 . Additional connections to PCI local bus 206 may be made through direct component interconnection or through add-in boards. In the depicted example, local area network (LAN) adapter 210 , SCSI host bus adapter 212 , and expansion bus interface 214 are connected to PCI local bus 206 by direct component connection. In contrast, audio adapter 216 , graphics adapter 218 , and audio/video adapter (A/V) 219 are connected to PCI local bus 206 by add-in boards inserted into expansion slots. Expansion bus interface 214 provides a connection for a keyboard and mouse adapter 220 , modem 222 , and additional memory 224 . In the depicted example, SCSI host bus adapter 212 provides a connection for hard disk drive 226 , tape drive 228 , CD-ROM drive 230 , and digital video disc read only memory drive (DVD-ROM) 232 . Typical PCI local bus implementations will support three or four PCI expansion slots or add-in connectors.
An operating system runs on processor 202 and is used to coordinate and provide control of various components within data processing system 200 in FIG. 2 . The operating system may be a commercially available operating system, such as OS/2, which is available from International Business Machines Corporation. “OS/2” is a trademark of International Business Machines Corporation. An object-oriented programming system, such as Java, may run in conjunction with the operating system, providing calls to the operating system from Java programs or applications executing on data processing system 200 . Instructions for the operating system, the object-oriented operating system, and applications or programs are located on a storage device, such as hard disk drive 226 , and may be loaded into main memory 204 for execution by processor 202 .
Those of ordinary skill in the art will appreciate that the hardware in FIG. 2 may vary depending on the implementation. For example, other peripheral devices, such as optical disk drives and the like, may be used in addition to or in place of the hardware depicted in FIG. 2 . The depicted example is not meant to imply architectural limitations with respect to the present invention. For example, the processes of the present invention may be applied to multiprocessor data processing systems.
With reference now to FIG. 3, a block diagram of a data processing system, which may be implemented as a logically partitioned server, such as server 104 in FIG. 1, is depicted in accordance with the present invention. Data processing system 300 may be a symmetric multiprocessor (SMP) system including a plurality of processors 301 , 302 , 303 , and 304 connected to system bus 306 . For example, data processing system 300 may be an IBM RS/6000, a product of International Business Machines Corporation in Armonk, N.Y. Alternatively, a single processor system may be employed. Also connected to system bus 306 is memory controller/cache 308 , which provides an interface to a plurality of local memories 360 - 363 . I/O bus bridge 310 is connected to system bus 306 and provides an interface to I/O bus 312 . Memory controller/cache 308 and I/O bus bridge 310 may be integrated as depicted.
Data processing system 300 is a logically partitioned data processing system. Thus, data processing system 300 may have multiple heterogeneous operating systems (or multiple instances of a single operating system) running simultaneously. Each of these multiple operating systems may have any number of software programs executing within in it. Data processing system 300 is logically partitioned such that different I/O adapters 320 - 321 , 328 - 329 , 336 - 337 , and 346 - 347 may be assigned to different logical partitions.
Thus, for example, suppose data processing system 300 is divided into three logical partitions, P 1 , P 2 , and P 3 . Each of I/O adapters 320 - 321 , 328 - 329 , and 336 - 337 , each of processors 301 - 304 , and each of local memories 360 - 364 is assigned to one of the three partitions. For example, processor 301 , memory 360 , and I/O adapters 320 , 328 , and 329 may be assigned to logical partition P 1 ; processors 302 - 303 , memory 361 , and I/O adapters 321 and 337 may be assigned to partition P 2 ; and processor 304 , memories 362 - 363 , and I/O adapters 336 and 346 - 347 may be assigned to logical partition P 3 .
Each operating system executing with data processing system 300 is assigned to a different logicical pattern. Thus, each operating system executing within data processing system 300 may access only those I/O units that are within its logical partition. Thus, for example, one instance of the Advanced Interactive Executive (AIX) operating system may be execting within partition P 1 , a second instance (image) of the AIX operating system may be execting within partition P 2 , and a Windows™ operating system may be operating within logical partition P 3 . Windows 2000 is a product and trademark of Microsoft Corporation of Redmond, Wash.
Peripheral component interconnect (PCI) Host bridge 314 connected to I/O bus 312 provides an interface to PCI local bus 315 . A number of Terminal Bridges 316 - 317 may be connected to PCI bus 315 . Typical PCI bus implementations will support four Terminal Bridges for providing expansion slots or add-in connectors. Each of Terminal Bridges 316 - 317 is connected to a PCI/I/O Adapter 320 - 321 through a PCI Bus 318 - 319 . Each I/O Adapter 320 - 321 provides an interface between data processing system 300 and input/output devices such as, for example, other network computers, which are clients to server 300 . Only a single I/O adapter 320 - 321 may be connected to each terminal bridge 316 - 317 . Each of terminal bridges 316 - 317 is configured to prevent the propagation of errors up into the PCI Host Bridge 314 and into higher levels of data processing system 300 . By doing so, an error received by any of terminal bridges 316 - 317 is isolated from the shared buses 315 and 312 of the other I/O adapters 321 , 328 - 329 , and 336 - 337 that may be in different partitions. Therefore, an error occurring within an I/O device in one partition is not “seen” by the operating system of another partition. Thus, the integrity of the operating system in one partition is not effected by an error occurring in another logical partition. Without such isolation of errors, an error occurring within an I/O device of one partition may cause the operating systems or application programs of another partition to cease to operate or to cease to operate correctly.
Additional PCI host bridges 322 , 330 , and 340 provide interfaces for additional PCI buses 323 , 331 , and 341 . Each of additional PCI buses 323 , 331 , and 341 are connected to a plurality of terminal bridges 324 - 325 , 332 - 333 , and 342 - 343 , which are each connected to a PCI I/O adapter 328 - 329 , 336 - 337 , and 346 - 347 by a PCI bus 326 - 327 , 334 - 335 , and 344 - 345 . Thus, additional I/O devices, such as, for example, modems or network adapters may be supported through each of PCI I/O adapters 328 - 329 , 336 - 337 , and 346 - 347 . In this manner, server 300 allows connections to multiple network computers. A memory mapped graphics adapter 348 and hard disk 350 may also be connected to I/O bus 312 as depicted, either directly or indirectly. Hard disk 350 may be logically partitioned between various partitions without the need for additional hard disks. However, additional hard disks may be utilized if desired.
Those of ordinary skill in the art will appreciate that the hardware depicted in FIG. 3 may vary. For example, other peripheral devices, such as optical disk drives and the like, also may be used in addition to or in place of the hardware depicted. The depicted example is not meant to imply architectural limitations with respect to the present invention.
With reference now to FIG. 4, a block diagram of an exemplary logically partitioned platform is depicted in which the present invention may be implemented. The hardware in logically partitioned platform 500 may be implemented as, for example, server 300 in FIG. 3 . Logically partitioned platform 400 includes partitioned hardware 430 , hypervisor 410 , and operating systems 402 - 408 . Operating systems 402 - 408 may be multiple copies of a single operating system or multiple heterogeneous operating systems simultaneously run on platform 400 .
Partitioned hardware 430 includes a plurality of processors 432 - 438 , a plurality or system memory units 440 - 446 , a plurality of input/output (I/O) adapters 448 - 462 , and a storage unit 470 . Each of the processors 432 - 438 , memory units 440 - 446 , and I/O adapters 448 - 462 may be assigned to one of multiple partitions within logically partitioned platform 400 , each of which corresponds to one of operating systems 402 - 408 .
Hypervisor 410 , implemented as firmware, performs a number of functions and services for operating system images 402 - 408 to create and enforce the partitioning of logically partitioned platform 400 . Firmware is “hard software” stored in a memory chip that holds its content. without electrical power, such as, for example, read-only memory (ROM), programmable ROM (PROM), erasable programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM), and non-volatile random access memory (non-volatile RAM).
Hypervisor 410 provides a secure direct memory access (DMA) window, per IOA, such as, for example, IOA 328 in FIG. 3, on a shared I/O bus, such as, for example, I/O bus 312 in FIG. 3, into the memory resources allocated to its associated OS image, such as, for example, OS image 402 in FIG. 4 . The secure DMA window provides access from an IOA to memory which is allocated to the same partition as the IOA, while preventing the IOA from getting access to the memory allocated to a different partition.
In one embodiment, as implemented within an RS/6000 Platform Architecture, the hypervisor makes use of two existing hardware mechanisms. These hardware mechanisms are called the translation control entry (TCE) facility and the DMA range register facility Bridge. In one embodiment, the TCE facility is implemented in the PCI Host Bridge, such as PCI Host Bridges 314 , 322 , 330 , and 340 in FIG. 3, and the range register facility is implemented in the Terminal Bridge, such as Terminal Bridges 316 - 317 , 324 - 325 , 332 - 333 , and 342 - 343 .
The TCE facility (not shown) is a facility for the I/O which is analogous to the virtual memory address translation facility provided by most processors today. That is, the TCE facility provides a mechanism to translate a contiguous address space on the I/O bus to a different and possibly non-contiguous address space in memory. It does this in a manner similar to the processor's translation mechanism, and thus breaks the address space of the memory and the address space of the I/O bus into small chunks, called pages. For IBM PowerPC processor based platforms, this size is generally 4 Kbytes per page. Associated with each page is a translation and control entry. This translation and control entry is called a TCE for this I/O translation mechanism, and is sometimes called the Page Table Entry for the corresponding processor virtual translation mechanism. These translation entries are in different tables for the processor and I/O.
When an I/O operation starts on the bus, the TCE facility accesses the entry for that page in the TCE table, and uses the data in that entry as the most significant bits of the address to access memory, with the least significant bits being taken from the I/O address on the bus. The number of bits used from the bus is dependent on the size of the page, and is the number of bits necessary to address to the byte level within the page (e.g., for the 4 Kbyte page size example, the number of bits taken from the bus would be 12, as that is the number of bits required to address to the byte level within the 4 Kbyte page). Thus, the TCE provides bits to determine which page in memory is addressed, and the address bits taken from the I/O bus determines the address within the page.
The bus address ranges that the IOAs are allowed to place onto the I/O bus are limited by the range register facility. The range register facility contains a number of registers that hold addresses that are compared to what the IOA is trying to access. If the comparison shows that the IOA is trying to access outside of the range of addresses that were programmed into the range registers by the firmware, then the bridge will not respond to the IOA, effectively blocking the IOA from accessing addresses that it is not permitted to access. In this embodiment, these two hardware mechanisms are placed under the control of the hypervisor.
When platform 400 is initialized, a disjoint range I/O bus DMA addresses is assigned to each of IOAs 448 - 462 for the exclusive use of the respective one of IOAs 448 - 462 by hypervisor 410 . Hypervisor 410 then configures the Terminal Bridge range register (not shown) facility to enforce this exclusive use. Hypervisor 410 then communicates this allocation to the owning one of OS images 402 - 408 . Hypervisor also initializes all entries in a particular IOA's associated section of the TCE table to point to a reserved page per image that is owned by the OS image that is allocated that IOA, such that unauthorized accesses to memory by an IOA will not create an error that could affect one of the other OS images 402 - 408 .
When an owning one of OS images 402 - 408 requests to map some of its memory for a DMA operation, it makes a call to the hypervisor 410 including parameters indicating the IOA, the memory address range, and the associated I/O bus DMA address range to be mapped. The hypervisor 410 checks that the IOA and the memory address range are allocated to the owning one of OS images 402 - 408 . The hypervisor 410 also checks that the I/O bus DMA range is within the range allocated to the IOA. If these checks are passed, the hypervisor 410 performs the requested TCE mapping. If these checks are not passed, he hypervisor rejects the request.
Hypervisor 410 also may provide the OS images 402 - 408 running in multiple logical partitions each a virtual copy of a console and operator panel. The interface to the console is changed from an asynchronous teletype port device driver, as in the prior art, to a set of hypervisor firmware calls that emulate a port device driver. The hypervisor 410 encapsulates the data from the various OS images onto a message stream that is transferred to a computer 480 , known as a hardware system console.
Hardware system console 480 is connected directly to logically partitioned platform 400 , as illustrated in FIG. 4, or may be connected to logically partitioned platform through a network, such as, for example, network 102 in FIG. 1 . Hardware system console 480 may be, for example, a desktop or laptop computer, and may be implemented as data processing system 200 in FIG. 2 . Hardware system console 480 decodes the message stream and displays the information from the various OS images 402 - 408 in separate windows, at least one per OS image. Similarly, keyboard input information from the operator is packaged by the hardware system console, sent to logically partitioned platform 400 where it is decoded and delivered to the appropriate OS image via the hypervisor 410 emulated port device driver associated with the then active window on the hardware system console 480 . Hypervisor 410 may also perform other functions and services.
In order to prevent instruction fetch errors in hypervisor 410 from affecting OS images 402 - 408 and the rest of platform 400 , two copies of the hypervisor 410 instructions are loaded into the memory of platform 400 . A hypervisor 410 instruction fetch error occurs when one of the processors 432 - 438 is executing hypervisor 410 instructions, and after fetching the next instruction from one of memories 440 - 446 containing the hypervisor 410 instructions, detects that there is an error in the instruction. For example, the error could be the result of the instruction having been stored in a bad memory location, such that the instruction has become corrupted. Such an error in the instruction results in a machine check interrupt and the processor, an occurrence of such an interrupt, is unable to determine what instruction it should execute next. In the prior art, such an occurrence would result in either a need to reboot the entire system, thus interfering with the continuous operation of OS images 402 - 408 , or extra redundancy bits for the entire system memory plus more complex encoding and decoding logic were utilized to recover from the error. Allowing for the necessity of rebooting the entire system could result in the loss of data for applications executing in one of OS images 402 - 408 , which is unacceptable and should be avoided if at all possible. Utilizing the extra redundancy bits along with more complex encoding and decoding logic impairs the speed and performance of platform 400 .
Those of ordinary skill in the art will appreciate that the hardware and software depicted in FIG. 4 may vary. For example, more or fewer processors and/or more or fewer operating system images may be used than those depicted in FIG. 4 . The depicted example is not meant to imply architectural limitations with respect to the present invention.
With reference now to FIG. 5, a block diagram illustrating a primary and alternate copy of hypervisor instructions is depicted in accordance with the present invention. In the present invention, as illustrated in FIG. 5, the error recovery routine in the hypervisor 410 maintains pointers 502 , 504 to each of the copies of the hypervisor instructions 506 , 508 . In the depicted example, the instruction pointer 510 of one of the processors 423 - 438 points to the primary copy of Inst 5 . Inst 1 - 6 are equivalent instructions in both copies 502 , 504 . As the processor executing the hypervisor instructions executes the next instruction, the instruction pointer 510 is adjusted to point to the next instruction in the primary copy of the hypervisor instructions 506 . Each copy of the hypervisor instructions 506 , 508 should be stored in a platform specific location that minimizes the probability of the corruption of the alternate copy 508 of the hypervisor instructions by an error that may cause corruption of the primary copy 506 of the hypervisor instructions.
When the instruction fetch error is determined to be hard (i.e. that the error is not due to transient electrical noise which is recovered using retry common in the art), the machine check code points the processors interrupt vectors, that point to the primary copy 506 of the hypervisor instructions, to the alternate copy 508 of the hypervisor instructions. The machine check code than computes the new location for the instruction restart within the alternate copy based on pointer 504 . The processor then continues with the instruction from the new location within alternate copy 508 . Thus, the instruction fetch error has been recovered from and the instruction fetch error has had a minimal or no effect on the OS images running within the platform. When and if all processors within the platform are using the alternate copy 508 , the primary copy 506 of the hypervisor instructions may be refreshed from the alternate copy 508 as a background operation. By duplicating this relatively small amount of hypervisor code, the amount of memory used is insignificant and the performance and simplicity of the memory system is maintained.
With reference now to FIG. 6, a flowchart illustrating an exemplary method of recovering from instruction fetch errors, is depicted in accordance with the present invention. To begin, the machine check code within a data processing system, such as, for example, data processing system 300 , loads a primary copy instructions of a software component into a first memory location (step 602 ). This software component may be, for example, hypervisor 410 in FIG. 4 . The machine check code then loads an identical but alternate copy of the instructions for the software component into a second memory location (step 604 ). The machine check code creates and maintains pointers to the origins of the corresponding sections of each copy of the instructions (step 606 ). These pointers identify the equivalent instruction in the opposite copy of the instructions. The processor then executes the software component process using instructions fetched from the primary copy of the instructions (step 608 ).
The machine check code then determines whether an instruction fetch error has been received from the processor executing the software component's instructions (step 610 ). If no instruction fetch error has been received, then the processor continues executing the software component's instructions as fetched from the primary copy of the instructions (step 610 ). If an instruction fetch error has been received, then the machine check code points the processor to the corresponding section of the alternate copy (step 612 ) and the processor restarts the software component's process by fetching instructions from the alternate copy beginning with the instruction in the location to which the pointer is pointing (step 614 ). The machine check code then refreshes the primary copy of the instructions using the alternate copy of the instructions (step 616 ). If there are more than one processor executing instructions for the software component, then the machine code waits until all processors have switched to the alternate copy and then refreshes the primary copy.
Although the present invention has been described primarily with respect to a firmware implemented hypervisor for maintaining the integrity of partitions within a logically partitioned data processing system, the method, apparatus, and system of the present invention may be applied to any software component. It is also important to note that while the present invention has been described in the context of a fully functioning data processing system, those of ordinary skill in the art will appreciate that the processes of the present invention are capable of being distributed in the form of a computer readable medium of instructions and a variety of forms and that the present invention applies equally regardless of the particular type of signal bearing media actually used to carry out the distribution. Examples of computer readable media include recordable-type media such as a floppy disc, a hard disk drive, a RAM, and CD-ROMs and transmission-type media such as digital and analog communications links.
The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiment was chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. | A method, system, and apparatus for recovering form an instruction fetch error is provided. In one embodiment, a data processing system maintains a primary copy and an alternate copy of a set of instructions for a software component. The instructions for performing the processes of the software component are fetched from the primary copy for execution by a processor. A pair of pointers is maintained in each copy identifying the beginning of each copy. Responsive to a determination that an instruction fetch error has been received, a corresponding current instruction in the alternate copy is determined and the software component is restarted by fetching and executing instructions from the alternate copy starting with the corresponding current instruction. The corresponding current instruction is determined by subtracting the beginning address of the copy with the error from the address of the current instruction, then adding the beginning address of the alternate copy. | 6 |
RELATED APPLICATIONS
[0001] This application claims priority and herein incorporates by reference U.S. provisional patent application 60/885,553, filed Jan. 18, 2007.
BACKGROUND OF THE INVENTION
[0002] The internal combustion engine has revolutionized the world we live in. Although some engines use air cooling techniques to control the temperature, most vehicles use liquid cooled systems that utilize a radiator filled with a liquid that circulates through a series of hoses and channels in the engine block designed to transfer heat away from the engine. There are basically two types of water cooling systems. The older system utilizes a non-pressurized radiator that operates at a temperature of approximately 180° F. The hot water from the engine is pumped through the radiator while airflow keeps the operating temperature constant. This means that while the system is operating properly, the water is kept below the boiling point, and therefore the radiator cap of such a system can be opened without significant risk of injury. Of course, even with this system, overheating can result in serious injury when trying to remove the radiator cap.
[0003] Because of the thermodynamic advantage associated with greater temperature differences, most current liquid cooled systems operate with a pressurized radiator, allowing the coolant to remain a liquid above the atmospheric boiling point. Because of this, even in a properly operating system, it is extremely dangerous to remove the radiator cap until the coolant is been given sufficient time to cool down. In such systems, if the radiator cap is removed before cooling, the liquid will instantly vaporize in a dangerous explosion of steam. There is a need for a radiator cap that keeps a user from being injured when trying to access the cooling system of the vehicle.
SUMMARY OF THE INVENTION
[0004] A safety radiator cap has a centrally located pressure plunger that forces pins outward against the inside of a radiator fill tube to prevent opening of the cap when the system is under pressure. As the liquid cools, the pressure is reduced and the pins retract due to biasing springs which allow the cap to be removed thus ensuring that the cap can only be removed when safe. Pressure pads at the end of the pins allow an embodiment of the invention to be used in any vehicle without retrofitting.
[0005] Other features and advantages of the instant invention will become apparent from the following description of the invention which refers to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a cutaway view of an embodiment according to the present invention.
[0007] FIG. 2 is a cutaway view of the embodiment shown in FIG. 1 showing the safety pins engaged.
[0008] FIG. 3 is a cutaway view of the embodiment according to the present invention showing the safety pin engaged with a specialized radiator fill tube.
[0009] FIG. 4 is a perspective view of a radiator fill tube according to the present invention.
[0010] FIG. 5 is a perspective view of the safety radiator cap engaged according to the present invention.
[0011] FIG. 6 is a close up view of a section shown in FIG. 5 .
[0012] FIG. 7 is a cutaway view of another embodiment according to the present invention.
[0013] FIG. 8 is a cutaway view of the embodiment shown in FIG. 7 with safety pins engaged.
[0014] FIG. 9 is a perspective view of a safety radiator cap according to the embodiment shown in FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
[0015] Reference is now made to the drawings in which reference numerals refer to like elements.
[0016] Referring now FIGS. 1 through 4 , a safety radiator cap 100 has a center slide 126 along which a pressure plunger 134 moves up and down in response to the pressure within a radiator (not shown). In the embodiment shown, at least two pins 118 are radially disposed within a channel in lower ring 122 , which guides pin 118 as it moves back and forth in response to pressure. At another end of pin 118 is a distally disposed pin follower 116 , which rides along an angled section of pressure plunger 134 . Disposed along a bottom portion of pressure plunger 134 is pressure plate 136 .
[0017] Safety radiator cap 100 has a Portion 106 is held in place by a end holder 104 which is welded, bolted or glued to maintain integrity. An upper ring 102 applies pressure to an upper gasket 108 which is spring-loaded connection with outer spring 110 . As safety radiator 100 is pushed down on upper sealing seat 144 upper gasket 108 seals the cooling system accessible through radiator fill tube 140 by pushing against upper sealing ring 154 of radiator fill tube 140 . Safety radiator cap 100 is locked in place by locking tabs 158 fitting within locking cutouts 146 as is known in the art. In this embodiment, as soon as pressure begins to build within the cooling system, pressure plate 136 moves upward along center slide 126 overcoming center spring 114 which biases pressure plunger 14 in a non-locked position. Pressure plunger 134 has a sloped portion where pin followers 116 ride up and down causing them to move laterally in response to the pressure change within the cooling system.
[0018] Pins 118 are biased in an unlocked position by pin springs 124 which are held in place by pin spring retainers 138 . A lower gasket 120 seals against a lower sealing ring 156 of radiator fill tube 140 during normal operation. In the event of an over pressurized condition, liquid and gas escapes by forcing lower ring 122 to move up so that the liquid and gas is released through overflow tube 142 . Pins 118 make contact with a locking ring groove 148 disposed within radiator fill tube 140 preventing safety radiator cap 100 from being removed until the cooling system is no longer under pressure.
[0019] Pressure plunger 134 is biased in an un-locked condition by center spring 114 which pushes against a center housing 132 and is held in place by center spring retainer 112 . As the pressure decreases, center spring 114 forces pressure plunger 134 to move downwards which allows pins 118 to retract which in turn allows safety radiator cap 100 to be removed. This embodiment requires radiator fill tube 140 to be manufactured with locking pin ring 148 .
[0020] Referring now to FIGS. 5 and 6 , another embodiment of the safety radiator cap is shown having a conventional radiator fill tube 300 that lacks locking pin ring 148 ( FIG. 4 ). Pins 118 have pressure pads 152 mounted on their ends. As pins 118 are forced outward, pressure packed 152 deform against the inside surface of radiator fill tube 300 . Pressure pads 152 may be made of rubber or other high friction deformable material. As the pressure increases in the cooling system, safety radiator cap will be highly resistant to movement due to the pressure of pins 118 and pressure pads 152 being forced against the inside of radiator fill tube 300 . At the pressure is released, pins 118 will retract thus allowing safety radiator cap to be removed.
[0021] Now referring to FIGS. 7 , 8 and 9 , another embodiment of the safety radiator 200 is shown having a stationary center slide to 234 mounted on a center support to 226 . In this embodiment, safety radiator 200 has a cap portion 206 held in place by an end holder 204 . Of course other means are acceptable to hold cap 206 in place thus eliminating the need for end holder 204 . Cap portion 206 encloses an upper ring 202 in contact with an upper gasket 208 . The cooling system is sealed when lower sealing ring 222 pushes against a sealing portion of a radiator fill tube (not shown). As the pressure increases within the system lower sealing ring 222 is forced up allowing liquid and gas to escape but also forcing pins 218 outward exerting pressure against an interior wall of radiator fill tube (not shown).
[0022] Pins 218 move outward when pin followers 216 follow the angled surface of center slide 234 as lower ring 222 is forced upward due to pressure within the cooling system. Pressure pads 252 deform to apply frictional pressure making removal of safety radiator 200 difficult in an unsafe condition. Pins 218 are biased in an unlocked condition by pin springs 234 which are held in place by pin spring retainer 238 . Lower ring 222 is biased to normally seal the cooling system by spring 210 which moves upward in response to the pressure within the cooling system. A center housing 232 provides support for a center pin 226 which holds center slide 234 firmly in place.
[0023] The amount of play that lower ring 222 has may be adjusted by appropriate selection of pin springs 224 . As the pressure builds, lower ring 222 begins to move upward releasing some pressure through an overflow tube (not shown). As the pressure begins to build more however, lower ring 222 will be forced to move further upward applying pressure through pins 218 making removal of safety radiator cap 200 more and more difficult as the pressure increases.
[0024] Additionally, although the present invention is described in use with a radiator, it is easily adaptable for use with any pressurized application such as a hydraulic filling system, steam lines, etc. Also, some radiator systems do not have a user access cap as described above. Those systems use a pressurized overflow system that utilizes a fill cap attached to the overflow container rather than on the radiator directly. It is within the scope of this disclosure to include using the instant invention in such a system in the same way as described above with the difference being that the safety pressure cap fits within the overflow collar rather than the radiator directly.
[0025] Although the instant invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. | A safety radiator cap has a centrally located pressure plunger that forces pins outward against the inside of a radiator fill tube to prevent opening of the cap when the system is under pressure. As the liquid cools, the pressure is reduced and the pins retract due to biasing springs which allow the cap to be removed thus ensuring that the cap can only be removed when safe. Pressure pads at the end of the pins allow an embodiment of the invention to be used in any vehicle without retrofitting. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application under 35 USC §120 and 37 CFR 1.53(b)(1) of co-pending U.S. patent application Ser. No. 13/031,355 ( filed Feb. 21, 2011 and scheduled to issue on Mar. 12, 2013 as U.S. Pat. No. 8,396,072): the contents of which are herby incorporated in thier entirety.
FIELD OF THE INVENTION
[0002] The invention relates to mobile communications networks, and in particular to channel traffic congestion detection and management in a mobile communication system.
BACKGROUND
[0003] In mobile communication systems a cell is managed by a base station, BS. Any communication traffic in or out of or within the cell is routed via the BS. The communication is usually sent along a number of channels, each channel assigned to control or data traffic of a particular kind. One example being the Broadcast Control Channel, BCCH, used by a BS to provide a mobile node or Mobile Station, MS, in the cell with control information. Other examples being the Common Control Channel CCCH, compromising of paging, random access, access grant and notification channels used for control signaling during connection establishment.
[0004] At times when many MSs are trying to communicate at the same time in a cell, the control or data traffic can become higher than the BS is capable of handling and the data channels that are used then become congested. In practice this means that some of the mobile station's (MSs) traffic will not be handled in a timely manner. Congestion may occur on uplink channels (RACH) or on downlink channels.
[0005] To enable devices to communicate freely even under heavy data or control traffic a protocol has been developed wherein a MS has to require a data channel access before starting to communicate. In a system such as the GERAN (GSM EDGE Radio Access Network. GSM—Global System for Mobile communication, EDGE—Enhanced Data rates for GSM Evolution) mobile stations have to send a CHANNEL REQUEST message or an EGPRS CHANNEL REQUEST message on a channel named RACH (Radio Access Channel). If the BS is able to handle the communication a message is sent out granting access on a channel named AGCH (Access Granted CHannel). If the BS is not able to handle the communication a message rejecting the access is sent out on the same channel. The BS may fail to comedy receive the RACH message e.g. if simultaneous RACH messages collide or if the radio link quality is not sufficient. In this case no response is sent to the mobile station at all. Should such a response not be received a MS would resend the request over the RACH. However, during congestion these requests only lead to increased control traffic and therefore adds to the congestion. It should be noted that congestion may occur on either of an upload channel and a download channel or both.
[0006] Therefore, it would be beneficial to control the access requests so as not to burden the base stations unnecessarily and thereby alleviate the congestion in a cell.
[0007] A procedure during which the MS requests resources for control or data traffic is commonly known as the random access procedure. The MS initiates the random access procedure by transmitting a request message. When the MS sends a request message such as a CHANNEL REQUEST message or an EGPRS CHANNEL REQUEST message on a channel named RACH, the MS is expecting to receive a response from the BS within a given time derived from broadcast parameters. The MS is not allowed to retransmit the request sooner than this time. The reason why the BS does not respond to the request message may be one of the following. Firstly, the request message was not received correctly due to the congestion on a channel named RACH or due to poor link conditions. Secondly, the BS cannot send the response within the time constraints due to the congestion on a channel named AGCH. The random access procedure is delayed in either case by the waiting time between the retransmissions of the request messages.
[0008] Therefore, it would be beneficial to estimate the cause of delay in the BS response and allow for shorter waiting time between the retransmissions of the request messages (i.e. faster random access procedure) if the estimation suggests the cause of the delay is an incorrect reception of the request message due to poor link conditions.
SUMMARY
[0009] According to an aspect, a method for operating a mobile station is disclosed, the method comprising: detecting by the mobile station whether there is congestion in a cell by monitoring a first channel for downlink messages and decoding the messages to see if the decoded messages indicate congestion, where the first channel is a common control channel (CCCH): and:
for the case in which the mobile station determines from the decoded messages that there is no congestion, the mobile station initiating a random access procedure by transmitting a request message uplink on a random access channel (RACH); else for the ease in which the mobile station determines from the decoded messages that there is congestion, the mobile station waiting for a waiting time before initiating a random access procedure an apparatus is disclosed, comprising at least one controller.
[0012] In one embodiment to be used in a GERAN system the first channel is the ACCESS GRANTED CHANNEL, AGCH, and the second channel is the REQUEST ACCESS CHANNEL, RACEL
[0013] According to a further aspect, an apparatus for controlling a mobile station is disclosed, the apparatus comprising: at least one controller, and a memory storing a computer program. The controller and the memory with the program are configured to cause the mobile station at least to: detect whether there is congestion in a cell by monitoring a first channel for downlink messages and decoding the messages to see if the decoded messages indicate congestion, where the first channel is a common control channel (CCCH); and
for the case in which the mobile station determines from the decoded messages that there is no congestion, to initiate a random access procedure by transmitting a request message uplink on a random access channel (RAM): else for the case in which the mobile station determines from the decoded messages that there is congestion, to wait for a waiting time before initiating a random access procedure.
[0016] According to a further aspect, a memory storing a computer program is disclosed. The stored computer program comprises a set of instructions, which, when executed on a data-processing system (such as of a mobile station), causes the data processing system to: detect whether there is congestion in a cell by monitoring a first channel for downlink messages and decoding the messages to see if the decoded messages to indicate congestion, where the first channel is a common control channel (CCCH); and
for the case in which it is determined, from the decoded messages that there is no congestion, initiate a random access procedure by transmitting a request Message Uplink on a random access channel (RACH); else for the case in which it is determined from the decoded messages that there is congestion, wait for a waiting time before initiating a random access procedure.
[0019] In one embodiment, the computer program is stored on a computer readable memory. The computer readable memory may be, but is not limited to, a removable memory card, a removable memory module, a magnetic disk, an optical disk, a holographic memory or a magnetic tape. A removable memory module may be, for example, a USB memory stick, a PCMCIA card or a smart memory card.
[0020] It should be noted that congestion may occur on either of an upload channel and a download channel or on both or on a channel for both upload and download and the teachings herein apply equally to these different arrangements.
[0021] The embodiments described hereinbefore may be used in any combination with each other. Several of the embodiments may be combined together to form a further embodiment. A method, a system, an apparatus, a computer program or a computer program product to which the invention is related may comprise at least one of the embodiments described hereinbefore.
[0022] The benefits of the teachings herein are related to reducing congestion on data traffic channels by enabling user equipment to monitor the traffic on the channels and only make requests when there is no congestion.
[0023] A further benefit is that priority is given to some devices either requiring lower priority devices to adhere to the processes described herein or by giving lower priority devices longer waiting times.
[0024] An even further benefit is that user equipment may be dynamically informed of the congestion status by a base station or other network component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The accompanying drawings, which are included to provide a further understanding and constitute a part of this specification, illustrate embodiments and together with the description help to explain the principles In the drawings:
[0026] FIG. 1 a is a block diagram illustrating an apparatus according an embodiment according to the teachings herein;
[0027] FIG. 1 b is a block diagram illustrating an apparatus according an embodiment according to the teachings herein;
[0028] FIG. 2 a is a flowchart according to an embodiment of a method discussed herein;
[0029] FIG. 2 b is a flowchart according to an embodiment of a method discussed herein;
[0030] FIG. 2 c is a flowchart according to an embodiment of a method discussed herein;
[0031] FIG. 2 d is a flowchart according to an embodiment of a method discussed herein;
[0032] FIG. 2 e is a flowchart according to an embodiment of a method discussed herein;
[0033] FIG. 2 f is a flowchart according to an embodiment of a method discussed herein
[0034] FIG. 2 g is a flowchart according to an embodiment of a method discussed herein;
[0035] FIG. 2 h is a flowchart according to an embodiment of a method discussed herein.
[0036] FIG. 2 i is a flowchart according to an embodiment of a method discussed herein.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0037] Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings,
[0038] FIG. 1 a is a block diagram illustrating an apparatus according to an embodiment. The apparatus comprises at least one controller 100 , such as a processor, a memory 110 and a communication interface 120 . In one embodiment the apparatus is a computer chip. In the memory 110 computer instructions are stored which are adapted to be executed on the processor 110 . The communication interface 120 is adapted to receive and send information to and from the processor 100 .
[0039] FIG. 1 b is a block diagram illustrating an apparatus according to an embodiment. In one embodiment the apparatus is a mobile station. The apparatus comprises at least one controller 100 , such as a processor, a memory 110 and a communication interface 120 . In the memory 110 computer instructions are stored which are adapted to be executed on the processor 110 . The communication interface 120 is adapted to receive and send information to and from the processor 100 . The communication interface 120 further comprises a radio frequency interface 125 for communicating between apparatuses and a man-machine interface (MMI) 126 for communicating between the apparatus and a user. Such an MMI may include a touch pad, a display, a. keypad, audio in and output and/or a touch display as are known (not shown). The mobile station further comprises an antenna 130 and a second memory 140 that comprises user applications such as a message handling application, a voice call handling application, a text editor, an interact browser application and drivers for further devices to be connected to or incorporated in the apparatus, such as a camera module for example. In one embodiment memories 110 and 140 are incorporated within the same memory module.
[0040] In one embodiment the apparatus is, for example, a mobile node, user equipment, cellular phone, a mobile terminal, an Application Specific Integrated Circuit (ASIC), an Integrated Chip (IC) or any chip. FIG. 1 a is an example embodiment of an ASIC. FIG. 1 b is an example embodiment of a mobile phone.
[0041] In one embodiment an apparatus according to above is adapted to be part of a radio network. The network may be a GSM-Edge Radio Access Network (GERAN). The network may also be any cellular radio access network such as, for example, an E-UTRAN or a UMTS Terrestrial Radio Access Network (UTRAN). Such a system comprises a number of base stations each handling a cell. At least one User Equipment, UE, is part of a cell and being handled by the cell's base station. A UE may be mobile and is thus able to move between cells. In one embodiment a UE is an apparatus according to above.
[0042] FIG. 2 shows a series of flow charts each according to an embodiment of the teachings herein.
[0043] In one embodiment, FIG. 2 a , a MS detects if there is congestion 210 . If there is no congestion the MS proceeds with sending a CHANNEL REQUEST message or an EGPRS PACKET CHANNEL REQUEST message on a Request Access CHannel, RACH 250 . If there is congestion the MS waits 260 and then again detects if there is congestion 210 .
[0044] In one embodiment an apparatus is configured to determine if a network node, such as a base station, BS, has received a request message, an RACH message, from a mobile station and if such a message is received then the controller is configured to apply a random delay or waiting time before repeating the RACH transmission.
[0045] In one embodiment, an apparatus is configured to determine if a network node, such as a base station, BS, has received a request message, an RACH message, from a mobile station and if such a message is not received then the controller is configured to apply a shorter random delay or waiting time before repeating the RACH transmission.
[0046] In one embodiment, an apparatus is configured to determine a network node, such as a base station. BS, has received a request message, an RACH message, from a mobile station if congestion is detected.
[0047] This avoids unnecessary delays when there is no congestion.
[0048] In the following reference will be made to FIGS. 1 and 2 simultaneously as the apparatus of FIG. 1 is adapted to execute the method of FIG. 2 .
[0049] In one embodiment, see FIG. 2 b , the controller 100 of an apparatus is configured to detect that there is congestion 210 by receiving through the communication interface 120 a series of blocks 220 that have been transmitted on a channel, such as the AGCH. In a system such as a GERAN system it is possible to detect whether there is congestion by monitoring the AGCH channel as if there is not enough traffic to fully utilize the capacity of the BS the BS will transmit blocks with L2 fill frames.
[0050] In one embodiment the processor therefore reads or decodes the blocks 220 being transmitted and counts the number of L2 fill frames 225 . If the number of fill frames is 0 (zero) there is congestion.
[0051] In one embodiment the series of blocks has a length of N and in one embodiment N is 3. In one embodiment N is in the range of 2 to 4. In one embodiment N is 5. In one embodiment N is 10. In one embodiment N is in the range 3 to 15. In such an embodiment the controller 100 is free to perform other tasks when there is congestion after having decoded the N blocks. It should be noted that longer series provide for a more accurate determination of the congestion, but also take longer time to decode. A tradeoff of which feature to focus on is left to a system designer.
[0052] In one embodiment the series of blocks does not have a specified length, but the controller is configured to read blocks until a 1 , 2 fill frame is detected. This enables the processor to start transmitting the channel request as soon as it is detected that there is no congestion, but it may also lead to that the controller is busy reading many blocks unnecessarily if there is congestion, i.e. the processor 100 keeps decoding until the congestion is dissolved. In such an embodiment the box with reference 260 in FIG. 2 is not needed.
[0053] In one embodiment, see FIG. 2 c , the controller 100 is further configured to count 230 the number of assignment messages such as IMMEDIATE ASSIGNMENT messages and IMMEDIATE ASSIGNMENT REJECT messages that are decoded or read in the series of blocks having been read 220 . In this embodiment the controller is configured to determine a ratio between the L2 fill frames and the IMMEDIATE ASSIGNMENT messages and IMMEDIATE ASSIGNMENT REJECT messages 235 . If this ratio is below a threshold value T then there is no congestion.
[0054] In one embodiment the threshold value T is 1:9. In one embodiment the threshold value T is 1:3. In one embodiment the threshold value T is 2:5. In one embodiment the threshold value is in the range of 1 to 3.
[0055] In one embodiment the IMMEDIATE ASSIGNMENT messages and/or IMMEDIATE ASSIGNMENT REJECT messages comprises a congestion flag (a I bit logical marker) which is set (the bit is set to I in one embodiment) by a base station if there is congestion and not set (the bit is set to 0 in one embodiment) if there is no congestion.
[0056] In one such embodiment, see FIG. 2 d the controller is adapted to read a series of blocks 220 and determine 240 if a block is decoded to contain a congestion flag which is set there is congestion and if a block is decoded to contain a congestion flag which is not set there is no congestion.
[0057] In one embodiment the series of blocks has a length of N and in one embodiment N is 3. In one embodiment N is in the range of 2 to 4. In one embodiment N is 5. In one embodiment N is 10. In one embodiment N is in the range 3 to 15. In such an embodiment the controller 100 is free to perform other tasks when there is congestion after having decoded the N blocks.
[0058] In one embodiment the series of blocks does not have a specified length, but the controller is configured to read blocks until a not set congestion flag is detected. This enables the processor to start transmitting the channel request as soon as it is detected that there is no congestion, but it may also lead to that the controller is busy reading many blocks unnecessarily if there is no congestion, i.e. the processor is 100 keeps decoding until the not set congestion bit is received.
[0059] In one such an embodiment having a congestion flag the apparatus is enabled to be dynamically informed of the congestion status by a network node such as a base station or other network component.
[0060] In one such embodiment a network node such as a base station or other network component is configured to set the congestion flag based on the current queue length for the AGCH.
[0061] In one such embodiment a network node such as a base station or other network component is configured to set the congestion flag more accurately based on implementation specific criteria that include other factors such as the packet utilization.
[0062] In one embodiment a controller 100 is configured to determine the waiting time based on the number of channels and/or their availability.
[0063] In one embodiment a controller 100 is configured to employ a statistical analysis of the channel usage to predict when congestion is about to arise and/or to dissolve to determine a waiting time.
[0064] In one such embodiment a network node such as a base station or other network component is configured to set the congestion flag more accurately based on a combination of implementation specific criteria that includes other factors such as the packet channel utilization and the current queue length for the AGCH.
[0065] In one such embodiment the process of checking for congestion may be run in the background and an apparatus therefore does not need to make a congestion check each time a channel is to be requested as the apparatus is kept aware of the congestion status by the base station. In one embodiment a copy of the congestion flag is stored in the memory 110 of the apparatus for quick and easy reference.
[0066] FIG. 2 e shows a combination of the embodiments above as has been described with reference to FIGS. 1 , 2 a , 2 b . 2 c , and 2 d.
[0067] In one embodiment the controller 100 is configured to wait between attempts to determine whether there is congestion or not.
[0068] FIG. 2 a shows a flowchart where a controller 100 is configured to wait 260 for a pre-determined time WT until making another attempt. The time to wait WT may be standard specific. If the time to wait WT is set to zero (0) the controller 100 is configured to continuously read blocks until it is detected that there is no congestion.
[0069] In one embodiment see FIG. 2 f , the controller 100 is configured to listen to a broad cast channel, such as a Broadcast Control CHannel, BCCH, on which a base station is transmitting for a waiting time WT 252 . In such an embodiment a base station is configured to broadcast a waiting time VT. This enables a base station to control how long different MSs are to wait and thus allow the base station to both control the traffic on the channels (reducing unnecessary attempts) and ordering a further priority scheme among devices (lower priority devices get longer waiting times).
[0070] In one embodiment the controller 100 is configured to determine a waiting time WT based on other broadcast parameters related to non-congested behavior such as time between request retransmission and maximum allowed number of retransmissions
[0071] In one embodiment see FIG. 2 g , the controller 100 is configured to increase the waiting time WT with the number of times that a detection of congestion has been made 254 . In one embodiment the waiting time increases linearly with the number of attempts, for example through a formula such as:
[0000] WT=number of attempts*Constant.
[0072] In one embodiment the controller 100 is configured to base the waiting time on a geometric series.
[0073] In one embodiment the waiting time increases non-linearly with the number of attempts, for example through a formula such as:
[0000] WT=Constant̂ A number of attempts.
[0074] In one embodiment see FIG. 2 h , the controller 100 is configured to increase the waiting time WT with the number of IMMEDIATE ASSIGNMENT and/or IMMEDIATE ASSIGNMENT REJECT messages received 256 . In one embodiment the waiting time increases linearly with the number of messages received, for example through a formula such as:
[0000] WT=number of messages*Constant.
[0075] In one embodiment the controller 100 is configured to base the waiting time on a geometric series.
[0076] In one embodiment see FIG. 2 i , the controller 100 is configured to set the waiting time WT to a random number 258 . This improves the synchronization of many UEs simultaneously waiting for congestion to disappear or a new congestion night occur should all waiting UEs send their requests at the same time
[0077] It should be noted that the random element may be added in all embodiments described above. For example, the formula for the waiting time of FIG. 2 g becomes
[0000] WT =number of attempts*Constant±Random
[0000] or
[0000] WT=number of attempts*Constant * Random.
[0078] In one embodiment the random element is taken from a range that grows with the number of attempts and/or messages. For example the random element could be taken from the range [constant1, constant2*nbr of attempts].
[0079] It should be noted that in the embodiments above the waiting time is proportionate to one or more parameters of the system, wherein it should be noted that the waiting time is not necessarily directly proportionate to the parameters.
[0080] The embodiments described hereinbefore in association with FIGS. 1 and 2 may be used in any combination with each other. Several of the embodiments may be combined together to form a further embodiment.
[0081] The exemplary embodiments can be included within any suitable device, for example, including any suitable servers, workstations, PCs, laptop computers, PDAs, Internet appliances, handheld devices, cellular telephones, wireless devices, other devices, and the like, capable of performing the processes of the exemplary embodiments, and which can communicate via one or more interface mechanisms, including, for example, Internet access, telecommunications in any suitable form (for instance, voice, modem, and the like), wireless communications media, one or more wireless communications networks, cellular communications networks, 3 G communications networks, 43 communications networks Public Switched Telephone Network (PSTNs), Packet Data Networks (PDNs), the Internet, intranets, a combination thereof, and the like,
[0082] It is to be understood that the exemplary embodiments are for exemplary purposes, as many variations of the specific hardware used to implement the exemplary embodiments are possible, as will be appreciated by those skilled in the hardware art(s). For example, the functionality of one or more of the components of the exemplary embodiments can be implemented via one or more hardware devices, or one or more software entities such as modules.
[0083] The exemplary embodiments can store information relating to various to processes described herein. This information can be stored in one or more memories, such as a hard disk, optical disk, magneto-optical disk, RAM, and the like. One or more databases can store the information used to implement the exemplary embodiments of the present inventions. The databases can be organized using data structures (e.g., records, tables, arrays, fields, graphs, trees, lists, and the like) is included in one or more memories or storage devices listed herein. The processes described with respect to the exemplary embodiments can include appropriate data structures for storing data collected and/or generated by the processes of the devices and subsystems of the exemplary embodiments in one or more databases.
[0084] All or a portion of the exemplary embodiments can be implemented by the preparation of application-specific integrated circuits or by interconnecting an appropriate network of conventional component circuits, as will be appreciated by those skilled in the electrical art(s).
[0085] As stated above, the components of the exemplary embodiments can include computer readable medium or memories according to the teachings of the present inventions and for holding data structures, tables, records, and/or other data described herein. Computer readable medium can include any suitable medium that participates in providing instructions to a processor for execution. Such a medium can take many forms, including but not limited to, non-volatile media, volatile media, transmission media, and the like. Non-volatile media can include, for example, optical or magnetic disks, magneto-optical disks, and the like. Volatile media can include dynamic memories, and the like. Transmission media can include coaxial cables, copper wire, fiber optics and the like. Transmission media also can take the form of acoustic, optical, electromagnetic waves, and the like, such as those generated during radio frequency (RF) communications, infrared (IR) data communications, and the like. Common forms of computer-readable media can include, for example, a floppy disk, a flexible disk, hard disk, magnetic tape, any other suitable magnetic medium, a CD-ROM, CDRW, DVD, any other suitable optical medium, punch cards, paper tape, optical mark sheets, any other suitable physical medium with patterns of holes or other optically recognizable indicia, a RAM, a PROM, an EPROM, a FLASH-EPROM, any other suitable memory chip or cartridge, a carrier wave or any other suitable medium from which a computer cart read.
[0086] While the present inventions have been described in connection with a number of exemplary embodiments, and implementations, the present inventions are not so limited, but rather cover various modifications, and equivalent arrangements, which fall within the purview of prospective claims.
[0087] The embodiments described hereinbefore in association with FIGS. 1 and 2 may be used in any combination with each other. Several of the embodiments may be combined together to form a further embodiments.
[0088] It is obvious to a person skilled in the art that with the advancement of technology, the basic idea may be implemented in various ways. The invention and its embodiments are thus not limited to the examples described above; instead they may vary within the scope of the claims. | A mobile station detects whether there is congestion in a cell by monitoring a first channel fix downlink messages and decoding the messages to see if the decoded messages indicate congestion, where the first channel is a common control channel (CCCH). For the case in which the mobile station determines from the decoded messages that there is no congestion, the mobile station initiates a random access procedure by transmitting a request message uplink on a random access channel (RACH). Else for the case in which the mobile station determines from the decoded messages that there is congestion, the mobile station waits for a waiting time before initiating a random access procedure. | 7 |
BACKGROUND OF THE INVENTION
[0001] (1) Field of the Invention
[0002] The present invention relates to electrochemical cells such as solid oxide fuel cells (SOFCs), steam electrolysis cells, oxygen pumps, and NOx decomposition cells. The invention also relates to a producing process for the production of such electrochemical cells, and electrochemical devices using such electrochemical cells.
[0003] (2) Related Art Statement
[0004] The solid oxide fuel cells (SOFCs) are broadly classified into the so-called flat planar type and the so-called tubular type. Although it is said that the tubular type SOFC is most likely to be practically used, the flat planar type SOFC is more advantageous from the standpoint of the output density per unit volume. However, in the flat planar type SOFC, an electric power-generating stack is constructed by alternatively laminating so-called separators and electric power-generating layers, but the SOFC thus produced has a difficult problem in sealing.
[0005] On the other hand, so-called integrated (monolithic) type SOFCs different from the above type SOFCs are proposed. The above-mentioned tubular SOFC and the flat planar type SOFC are of a design in which separate unit cells are laminated successively one upon another. To the contrary, the monolithic type SOFC was proposed by Argonne National Laboratory in the United States, is obtained by preliminarily preparing green sheets of respective components of the SOFC, forming a laminate through laminating the above green sheets of the components in a given shape, and sintering the entire laminate. The monolithic type SOFCs include a parallel flow type (co-flow type) and an orthogonal flow type (cross flow type). It is expected that the monolithic type SOFC can realize an extremely high output density of as high as around 8 kW/kg (“Fuel Cell Generation” published by CORONA PUBLISHING CO., LTD. in May 20, 1994).
[0006] Among them, the parallel flow type SOFC is constructed such that corrugated three layers of a fuel electrode, a solid electrolyte and an air electrode are integrated, and the thus integrated corrugated laminate is sandwiched by flat planar interconnectors. The orthogonal flow type SOFC is constructed such that the flat planar electrodes and electrolyte plate are laminated and sandwiched between corrugated interconnector. However, these fine constructions are so complicated that it is difficult to form a molded body by laminating respective green sheets of the air electrode, the fuel electrode, the solid electrolyte and the interconnector. In addition, since the air electrode, the fuel electrode, the solid electrolyte and the interconnector have utterly different porosities, characteristics, and optimum sintering temperatures, it is extremely difficult to finish SOFC components having their respective favorable characteristics by simultaneous sintering. Consequently, although the monolithic type SOFC has been proposed well before, it has been considered difficult to practically use such a monolithic type SOFC, and it is a present situation that such monolithic SOFC cells are still in a trial stage.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide electrochemical cells having a large electrode area per unit volume and a high efficiency. Further, it is another object of the present invention to provide a new electrochemical cell structure which is structurally relatively simple, needs not special structurally sealing mechanism, and can be produced by simultaneous sintering. It is a further object to provide a process for producing such an electrochemical cell, and also to provide an electrochemical device using such an electrochemical cell or such electrochemical cells.
[0008] An electrochemical cell according to the present invention includes at least one dense solid electrolyte body, at least two dense interconnectors for collecting current flowing in the cell, cathodes and anodes, wherein said at least one dense solid electrolyte body and at least two dense interconnectors constitute a structural body, a plurality of first gas flow channels and a plurality of second gas flow channels both extend through the structural body in a given direction, and are each defined and surrounded by a part of said at least one solid electrolyte body and a part of said at least two interconnectors, the anodes are formed on respective walls defined by said part of at least one solid electrolyte body and said part of at least two interconnectors and constituting the respective first gas flow channels, the cathodes are formed on respective walls defined by said part of at least one solid electrolyte body and said part of at least two interconnectors and constituting the respective second gas flow channels, every anode is opposed to an adjacent cathode or adjacent cathodes via a solid electrolyte body, and every cathode is opposed to an adjacent anode or adjacent anodes via a solid electrolyte body.
[0009] According to the electrochemical cell of the present invention, it is preferable that as viewed in a direction orthogonal to the flow channels, every first gas flow channels excluding those in extremely opposite sides of the honeycomb structural body is adjacent to four second gas flow channels, whereas every second gas flow channels excluding those in extremely opposite sides is adjacent to four first gas flow channels.
[0010] The process for producing the electrochemical cell according to the present invention is characterized by including the steps of forming a green molded body of said structural body by simultaneously extrusion molding a body for said at least one electrolyte body and a body for said at least two interconnectors, obtaining the structural body by firing said green molded body, and forming said anodes and cathodes on said respective walls defined by said part of at least one solid electrolyte body and said part of at least two interconnectors and constituting the respective first and second gas flow channels, respectively.
[0011] Another aspect of the process for producing the electrochemical cell according to the present invention is characterized by including the steps of forming a green molded body of said structural body by simultaneously extrusion molding a body for said at least one electrolyte body and a body for said at least two interconnectors, applying respective materials for said anodes and cathodes on said respective walls defined by said part of at least one solid electrolyte body and said part of at least two interconnectors and constituting the respective first and second gas flow channels, respectively, and firing the green molded body together with the materials applied.
[0012] The present invention is also related to an electrochemical device provided with the electrochemical cell or cells set forth above.
[0013] Having repeatedly made investigations to produce solid oxide fuel cells having a monolithic structure and a high electric power-generating efficiency, the present inventors have reached the technical idea that in order to produce such a solid oxide fuel cell, a honeycomb structural body is formed by integrating at least one dense solid electrolyte body and at least two dense interconnectors, and electrodes are formed on walls of channels extending through the honeycomb structural body.
[0014] According to the thus constructed electrochemical cell, the power-generating efficiency per unit volume is extremely high, and gas-tightness of the channels of the honeycomb structure are independently assured by the dense solid electrolyte body and the interconnectors, so that a power-generating device having a seal-less structure can be readily produced. In addition, the honeycomb-molded body to constitute at least one solid electrolyte body and at least two interconnectors can be produced by simultaneous extrusion molding. Further, since the solid electrolyte body and the interconnector are both required to be dense or gas-tight, it is easy to integrally sinter them without necessitating fine control of their porosities to fall in their respective specific ranges as in the case of the air electrode or fuel electrode.
[0015] Furthermore, since the interconnector and the solid electrolyte body are both made of their respective dense materials with high relative densities, the honeycomb structure body constituted by these dense materials has a high structural strength.
[0016] The air electrode and the fuel electrode may be formed by feeding respective materials for the air electrode and the fuel electrode into the channels of the honeycomb structural body formed above, attaching the materials upon the respective walls of the channels, and sintering the attached materials.
[0017] The present inventors applied the above structure to electrochemical cells other than the SOFC, for example, the steam electrolysis cell, and they confirmed that the efficiency per unit volume, e.g., electrolysis efficiency can be also largely enhanced, and the above mentioned function and effects can be obtained.
[0018] These and other objects, features and advantages of the present invention will be apparent from the following description of the invention when taken in conjunction with the attached drawings, with the understanding that any modifications, variations and changes may be easily made by the skilled person in the art to which the invention pertains.
BRIEF DESCRIPTION OF THE ATTACHED DRAWINGS
[0019] For a better understanding of the invention, reference is made to the attached drawings, wherein:
[0020] [0020]FIG. 1 is a cross-sectional view illustrating a part of an electrochemical cell 10 A according to a first embodiment of the present invention;
[0021] [0021]FIG. 2 is a cross-sectional view illustrating a part of an electrochemical cell 10 B according to a second embodiment of the present invention;
[0022] [0022]FIG. 3 is a cross-sectional view illustrating a part of an electrochemical cell 10 C according to a third embodiment of the present invention;
[0023] [0023]FIG. 4 is a cross-sectional view illustrating a part of an electrochemical cell 10 D according to a fourth embodiment of the present invention;
[0024] [0024]FIG. 5 is a perspective view for illustrating the outer configuration of one embodiment of the electrochemical cell according to the present invention;
[0025] [0025]FIG. 6 is a sectional view for diagrammatically illustrating a favorable embodiment of an electrochemical device to which an electrochemical cell according to the present invention is applied;
[0026] [0026]FIG. 7 is a sectional view for diagrammatically illustrating another favorable embodiment of an electrochemical device to which an electrochemical cell according to the present invention is applied;
[0027] [0027]FIG. 8 is a diagrammatic view for illustrating the extrusion molding process for producing a structural body for an electrochemical cell according to the present invention;
[0028] FIGS. 9 ( a ) through 9 ( h ) diagrammatically illustrate the embodiment in FIG. 8;
[0029] FIGS. 10 ( a ) through 10 ( d ) diagrammatically illustrate an embodiment similar to FIG. 9( a ) through FIG. 9( h ); and
[0030] FIGS. 11 diagrammatically illustrates a sectional view of the embodiment of FIGS. 10 ( a ) through FIG. 10( d ).
DETAILED DESCRIPTION OF THE INVENTION
[0031] The present invention will be explained in more detail with reference to more specific embodiments to which the present invention should not be limited.
[0032] The entire configuration of the honeycomb structural body is not particularly limited to any configuration. Further, the configuration of each channel in the honeycomb structural body is not limited to a particular one. However, from the standpoint of effectively utilizing the space, the cross-sectional shape of each channel is preferably of such a shape as an isosceles triangular shape, an equilateral triangular shape, a rectangular shape, a square shape or an equilateral hexagonal shape that the sections of the channels may fill a plane at an end side thereof. In addition, the channels may be designed such that the channels having different cross-sectional shapes such as an equilateral triangular shape and an equilateral hexagonal shape may be adjacent to each other.
[0033] The material of the interconnector is preferably a perovskite-type complex oxide containing lanthanum, more preferably lanthanum chromite, because lanthanum chromite has heat resistance, oxidation resistance and reduction resistance.
[0034] The material of the solid electrolyte body is preferably yttria-stabilized zirconia or yttria partially stabilized zirconia, but other materials may be also used. In the case of an NOx decomposition cell, cerium oxide is preferable, too.
[0035] A raw material for the anode and cathode is preferably a pervskite-type complex oxide containing lanthanum, more preferably lanthanum manganite or lanthanum cobaltite, most preferably lanthanum manganite. Lanthanum chromite and lanthanum manganite may be doped with strontium, calcium, chromium (for lanthanum manganite), cobalt, iron, nickel or aluminum. Further, the raw material may be palladium, platinum, ruthenium, a mixed powder of platinum and zirconia, a mixed powder of palladium and zirconia, a mixed powder of ruthenium and zirconia, a mixed powder of platinum and cerium oxide, a mixed powder of palladium and cerium oxide, or a mixed powder of ruthenium and cerium oxide.
[0036] The electrochemical cell according to the present invention may be used as an oxygen pump to supply oxygen.
[0037] Further, the electrochemical cell according to the present invention may be used as a high temperature steam electrolysis cell. This cell may be also used as a device for producing hydrogen, or may be used as a device for removing steam. In this case, the following reactions occur at respective electrodes.
Cathode: H 2 O+2 e − →H 2 +O 2−
Anode: O 2− →2 e − +½O 2
[0038] Furthermore, the electrochemical cell according to the present invention may be used as an NOx decomposing cell. This decomposing cell can be used as a purifier for exhaust gases from an automobile or an electric power-generating apparatus. Although the exhaust gases from the gasoline engines are now disposed of with three-way catalysts, such three-way catalysts will be less effective if the number of low mileage type engines such as lean burn engines and diesel engines, That is, since the content of oxygen in exhaust gases from those engines is large, such a three-ay catalyst cannot well work with respect to low mirage type engines.
[0039] If the electrochemical cell according to the present invention is used as an NOx decomposing cell, it can remove oxygen in exhaust gases through the solid electrolyte filmy body, and simultaneously decompose NOx into N 2 and O 2− and remove the oxygen produced by this decomposition. Besides the above process, water vapor in the exhaust gases is electrolyzed into hydrogen and oxygen, and this hydrogen reduces NOx into N 2 .
[0040] If the electrochemical cell is used as the NOx decomposing cell, the solid electrolyte filmy body is particularly preferably made of a cerium oxide based ceramic material, whereas the cathode material is preferably palladium or palladium-cerium oxide cermet.
[0041] FIGS. 1 to 4 are cross sectional views all illustrating parts of electrochemical cells as preferred embodiments according to the present invention as cut in a direction crossing channels. In the electrochemical cell 10 A of FIG. 1, first gas (e.g. oxidative gas) flow channels 6 A and second gas (e.g., fuel gas) flow channels 7 A all having an almost square cross section are formed in a structural body 1 A. A cathode 4 A is formed on a surrounding wall surface of each first gas flow channel 6 A, whereas an anode 5 A is formed on that of each second gas flow channel 7 A. In FIG. 1, both the flow channels 6 A and the flow channels 7 A are arranged vertically, while the gas flow channels 6 A are opposed to the respectively adjacent gas flow channels 7 A in a lateral direction via a solid electrolyte body 3 A.
[0042] The structural body 1 A also includes an interconnectors 2 A and the above solid electrolyte body 3 A, and each of the flow channels 6 A and 7 A is surrounded in a by a part of the interconnector 2 A and in the remaining half by a part of the solid electrolyte body 3 A. Consequently, each of the flow channels 6 A and 7 A is kept gas-tight in a cross-sectional direction thereof. In the electrochemical cell 10 A of FIG. 1, two pairs of the first gas flow channel 6 A rows and the second gas flow channels 7 A rows are arranged in the honeycomb structural body 1 A, while the first gas flow channels 6 A rows and the second gas flow channel 7 A rows are alternatively arranged in the lateral direction, and the interconnectors 2 A are arranged at opposite sides of the structural body 1 A and between the two pair of the first gas flow channel 6 A rows and the second gas flow channels 7 A rows.
[0043] In the electrochemical cell 10 B of FIG. 2, first gas flow channels 6 B and second gas flow channels 7 B all having an almost square cross-sectional shape are formed in a structural body 1 B. A cathode 4 B is formed on a surrounding wall surface of each of the first gas flow channel 6 B, and an anode 5 B is formed on that of each of the second gas flow channels 7 B.
[0044] The first gas flow channels 6 B and the second gas flow channels 7 B are arranged alternatively as viewed vertically in FIG. 2. As to the adjacent two rows, the first and second gas flow channels 6 B and 7 B are staggered in every other row vertically by a half of a side of each flow channel as viewed in the lateral direction of FIG. 2. That is, one first gas flow channel 6 B and one second gas flow channel 7 B in one row are half-by-half opposed to one flow channel 6 B in an adjacent row. Accordingly, each first flow channel 6 B is adjacent to four second flow channels 7 B, excluding those located at opposite sides of the structural body, whereas each second flow channel 7 B is adjacent to four first flow channels, excluding those located at opposite sides of the structural body. When the configuration in FIG. 2 is adopted, the area of the electrodes can be increased, and efficiency of the electrochemical cell, for example, power-generating efficiency, electrolyzing efficiency, or oxygen-feeding efficiency can be enhanced. Further, in order to obtain a given efficiency as referred to above, the entire electrochemical device can be made compact.
[0045] The structural body 1 B also includes dense interconnectors 2 B and dense solid electrolyte bodies 3 B, and each of the flow channels 6 B and 7 B is surrounded in a portion by a part of the interconnector 2 B and in the remaining portion by a part of the solid electrolyte body 3 B. Consequently, each of the flow channels 6 B and 7 B is kept gas-tight in a cross-sectional direction thereof. In the electrochemical cell 10 B of FIG. 2, the first gas flow channel 6 B zigzag lines and the second gas flow channels 7 B zigzag lines are alternatively arranged in the vertical direction, and the interconnectors 2 A are arranged at opposite sides of the structural body 1 A and between the two pair of the first gas flow channel 6 A lines and the second gas flow channels 7 A lines.
[0046] In the electrochemical cell of FIG. 3, a structural body 10 C includes dense interconnectors 2 C and dense solid electrolyte bodies 3 C vertically alternatively piled one upon another, and a number of channels each having a triangular cross section are formed among the interconnectors 2 C and the solid electrolyte bodies 3 C in the structural body 10 C. A pair of a line of first gas flow channels 6 C and a line of second gas flow channels 7 C are opposed to each other via each of the solid electrolyte bodies 3 C, and each of the first and second gas flow channels 6 C and 7 C is surrounded by a part of the interconnector 2 C and a part of the solid electrolyte body 3 C as shown in FIG. 3. As viewed vertically, the lines of the first gas flow channels 6 C and the lines of the second gas flow channels are alternatively arranged. A cathode 4 C is formed on a surrounding wall surface of each first gas flow channels 6 C, and an adnode 5 C formed on that of each of the second gas flow channels 7 C. Electric power is to be generated between a pair of the adjacent first and second gas flow channels 6 C and 7 C opposed to each other via the solid electrolyte body 3 C. Between the adjacent first gas flow channels 6 C in each line and between the adjacent second flow channels 7 C in each line are formed channels 8 each having an almost triangular cross section. Each of the first and second gas flow channels 6 C and 7 C is kept by the gas-tight interconnector 2 C and the gas-tight solid electrolyte body 3 C as viewed in a crossing direction thereof.
[0047] In the electrochemical cell 10 D of FIG. 4, a structural body ID includes gas-tight interconnectors 2 D and gas-tight solid electrolyte bodies 3 D laterally alternatively piled one upon another and forming zigzag lines of first gas flow channels 6 D and zigzag lines of second gas flow channels 7 D in which the former zigzag lines are opposed to corresponding latter zigzag lines via the respective solid electrolyte bodies 3 D as shown. The first and second gas flow channels 6 D and 7 D each have an almost equilateral hexagonal cross sectional shape, and are arranged in a honeycomb fashion. A cathode 4 D is formed on a surrounding wall surface of each first gas flow channel 6 D, and an anode 5 D formed on that of each second gas flow channel 7 D. Each of the first and second gas flow channels 6 D and 7 D is surrounded and kept gas-tight as viewed in a crossing direction thereof by a part of the gas-tight interconnector 2 D and a part of the gas-tight solid electrolyte body 3 D.
[0048] In the present invention, the channels in the honeycomb structural body can be easily shaped if the dimension of them in the cross section is not less than 1 mm. Further, the dimension of the channel in the cross section is preferably not more than 5 mm, because in this case, the electric resistance of the electrochemical cell unit decreases and the area of the electrodes per unit volume increases. From this point of view, the dimension of each channel is more preferably not more than 3 mm.
[0049] The entire shape-of the honeycomb structural body is not limited to any particular one. However, as viewed diagrammatically three-dimensionally in FIG. 5, a big capacity can be easily realized if the lateral and vertical dimensions “a” and “b” are not less than 5 cm, whereas excessive increase in the pressure required for the extrusion molding can be prevented if the dimensions “a” and “b” are not more than 30 cm. If the longitudinal dimension “c” is less than 10 cm, the ratio of end portions not contributing to power generation, electrolysis or oxygen feeding increases to deteriorate the efficiency of the electrochemical cell. Therefore, the longitudinal dimension “c” is preferably not less than 10 cm. If the longitudinal dimension “c” is not more than 100 cm, handling is easy at the time of extrusion molding.
[0050] The entire shape of an electrochemical device using the electrochemical cell according to the present invention is not limited to any particular one. In the electrochemical cell according to the present invention, the flow channels are each surrounded by a part of the gas-tight interconnectors and a part of the gas-tight solid electrolyte body (bodies). Therefore, the electrochemical device preferably has a seal-less structure utilizing that of the electrochemical cell. Preferred embodiments of such seal-less structures are diagrammatically shown in FIGS. 6 and 7, respectively, in which interconnectors and solid electrolyte bodies are omitted. In the electrochemical device of FIG. 6, a first gas and a second gas are flown in opposite directions, respectively. In the electrochemical device of FIG. 6, the electrochemical cell 10 A ( 10 B, 10 C, 10 D) is placed in a can 13 of the electrochemical device such that a gas chamber 15 and a gas chamber 16 are defined at opposite sides of the can 13 as shown. An exhaust opening 17 for the first gas and an exhaust opening 18 for the second gas are formed in the can 13 .
[0051] The first gas flow channels 6 A ( 6 B, 6 C, 6 D) of the electrochemical cell are extended in a right direction of FIG. 6, and their extensions 11 are opened to a first gas feed mechanism (not shown) outside the can 13 . On the other hand, the second gas flow channels 7 A ( 7 B, 7 C, 7 D) are extended in a left direction of FIG. 6, and their extensions 12 are opened to a second gas feed mechanism (not shown) outside the can 13 .
[0052] The first gas is fed to the extensions 11 of the first gas flow channels 6 A as shown by arrows A, flown inside the flow channels 6 A and further in the gas chamber 16 as shown by arrows B, and discharged through the exhaust opening 17 . On the other hand, the second gas is fed to the extensions 12 of the second gas flow channels 7 A as shown by arrows C, flown inside the flow channels 7 A and further in the gas chamber 15 as shown by arrow D, and discharged through the exhaust opening 18 .
[0053] In the electrochemical device of FIG. 7, the first gas and the second gas are flown in the same direction. The electrochemical cell 10 A ( 10 B, 10 C, 10 D) is placed in a can 13 such that a first gas chamber 30 and a combustion chamber 31 are defined at left and right sides of the electrochemical cell inside the can 13 , respectively. A first gas feed opening 19 , a first gas exhaust opening 20 , and a combustion gas exhaust opening 21 are formed in the can 13 as shown.
[0054] The second gas flow channels 7 A ( 7 B, 7 C, 7 D) of the electrochemical cell are extended in a left direction of FIG. 7, and their extensions 12 are opened to a second gas feed mechanism outside the can 13 . None of the first gas flow channels 16 are extended outwardly from the electrochemical cell.
[0055] The first gas is fed to the gas feed chamber 30 inside the can 13 through the gas feed opening 19 as shown in an arrow E. Alternatively, the first gas may be fed to the gas chamber 30 from a direction vertical to the drawing paper, for example, from a front side of the drawing paper. A part of the first gas is discharged outside through the exhaust opening 20 , whereas the remainder is flown through the flow channels 6 A of the electrochemical cell as shown by arrows G, and discharged to the combustion chamber 31 through downstream openings of the flow channels 6 A. On the other hand, the second gas is fed to the extensions 12 of the second gas flow channels 7 A as shown by arrows F, flown through the flow channels 7 A and discharged into the combustion chamber 31 . The combustion gas is flown as shown by arrows H, and discharged through the exhaust opening 21 .
[0056] When the electrochemical device is used as an electric power-generating device (SOFC), current collectors 14 are set at upper and lower end portions, respectively, in FIGS. 6 and 7. Electric power is taken outside through these current collectors 14 . A porous conductor having a buffering function, for example, a felt, is preferably set between each current collector and the SOFC, because stress is mitigated and contact electric resistance is reduced in this case. Nickel is preferred as a material for the felt and the current collectors.
[0057] A preferred embodiment of the process for producing the electrochemical cell according to the present invention will be explained with reference to a diagrammatic view of FIG. 8. In this embodiment, a body constituting a green molded body for the formation of the interconnectors and a body constituting a green molded body for the formation of the solid electrolyte bodies are continuously fed into a single die device so that the green molded bodies of the interconnectors and the solid electrolyte bodies may be extruded through the die device in a integrally joined fashion. Then, the extruded body is integrally sintered.
[0058] In a particularly preferred embodiment, the body constituting the green molded body for the formation of the interconnectors and the body constituting the green molded body of the solid electrolyte bodies are continuously fed into a single die device such that the body constituting the green molded body for the formation of the interconnectors is pushed toward the die device through a first extruding mechanism, whereas the body constituting the green molded body for the formation of the solid electrolyte bodies is pushed toward the die device through a second extruding mechanism. By so doing, the first extruding mechanism and the second extruding mechanism can be mechanically adjusted with respect to the extruding speed and the extruding pressure so that peeling or curving of the extruded body may be prevented.
[0059] The green molded body of each of the inter-connector a and the solid electrolyte body is preferably made by molding a mixture in which an organic binder and water are mixed into a main ingredient. As the organic binder, polyvinyl alcohol, methyl cellulose, ethyl cellulose or the like may be used. The addition amount of the organic binder is preferably 0.5 to 5 parts by weight, if the weight of the main ingredient is taken as 10 parts by weight.
[0060] In the embodiment of FIG. 8, a green shaped body 25 for the formation of the interconnectors and a green shaped body 26 for the formation of the solid electrolyte bodies are used. Each of the green molded bodies has, for example, a cylindrical shape. The die device 27 includes molding barrels 24 A and 24 B, a first die portion 27 a and a second die portion 27 b communicating with the molding barrels 24 A and 24 B, respectively, plungers 23 A and 23 B slidably arranged inside the molding barrels 24 A and 24 B, respectively, and not shown dies arranged in the die portions 27 a and 27 b, respectively. The green molded body 25 for the formation of the interconnectors is placed in the molding barrel 24 A, and the green molded body 26 for the formation of the solid electrolyte bodies placed in the molding barrel 24 B.
[0061] The body 25 is pushed into the die portion 27 a by moving a shaft of the plunger 23 A toward the die portion 27 a, whereas the body 26 is pushed into the die portion 27 b by moving a shaft of the plunger 23 B toward the die portion 27 b. The bodies are molded in the form of the interconnectors and the solid electrolyte bodies having the cross-sectional configuration as shown in FIG. 1, 2, 3 or 4 . A reference numeral 28 denotes a honeycomb structural body-extruding die. The thus extruded body may be fired at a firing temperature of 1400° C. to 1700° C. A reference numeral 28 is a honeycomb structural body-extruding die.
[0062] FIGS. 9 ( a ) to 9 ( f ) diagrammatically illustrating the embodiment shown in FIG. 8. The molding from FIG. 9( a ) to FIG. 9( c ) is effected by the die device 27 , whereas the molding from FIG. 9( c ) to FIG. 9( e ) is effected by the honeycomb structural body-extruding die 28 . FIGS. 9 ( a ) to 9 ( e ) are sectional views taken along lines IXa, IXb, IXc, IXd and IXe, respectively. Each of the green shaped bodies 25 and 26 (FIG. 9( a )) is extruded into plural planar bodies 29 , 30 (FIG. 9( b )). The planar bodies 29 are inserted between the planar bodies 30 at an inlet of the honeycomb-shaped body extruding die 28 as shown in FIG. 9( c ). Then, each of the planar bodies 29 and 30 arrayed as in FIG. 9( c ) is divided into a row of rod-shaped bodies 29 A and 30 A in a matrix as shown in FIG. 9( d ), and these rows of the rod-shaped bodies 29 A and 30 A are converted into a honeycomb structural body 31 shown in FIG. 9( e ). FIG. 9( f ) is an enlarged view of FIG. 9( c ), FIG. 9( g ) is an enlarged view of FIG. 10( d ), and FIG. 9( h ) an enlarged view of FIG. 9( e ) through a die not shown.
[0063] FIGS. 10 ( a ) to 10 ( f ) diagrammatically illustrate another embodiment similar to that shown in FIG. 8 and FIGS. 9 ( a ) to 9 ( h ). FIGS. 10 ( a ) to 10 ( d ) are sectional views taken along lines IXa, IXb, IXc and IXd of FIG. 11, respectively. The embodiment in FIGS. 10 ( a ) to 10 ( d ) differs from that in FIGS. 8 and 9( a ) to 9 ( h ) in that the steps in FIGS. 9 ( b ) and 9 ( c ) are modified. That is, each of the green shaped bodies 25 and 26 (FIG. 9( a )) is extruded into plural rod-shaped bodies 31 are inserted between the rod-shaped bodies 32 at an inlet of the honeycomb-shaped body extruding die 28 as shown in FIG. 10( c ). The thus arrayed rod-shaped bodies 31 and 32 are molded into a honeycomb structural body shown in FIG. 10( d ). In the embodiment of FIGS. 10 ( a ) to 10 ( f ) and FIG. 11, the die device 27 may be integrally formed with the honeycomb structural body-extruding die 28 .
[0064] Then, an anode material or a cathode material is applied to a surrounding wall surface of each of the channels through the thus sintered body. Although this applying method is not limited to any particular one, according to a preferred embodiment, slurries of the anode material and the cathode material are poured into the respectively intended channels, and discharged therethrough, followed by drying. Thereby, their powdery materials are attached to the respectively intended channels. Then, the resulting honeycomb structural body in entirely fired at 1100° C. to 1500° C. to form anodes and cathodes.
[0065] The present inventors actually produced steam electrolysis cells as shown in FIGS. 1 to 4 . Their honeycomb structural bodies and the interconnectors were prepared as mentioned above. The steam electrolysis cells were produced by applying a platinum paste to this honeycomb structural body.
[0066] More specifically, a slurry having fluidity was obtained by adding polyethylene glycol into a commercially available platinum paste. This slurry was poured into every channel, thereby attaching the slurry onto the wall surfaces thereof. In this case, since the anode and the cathode may be made of the same material, it is unnecessary to pour different materials for the anodes and the cathodes into respective channels as in the case of SOFC.
[0067] Since any platinum slurry attached to a place other than the surrounding wall surfaces of the channels may cause short circuit, such a slurry must be swept off. The thus obtained honeycomb structural bodies were fixed, for example, at 1000° C. for 1 hour, thereby forming platinum anodes and cathodes.
[0068] With respect to the thus produced steam electrolysis cells, argon and argon containing steam were flown on the anode side and the cathode side, respectively in the state that the cells were heated to 1000° C., while current was flown between the anodes and the cathodes. Thereby, hydrogen could be generated.
[0069] Anodes and cathodes may be formed through immersing the structural body into a slurry of a metal. For example, the structural bodies 1 A, 1 B, 1 C and 1 D as explained above were prepared. A fluidic slurry was obtained by adding polyethylene glycol into a commercially available platinum paste. Each of the structural bodies was immersed into this slurry.
[0070] At that time, the platinum slurry was attached to not only surrounding wall surfaces of the channels but also end faces of the structural body. If the structural bodies with the slurry thus attached are fixed, the anodes and the cathodes may be shorted. For this reason, portions near the respective end faces of the structural body were removed by cutting. By so doing, unnecessary platinum slurry can be easily removed from the structural body without sweeping away it. The thus obtained honeycomb bodies were fired at 1000° C., thereby forming the anodes and the cathodes made of platinum.
[0071] With respect to the thus produced steam electrolysis cells, argon and argon containing steam were flown on the anode side and the cathode side, respectively, in the state that the cells were heated to 1000° C., while current was flown between the anodes and the cathodes. Thereby, hydrogen could be generated.
[0072] As having been explained above, according to the present invention, the electrochemical cells which each have a large area of the electrodes per unit voltage and high power-generating efficiency, high electrolysis efficiency, high oxygen generating efficiency or the like can be provided. Further, the electrochemical cells are structurally relatively simple, and need no special sealing mechanism and can be produced by simultaneous sintering due to their structure. | An electrochemical cell including at least one dense solid electrolyte body, at least two dense interconnectors for collecting current flowing the cell, cathodes and anodes, wherein the at least one dense solid electrolyte body and at least two dense interconnectors constitute a structural body, a plurality of first gas flow channels and a plurality of second gas flow channels both extend in a given direction, and are each defined and surrounded by a part of the at least one solid electrolyte body and a part of the at least two interconnectors, the anodes are formed on respective walls defined by a part of at least one solid electrolyte body and a part of at least two interconnectors and constituting the respective first gas flow channels, the cathodes are formed on respective walls defined by a part of at least one solid electrolyte body and a part of at least two interconnectors and constituting the respective second gas flow channels, every anode is opposed to an adjacent cathode or adjacent cathodes via a solid electrolyte body, and every cathode is opposed to an adjacent anode or adjacent anodes via a solid electrolyte body. | 8 |
PRIORITY
This application claims the benefit under 35 U.S.C. Section 119(e) of prior U.S. Provisional Patent Application No. 60/218,023, filed Jul. 12, 2000, the disclosure of which is incorporated herein by this reference.
TECHNICAL FIELD
This invention relates to ridge type roof vents, and more particularly to a novel ridge type roof vent designed for placement on the ridge of a tile roof, including heavy or light tiles, whether slate, clay, or of similar looking material, to allow ventilation of the space below the tile roof.
BACKGROUND
Although a variety of designs exist for roof vents, historically, “ridge type” roof vents have not been widely used for tile roofs. This is rather easy to understand, since although such a design would reduce the number of roof penetrations necessary to achieve adequate ventilation, the cumbersome and weighty nature of roof tiles has not been generally conducive to incorporation of a ridge type vent system in the roof design. And, although a few designs have been proposed or actually used, in so far as is known to us, prior art ridge vent designs have not adequately addressed the problem of preventing ingress of wind blown water, as might occur during a thunderstorm or hurricane, for example. Thus, it would be desirable to provide a new ridge vent design that is resistant to entry of wind blown water, especially if such a design were provided in a structurally strong, low profile, artistically pleasing ridge top roof vent system suitable for tile roofs or the like.
SUMMARY
We have invented a novel ridge type roof vent for incorporation in tile or tile type roof applications. The ridge vent design may be easily adapted for various tile roofs, ranking from flat tile to high profile (undulating design) tile roof structures. The ridge vent design is simple and strong enough to support the necessary tile and weather loads (wind, water, snow, ice, etc.), even though relatively lightweight. The roof vent designs are relatively inexpensive and easy to manufacture, and otherwise superior to heretofore known roof vent designs for tile roofs. Importantly, my ridge type roof vent for tile roofs provides exemplary protection against entry of wind driven water, as well as unwanted debris, insects, or vermin, while allowing a preselected ventilation volume per running foot of installed roof vent.
The new ridge vent design utilizes (a) a pair of opposing sub-flashing portions, each having therein a longitudinally running, preferably substantially vertically oriented vent apertures that allow passage of air therethrough, and (b) a top cap portion, having therein longitudinally running vent apertures spaced a preselected distance from the center longitudinal axis thereof.
Each of the sub-flashing portions spans a gap in the roofing deck adjacent the longitudinally running ridge support. Preferably, a top batten is longitudinally attached above the sub-flashing to affix the sub-flashing to the roof deck. Tiles are mounted above the top batten, in conventional fashion, sloping down the roof.
An elongated top cap portion is then affixed above the ridge beam. The top cap portion supports the ridge cap tiles. Also, when a low profile or S-type tile design is utilized, an appropriate weather block is affixed between the top of the undulating tile and the lower side of the top cap portion. In a flat tile design, the underside of the top cap is directly sealed to the top of the adjacent flat tiles.
OBJECTS, ADVANTAGES, AND FEATURES OF THE INVENTION
An important and primary object of the present invention resides in the provision of a novel, ridge type vent that is easy to manufacture and install on tile type roofs. Other important objects, advantages, and novel features include a ridge vent which:
can be manufactured in a simple, straightforward manner;
in conjunction with the preceding object, have the advantage that they can be configured by installation personnel to quickly and efficiently utilize the method disclosed herein to provide a ridge vent in a tile roof;
provides a ridge type vent that is fully protective from windblown debris, large insects, and vermin; and
that are structurally designed to provide sturdy support for heavy tiles;
that provide appropriate variations in the design for use in either flat tile roofs or in undulating type tile roofs.
Other aspects of various embodiments will become apparent to those skilled in the art from the foregoing and from the detailed description that follows and the appended claims, evaluated in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
In order to enable the reader to attain a more complete appreciation of the invention, and of the novel features and the advantages thereof, attention is directed to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a perspective view of an exemplary ridge vent system installed in a flat type tile roof, showing the use of the sub-flashing to span a gap in the roof deck, and a ventilated top cap flashing that supports a tile cap.
FIG. 2 is an exploded perspective view of the ridge vent system shown in FIG. 1, now showing the various parts and pieces that make up the system, including (a) a roof decking having therein voids defined by sidewall portions to allow upward flow of ventilation air through the roof deck, (b) first and second sub-flashing portions, one for each side of the roof, (c) first and second battens for securing the first and second sub-flashing portions, respectively, (d) a ridge beam that extends longitudinally across the ridge of a roof, (e) a top cap flashing portion that is mounted above the ridge beam, and over which a top cap or ridge-cap row of tiles is mounted.
FIG. 3 is a perspective view of a portion of the vent apertures in flashing, provided to more clearly show construction details of vent apertures.
FIG. 4 is an exploded perspective of the roof first shown in FIG. 1, now showing construction details, including the installation of first and second sub flashing portions, and a top flashing portion which is covered by a top cap row of roofing tiles.
FIG. 5 is a cross-sectional view of the roof vent system first illustrated in FIG. 1 above taken across line 5 — 5 of FIG. 1, now showing the ridge cap tiles at a longitudinal location where the lateral edges extend down to the flashing.
FIG. 6 shows a side view of a finished roof with ridge vent, installed utilizing the ridge vent system disclosed herein, and, in particular, illustrates the generally triangular space below the outer edge of slanted ridge-cap tiles which allows ventilation air to escape outward.
FIG. 7 is an exploded perspective view of the ridge vent system installed in a low profile S-type roofing, further illustrating the version which is useful in “S-tile” or “undulating” type tile roof construction, here showing the use of sub-flashing on both sides of the ridge beam, and a top beam mounted above the ridge beam to support ridge-cap tiles.
FIG. 8 is a vertical cross-section of a ridge top roof vent installed on a roof having low profile type roofing types as just illustrated in FIG. 7 .
FIG. 9 is an exploded perspective of view of a ridge vent system adapted for use in S-tile roofing.
FIG. 10 is a vertical cross-section of a ridge top roof vent installed on a roof having an S-tile roof as just illustrated I FIG. 9 above.
FIG. 11 is a top plan view of a section of subflashing, shown flat during manufacture of the subflashing, before the subflashing is formed and shaped for installation.
FIG. 12 is a close up view of a portion of FIG. 11, taken to more clearly show construction details of vent apertures.
FIG. 13 is yet a closer view of a portion of the sub-flashing shown in FIG. 12, provided to more clearly show construction details of one exemplary type of vent apertures.
FIG. 14 is a top plan view of a section of top cap flashing for a flat type tile roof, shown flat during manufacture of the top cap flashing, before the top cap flashing is shaped for installation.
FIG. 15 is a close-up view of a portion of FIG. 14, taken to more clearly show construction details of the top cap flashing.
FIG. 16 is yet a closer view of a portion of the top cap shown in FIG. 7, provided to more clearly show construction details of the top cap flashing.
FIG. 17 is a top plan view of a section of sub-flashing, shown flat during manufacture of the sub-flashing for an undulating tile roof, before the subflashing is formed and shaped for installation.
FIG. 18 is a close up view of a portion of FIG. 17, taken to more clearly show construction details of vent apertures.
FIG. 19 is yet a closer view of a portion of the sub-flashing shown in FIG. 18, provided to more clearly show construction details of one exemplary type of vent apertures.
FIG. 20 is a top plan view of a section of top cap flashing for use on an undulating type tile roof, shown flat during manufacture of the top cap flashing, before the top cap flashing is shaped for installation.
FIG. 21 is a close-up view of a portion of FIG. 20, taken to more clearly show construction details of the top cap flashing.
FIG. 22 is yet a closer view of a portion of the top cap shown in FIG. 21, provided to more clearly show construction details of the top cap flashing.
The foregoing figures, being merely exemplary, contain various elements that may be present or omitted from actual implementations depending upon the circumstances. An attempt has been made to draw the figures in a way that illustrates at least those elements that are significant for an understanding of the various embodiments and aspects of the invention. However, various other elements of the ridge vent system and accompanying roofing system are also shown and briefly described to enable the reader to understand how various optional features may be utilized in order to provide an efficient, ridge vent.
DETAILED DESCRIPTION
Attention is directed to FIGS. 1 and 5, where respectively a perspective view and a cross-sectional view are shown of a ridge vent system installed in a flat tile type roof system 28 . Roof rafters 30 and 32 have ridge ends 34 and 36 ending at a center beam 38 . Above the center beam 38 is mounted a longitudinally running ridge beam 40 which extends across the roof system. First 42 and second 44 roof decking is affixed above the upper sides 46 and 48 of the respective rafters 30 and 32 . Either through roof deck 42 , or preferably above the upper end 49 of first roof deck 42 and up to the first side 50 of ridge beam 40 , a first air gap G 1 is provided. First air gap G 1 is provided to allow air to flow upward or downward in the direction of reference arrows 60 and 62 , respectively. Between the upper end 64 of second roof deck 44 and the second side 66 of ridge beam 40 , a second air gap G 2 is provided to allow air to flow upward or downward in the direction of reference arrows 70 and 72 , respectively.
A first longitudinally extending sub-flashing 80 having a plurality of ventilation apertures A 1 therein is provided to span gap G 1 . A second longitudinally extending sub-flashing 84 having a plurality of apertures A 2 therein is provided to span gap G 2 . A first top batten 90 is provided to affix first subflashing 80 to the first roof deck 42 . A second top batten 92 is provided to affix the second sub-flashing 82 to the second roof deck 44 . Each of first and second top battens 90 and 92 may be secured to first and second roof decks 42 and 44 , respectively, by nails or other suitable fasteners N as indicated in FIG. 2 . First water proof roof felting 96 is provided above first roof deck 42 , below flat tiles generally noted with reference numeral 100 , but in this case, more specifically shown as 100 1 and 100 2 . A second water proof roof felting 102 is provided above second roof deck 44 , below flat tiles 100 3 and 100 4 .
A top cap flashing 120 is mounted over the top 122 of ridge beam 40 . The top cap flashing 120 is longitudinally extending to support a plurality of ridge cap tiles 130 , or as more specifically identified, cap tiles in a series from 130 1 , 130 2 , to 130 Z , where Z is a positive integer. In the embodiment shown in this FIG. 1, the top cap flashing 120 has a downwardly directed U-shaped center section 132 and a pair of opposing first and second outward wing portions 134 and 136 , each of which may be bounded at the outer tip T thereof by a an upwardly directed flange portion F. Preferably, a sealant layer S is provided between the lower side 138 and 140 of wing portions 134 and 136 , respectively, and the adjacent tiles 100 1 and 100 3 , respectively.
In FIG. 1, a view of an exemplary ridge vent flashing is in place on a roof, showing the position of (a) the sub-flashing 80 and 84 , and (b) the top cap flashing 120 , and including flat tile roofing 100 and the longitudinally oriented ridge cap tiles 130 . Also, the various figures provide general views of certain embodiments, without limitation as to details of exact size, for convenience of stocking distributors and for contractor installation, one set of exemplary dimensions for my ridge vent system as applied to flat type tile roofs can be provided, as detailed in FIGS. 11, 12 , and 13 . For example, sub-flashing 80 and 84 can be provided in convenient widths, often of about 6.5 inch width, when measured flat, before forming into an “S” shape for installation, and in standard lengths of 48 inches. Also, I have found it convenient to provide apertures A 1 and A 2 spaced at about 0.25 inch centers vertically (Y dimension) and at about 0.20 inch centers longitudinally (X dimension) as also noted in FIG. 3 . Also, for strength of sub-flashing 80 and 84 , I have found it useful to provide apertures A 1 and A 2 in rectangular strips of about 10.8 inches long, and slightly over one inch wide, with about 1.2 inch strips of solid metal provided longitudinally between rectangular strips of apertures, and with the first aperture spaced about 1.1 inches from the edge E (see FIG. 12 for this detail). However, these are merely exemplary embodiments and the actual dimensions and sizes may be varied to suit individual needs, without varying from the more general teachings hereof.
Turning now to the top cap 120 , FIG. 14 shows a top plan view of a 48 inch long section of top cap flashing 120 for a flat type tile roof, shown flat during manufacture of the top cap flashing in a 14.25 inch width, before the top cap flashing 120 is shaped for installation in the roofing system. Apertures A 3 and A 4 are provided in generally rectangular strips of about 10.8 inches long, longitudinally spaced apart by solid strengthening portions 150 of about 1.2 inches long, longitudinally (see FIGS. 15 and 16 for this detail). Also, it has been found it convenient to provide apertures A 3 and A 4 spaced at about 0.25 inch centers vertically and at about 0.20 inch centers longitudinally (see FIG. 15 for this detail). Drain holes 152 are provided, about 0.1875 inches in diameter and spaced inward from tip T about 0.75 inches and spaced longitudinally apart about 2 inches or so (see FIG. 14 for these details).
Returning now to FIGS. 2 and 4, a series of steps in an exemplary method for installing a ridge vent system for flat type tile roofs is shown. A first step in a method of installation of a ridge vent in a flat tile roof system is shown in FIG. 2, wherein the roof decks 42 and 44 are is cut back to provide an air flow space, optionally, but not necessarily U-shaped, defined by edge wall portions 154 , and providing space between roof decks 42 or 44 and the center beam 38 . Next, a second step involves covering the roof decking 44 with felt 102 prior to tile installation. Next, a third step in a method of installation of the ridge vent in a flat tile roof system, involves installing (a) the sub-flashing 84 is installed, and (b) securing the sub-flashing by use of a top batten 92 which is nailed over the subflashing 84 , to hold the sub-flashing 84 in place over deck 44 . It is easily understood that the first sub-flashing 80 and first batten 90 are similarly installed, either before or after installation of the second sub-flashing and the second batten. Now, a fourth step in a method of installation of a ridge vent in a flat tile roof, includes centering the top cap 120 and fastening it to the ridge beam 40 . the top cap flashing 120 is preferably fastened to the ridge beam 40 using a #6 or better galvanized roofing nails N spaced 12 inch on center. Further, as best seen in FIG. 5, a bead of caulking S is used to seal between the bottom 156 of first wing 134 and tile 100 1 , and between the bottom 158 of second wing 136 and tile 100 3 .
In FIG. 4, a fifth step in a method of installation of a ridge vent in a flat type tile roof is shown, wherein the “ridge cap” tiles 130 are centered over the top cap flashing 120 , and sealed together per the tile manufacturer's specifications.
To understand the functionality, it should be recognized that air escapes outward (or inward, as the case may be) between the ridge tiles 130 and the top cap flashing 120 . More specifically, between adjacent ridge tiles 130 , a slight triangular shaped gap is created between bottom edges 160 and 162 . and the upper surface 164 of the top cap flashing 120 therebelow. In FIGS. 1 and 6, the gap is indicated by the area between bottom edges 160 and 162 and the broken line of position 170 therebelow. In other words, from the line of position indicated in broken lines, to the bottom edges 160 and 164 of the ridge tiles 130 directly thereabove, a gap exists through which an adequate amount of ventilation air can escape, as indicated by arrows V in FIG. 1 and FIG. 6 . Of course, as shown in FIG. 1, a first laid ridge tile 130 1 , may be provided flat against top cap flashing 120 , or, alternately, a suitable height block may be provided to allow ventilation to occur.
Attention is now directed to FIGS. 7 through 10, where the installation of an exemplary ridge vent in two types of S-tile or “undulating” tile roof is shown. First, in FIGS. 7 and 8, the installation of tile in a low profile type undulating roof is shown. Roof rafters 230 and 232 have ridge ends 234 and 236 ending at a center beam 238 . Above the center beam 238 is mounted a longitudinally running ridge beam 240 which extends across the roof system. First 242 and second 244 roof decking is affixed above the upper sides 246 and 248 of the respective rafters 230 and 232 . Between the upper end 250 of first roof deck 242 and first side 254 of the ridge beam 240 , an air gap G 3 is provided to allow air to flow upward or downward in the direction of reference arrow 260 . Between the upper end 264 of second roof deck 244 and the second side 266 of ridge beam 240 , an air gap G 4 is provided to allow air to flow upward or downward in the direction of reference arrow 270 .
A first longitudinally extending sub-flashing 280 , preferably but not necessarily in a general S-shape, and having a plurality of ventilation apertures A 5 therein is provided to span gap G 3 . A second longitudinally extending subflashing 280 , preferably but not necessarily in a general S-shape, and having a plurality of apertures A 6 therein is provided to span gap G 4 . A first top batten 290 is provided to affix first sub-flashing 280 to the first roof deck 242 . A second top batten 292 is provided to affix the second sub-flashing 282 to the second roof deck 244 . Each of first and second top battens 290 and 292 may be secured to first and second roof decks 242 and 244 , respectively, by nails or other suitable fasteners N (not shown). Also, a water proof roof felting 296 is provided above first roof deck 242 . A similar waterproof roof felting 202 is provided above decking 244 . Low profile type roof tiles 200 are shown affixed on the roof.
A top cap flashing 220 is mounted over the top 222 of ridge beam 230 . The top cap flashing 220 is longitudinally extending to support a plurality of ridge cap tiles 290 , as clearly shown in FIGS. 7 and 8. In the embodiment shown in FIGS. 7 and 8, the top cap flashing 220 has a relatively flat, outwardly spreading center section 232 with a slight downward U-shape, and a pair of opposing first and second outward wing portions 234 and 236 , each of which may be bounded at the outer tip T thereof by a an upwardly directed flange portion F. Placement of overlapping ridge cap tiles 290 , and resultant generally triangular air gap below the outer edges 292 and 294 thereof, is generally as just described above with respect to the flat tile type of ridge cap.
In FIGS. 17 through 22, I have provided a set of exemplary detailed dimensions for one embodiment of a ridge vent system as applied to undulating tile type roofs. For example, sub-flashing 280 and 284 can be provided in about a 8.5 inch width, when measured flat, before forming into an “S” shape for installation, and in standard lengths of 48 inches (see FIG. 17 for this detail). Also, it is convenient to provide apertures A 6 and A 7 spaced at about 0.25 inch centers laterally and at about 0.20 inch centers longitudinally (see FIG. 19 for this detail). Also, for strength of sub-flashing 280 and 284 , it is useful, but not necessary, to provide apertures A 6 and A 7 in rectangular strips of about 10.8 inches long, and slightly over one inch wide, with about 1.2 inch strips of solid metal provided longitudinally between rectangular strips of apertures, and with the first aperture spaced about 1.1 inches from the edge E (see FIG. 18 for this detail).
Attention is now directed to FIG. 20, where the top cap 220 is shown. In this figure, a top plan view of a 48 inch long section of top cap flashing 220 for an S-tile type roof is provided, shown flat during manufacture of the top cap flashing in a 15.5 inch width, before the top cap flashing 220 is shaped into generally recognized W-shape for installation in a roofing system. Apertures A 7 and A 8 are provided in generally rectangular strips of about 10.8 inches long, longitudinally spaced apart by solid strengthening portions 250 of about 1.2 inches long (see FIGS. 21 and 22 for this detail). Also, I have found it convenient to provide apertures A 7 and A 8 spaced at about 0.25 inch centers laterally and at about 0.20 inch centers longitudinally (see FIG. 22 for this detail). Drain holes 252 are provided, about 0.1875 inches in diameter and spaced inward from tip T about 0.75 inches and spaced longitudinally apart about 2 inches or so (see FIG. 20 for these details).
A method of installing a ridge vent system for an S-tile (undulating) type tile roof system can be easily understood in view of the previously provided method for installing an exemplary roof vent system for a flat tile roof. A first step in a method of installation of an exemplary ridge vent in an S-tile roof system is shown, wherein the roof deck 244 is cut back from the center beam 238 and the ridge beam 240 in the roof, to provide an aperture defined by edge wall 299 . A second step in a method of installation of a ridge vent in an S-type tile roof system is to cover roof decking 244 with a conventional roofing felt 296 prior to installation of the tiles 200 . Next, a third step in a method of installation of a ridge vent in an S-tile roof system, involves (a) installing the sub-flashing 284 , and (b) installing a top batten 292 by nailing it over the sub-flashing 284 , to hold the sub-flashing 284 in place. Although the second sub-flashing and second batten installation procedure is discussed, it is easily understood that the first sub-flashing 280 and first batten 290 are similarly installed, either before or after installation of the second sub-flashing and the second batten. Now, a fourth step in a method of installation of a ridge vent in an S-tile roof, involves centering the top cap 220 and fastening it to the ridge beam 240 ; this is preferably accomplished using a #6 or better galvanized roofing nails N spaced 12 inch on center. Finally, a fifth step in an exemplary method of installation of a ridge vent in a tile roof system is to install the “ridge cap” tiles 290 , centered over the top cap 220 flashing, and sealing the ridge cap tiles per the tile manufacturer's specifications.
In FIGS. 9 and 10, yet another embodiment of a ridge vent for tile roofs is illustrated, wherein the top cap flashing 320 includes a slight downwardly U-shaped center section 322 . This top cap flashing section 320 is provided with apertures A 9 and A 10 each of which are defined by edge portions, preferably as illustrated in FIG. 3 with respect to apertures A 1 . Wing portions 334 and 336 are similar to portion 234 and 236 previously described. Otherwise, the parts are structurally and functionally the same as previously identified with respect to the discussion of FIGS. 7 and 8, and thus the parts are identified accordingly.
In the various sub-flashing and top cap flashing designs, apertures are provided for passage of air therethrough. It is also a desirable function of such apertures, whether A 1 , A 2 , A 3 , A 4 , A 4 , A 6 , A 7 , or A 8 to resist the passage of water therethrough. Consequently, note that an exemplary design applicable to any of the just mentioned apertures is set forth in FIG. 3 . Rather than the provision of a mere punched hole, in one embodiment it has been found desirable to provide the apertures in an outwardly directed “volcano” or “cheese grater” shape, wherein water that is wind blown from the outside does not funnel toward passage through the aperture. In contrast, water would have to hit the aperture opening itself, since sloping sidewalls 400 provide for a narrow throat 402 that ends at the interior periphery (circumference 404 as shown in FIG. 3) of the preferably annular face portion 406 . Thus, the “volcano” shaped vent apertures protrude, in the outward direction (against ingress of water) for a preselected height H, as shown in FIG. 3, which height H may vary depending upon the desired ventilation and water intrusion results to be achieved.
Although the various embodiments of an exemplary ridge vent design have been described herein in detail, it is important to note that such ridge vents have been tested according to the Metro Dade County Florida Number PA100(A)-95 Test Procedure for Wind and Wind Driven Rain Resistance, and the designs described herein passed such testing. In particular, the test results indicated that there was no lift of movement of any tile or ridge vent components during the test. Also, the amount of water which entered through the vent opening during the test was well below the regulatory limits. In one test, 830,720 ml of water was delivered to an 8 foot by 6 foot test roofing area during 50 minutes of testing. In that test, the maximum amount of water infiltration allowable, per the test procedure, was 0.05% of the water delivered to the test area. Given the delivered quantity of water, a maximum of 415 ml was the regulatory limit established for the test. However, the novel ridge vent system disclosed and claimed herein was able to limit water passage to a total of only 194 ml; in other words only 0.023% of the water which was applied to the roof deck tested actually passed through the ridge vent system.
In another test, where the ridge vent system was tested on a High Profile Spanish “S” Tile type roof, a total of 830,720 ml of water was delivered to an 8 foot by 6 foot test area during 50 minutes of testing. Again, the maximum amount of water infiltration per the test procedure was 0.05% of the water delivered to the test area, or, given the delivered quantity of water, a maximum of 415 ml of leakage was permissible during the test. However, the test, as conducted by outside engineering experts, determined that only 1 ml of water (0.0001%) of the water applied to the test deck entered the vent-opening throughout the test. It is interesting that a portion of the two tests involved simulated rainfall of 8.8 inches per hour during wind velocity tests of 35 mph, 70 mph, 90 mph, and 110 mph. Moreover, during the tests, there was no lift or movement of tile or vent components. These results were totally unexpected by the test facility. Thus, the performance of the ridge vent design set forth herein represents an important advance in the state of the art of ridge vents for tile roofs.
It is to be appreciated that the novel ridge vent system provided by way of the present invention is a significant improvement in the state of the art of ridge type roof vents for tile roofs. The vent is lightweight, being normally manufactured of lightweight metal or other structurally strong material, and is capable of being easily packaged and shipped.
Importantly, the ridge vent for tile roofs allows installation of a ridge vent system even in locales where it has heretofore been impossible to do so and comply with building code requirements, since the ridge vent system is fully capable of passing the most stringent regulatory tests for wind and wind driven rain resistance.
Although only a few exemplary embodiments and aspects of this invention have been described in detail, various details are sufficiently set forth in the drawing and in the specification provided herein to enable one of ordinary skill in the art to make and use such exemplary embodiments and aspects, which need not be further described by additional writing in this detailed description. Importantly, the designs described and claimed herein may be modified from those embodiments provided without materially departing from the novel teachings and advantages provided by this invention, and may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Therefore, the embodiments presented herein are to be considered in all respects as illustrative and not restrictive. As such, this disclosure is intended to cover the structures described herein and not only structural equivalents thereof, but also equivalent structures. Numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein. Thus having described some embodiments of the invention, though not exhaustive of all possible equivalents, what is desired to be secured by letters patent is claimed below. Therefore, the scope of the invention, as set forth in the appended claims, and as indicated by the drawing and by the foregoing description, is intended to include variations from the embodiments provided which are nevertheless described by the broad interpretation and range properly afforded to the plain meaning of the claims set forth below. | A ridge vent for tile roofs. The vent includes first and second sub-flashing portions for spanning air gaps provided between the upper reaches of a roof deck and below a centrally located ridge beam. A plurality of ventilation apertures are provided in each of the sub-flashing portions. A top cap flashing is provided for attachment above the ridge beam. Included in the top cap flashing are a plurality of ventilation apertures defined by edge wall portions. A tile roof is provided, of the flat, low profile undulating, or of the S-tile (undulating) type. Tiles are provided in rows up to the edge of the sub-flashing. The gap between the top of the tiles and the bottom of the top cap flashing is preferably provided with a weathertight seal. Ridge cap tiles are provided in conventional stacked fashion running along above the top cap flashing. As a result, a generally triangular ventilation gap is provided along and below the lateral edges of the ridge cap tile, which allows air to enter and leave the attic space below the tile roof, while providing high resistance to wind blown water. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority of the U.S. patent application Ser. No. 60/822,806, filed Aug. 18, 2006 and U.S. patent application Ser. No. 60/822,659, filed Aug. 17, 2006.
TECHNICAL FIELD OF THE INVENTION
The present invention relates to switching power supplies, and more particularly relates to multiple phase switching power supplies that use pulse width modulation techniques.
BACKGROUND OF THE INVENTION
The unwaning desire to decrease the cost and size of switching power converters has put a focus on the output filter. However, smaller inductance and capacitance puts a more stringent requirement on the DC/DC controller, which will need to provide faster transient response through a higher bandwidth control loop. Double-edge pulse-width modulation (PWM) has shown some benefits over single-edge PWM in achieving higher bandwidth DC/DC controllers. This is discussed, for example, in “Control-loop bandwidth limitations for multiphase interleaving buck converters,” by Yang Qiu, Kaiwei Yao, Yu Meng, Ming Xu, F. C. Lee and Mao Ye, Nineteenth Annual IEEE Applied Power Electronics Conference and Exposition, 2004 . APEC ' 04, vol. 2, pp. 1322-1328. FIG. 1 shows an exemplary prior art double-edge PWM generated from an error signal (COMP) and a triangle wave oscillating signal (RAMP).
There is also a desire to provide a single PWM converter or module that can provide a wide range of input/output voltage and current ranges.
SUMMARY OF THE INVENTION
The following summary presents a simplified description of the invention, and is intended to give a basic understanding of one or more aspects of the invention. It does not provide an extensive overview of the invention, nor, on the other hand, is it intended to identify or highlight key or essential elements of the invention, nor to define the scope of the invention. Rather, it is presented as a prelude to the Detailed Description, which is set forth below, wherein a more extensive overview of the invention is presented. The scope of the invention is defined in the Claims, which follow the Detailed Description, and this section in no way alters or affects that scope.
The present invention provides a method and apparatus for use in a multi-phase power system. The power system is of the type having a plurality of Pulse Width Modulation (PWM) controllers including a first PWM controller and at least one second PWM controller. The first PWM controller generates at least one first PWM output signal based on a cyclic signal having a cyclically recurring parameter, and provides the cyclic signal including the cyclically recurring parameter to the second PWM controller. The second PWM controller generates at least one second PWM output signal based on the cyclic signal, and synchronizes the generation of the first and second output signals using the cyclically recurring parameter within the cyclic signal, thereby maintaining a predetermined phase relationship between the first and second output signals. The second PWM controller generates a cyclic, triangular RAMP waveform signal having a series of periods, the RAMP waveform having in each period a signal rising portion and a signal falling portion, and compares the RAMP waveform against an error signal to generate the second PWM signal, the RAMP waveform rising portion and falling portion being generated by charging and discharging, respectively, a capacitor. A feedforward path is provided by setting a charging current for the capacitor that is proportional to an input voltage.
These and other aspects and features of the invention will be apparent to those skilled in the art from the following detailed description of the invention, taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a waveform graph showing an exemplary prior art double-edge PWM generated from an error signal (COMP) and a triangle wave oscillating signal (RAMP).
FIG. 2( a ) is a diagram showing an SPS configured as a Master SPS 1 .
FIG. 2( b ) is a diagram showing an SPS configured as a Slave SPS 2 .
FIG. 2( c ) is a group of graphs of voltage versus time, showing several signals in a system including a Master SPS 1 and three Slave SPS 2 as in FIGS. 2( a ) and 2 ( b ), vertically aligned to show relative timing.
FIG. 3( a ) is a diagram showing preferred circuitry for the generating a RAMP signal.
FIG. 3( b ) is a graph showing the RAMP signal generated by the circuit of FIG. 3( a ).
FIG. 4 is a diagram of a circuit for applying the inventive method.
FIG. 5 is a graph of signals in a Slave PWM converter similar in form to that of FIG. 1 , but showing also the SYNC signal and a low voltage swing limit voltage V BTM .
FIG. 6( a ) is a graph of signal voltage waveforms illustrating an inventive principle.
FIG. 6( b ) is a graph of signal voltage waveforms for use in comparison with the waveforms of FIG. 6( a ).
FIG. 7 is a graph showing waveforms for respective RAMP signals and PWM signals for a 2-phase example of a stacked PWM converter system.
FIG. 8 is a graph showing waveforms for respective RAMP signals and PWM signals for an 8-phase example of a stacked PWM converter system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The making and use of the various embodiments are discussed below in detail. However, it should be appreciated that the present invention provides many applicable inventive concepts which can be embodied in a wide variety of specific contexts. The specific embodiments discussed are merely illustrative of specific ways to make and use the invention, and do not limit the scope of the invention.
Embodiments of the present invention may be employed to advantage in a Master/Slave PWM voltage regulator system. For example, a switching power supply (“SPS”), or converter, that has a ramp generator and a pulse width modulation (“PWM”) comparator can be synchronously paralleled and interleaved with other SPSs of the same construction. This may be done by communicating a common clock and time signature between them. One SPS is set to be the Master and to know the number of time slots in a PWM cycle. This Master SPS sends out the clock with a time signature that indicates a time reference for all paralleled SPSs. All other SPSs are the Slave SPSs, which are set to recognize the characteristics of the time signature and their own time slot. By assigning time slots, each SPS can synchronously generate PWM pulses that are interleaved or overlapped with each PS in the system.
Referring now to FIG. 2( a ), there is shown an SPS configured as a Master SPS 1 . Included are a ramp generator 10 , PWM comparator 11 , counter 12 , digital comparator 13 , signature and hclk generator 14 , and a driver 15 , all connected as shown.
The Master SPS 1 generates a PWM pulse, m_pwm, using the ramp generator 10 , the PWM comparator 11 , and an error signal, m_comp. The ramp generator 10 generates a triangular, or, sawtooth, signal, m_ramp, that is provided to one input of the PWM comparator 11 . The error signal m_comp is a signal generated by other circuitry, and sets the “cut-off” threshold for the PWM comparator 11 , by which the width of m_pwm is determined.
The ramp generator 10 also produces a synchronized clock, mclk, which has a frequency greater than the number of time slots, nslots, times the PWM frequency. The signal mclk is provided to the count input of the counter 12 , and to one input of the signature and hclk generator 14 . The counter 12 receives mclk and provides a count, m_count, of the mclk clock cycles to the digital comparator 13 , which compares m_count to nslots. When m_count reaches nslots, then the digital comparator 13 sends a reset signal, m_rst, to the counter 12 to restart the counting, and to the other input of the signature and hclk generator 14 . The signature and hclk generator 14 combines m_rst and mclk to create a clocking signal with a time signature, which is then put through a driver to create hclk. The time signature is a cyclically recurring parameter that functions to communicate the periodicity of the Master SPS signals, which Slave SPSs may use to time the start of the periods of their own signals. The driver functions as a conventional buffer to provide a “good” signal on the shared hclk line, i.e., having specified electrical characteristics required by the driven circuitry (not shown).
Referring now to FIG. 2( b ), there is shown an SPS configured as a Slave SPS 2 . Included are a signature detector 20 , edge detector 21 , counter 22 , digital comparator 23 , ramp generator 24 and PWM comparator 25 , all connected as shown.
The common clock, hclk, is received from the Master SPS 1 by the Slave SPS 2 and provided to the input of the signature detector 20 and the input of the edge detector 21 . The edge detector 21 creates a clocking signal, sclk, which is internal to the Slave SPS 2 . When a time signature is recognized by the signature detector 20 , it indicates this by asserting the s_rst signal. The s_rst signal resets the counter 22 , whereupon it immediately restarts counting. The counter 22 receives the sclk signal and provides a count, s_count, of the sclk clock cycles to one input of the digital comparator 23 . The other input of the digital comparator 23 receives a digital value, slot, which represents the relative phase of operation for that Slave SPS 2 . The digital comparator 23 compares s_count with slot, and when s_count matches slot, the digital comparator 23 changes the digital state of a sync signal, which it provides as an output signal. The sync signal is then utilized by the ramp generator 24 to create s_ramp, which is, in turn, used by the pwm comparator 25 to compare with an error signal, s_comp, and to create the Slave SPS's PWM pulse, s_pwm. The Slave's s_pwm signal is therefore synchronized with the Master's m_pwm signal and all other Slave s_pwm signals.
Referring now to FIG. 2( c ), this figure shows a group of graphs of voltage versus time, showing several signals in a system including a Master SPS 1 and three Slave SPS 2 as in FIGS. 2( a ) and 2 ( b ), vertically aligned to show relative timing. The signals shown are m_ramp, mclk, hclk, m_rst (which is substantially the same as s_rst), synch, S 1 (the synch signal in the first Slave SPS 2 ), synch, S 2 (the synch signal in the second Slave SPS 2 ), synch, S 3 (the synch signal in the third Slave SPS 2 ), s_ramp, S 1 (the s_ramp signal in the first Slave SPS 2 ), s_ramp, S 2 (the s_ramp signal in the second Slave SPS 2 ), and s_ramp, S 3 (the s_tramp signal in the third Slave SPS 2 ).
In this embodiment, the time signature is a modified width pulse in the hclk waveform. This is shown in the graph for signal m_rst in FIG. 2( c ) with a “skinny” pulse, i.e., one that is relatively narrow compared to a clock pulse. In FIG. 2( c ), the m_ramp signal is an oscillating triangular waveform with eight mclk cycles per period (nslots=7 in the Master SPS 1 ). The Master SPS 1 generates hclk with one skinny pulse at time t 0 , which coincides with the m_ramp change in direction, for every eight clock pulses. The Master SPS 1 and each Slave SPS 2 have a reset signal (m_rst and s_rst, respectively) that coincides with the skinny pulse event.
The counters start with a count of 0, establishing slot 0 , and count up to 7, upon which the counters reset to 0, and the process repeats. Each count represents a slot that is assigned the number of the count. The skinny pulse is placed in slot 0 , i.e., at time t 0 in the first exemplary period shown in the figure. The first, second and third Slave SPSs have been assigned slot 2 , 4 , and 6 , respectively, to create a synchronized, interleaved 4-phase system. Thus, it can be seen that the first Slave SPS generates its sync pulse at time t 1 , which coincides with slot 2 , the second Slave SPS generates its sync pulse at time t 2 , and the third Slave SPS generates its sync pulse at time t 3 . Time t 0 ′ is slot 0 for the next period. Using these three sync pulses, the three Slave SPSs generate their respective s_ramp signals, with their change in direction coinciding with their respective sync pulses, as shown. It will be readily apparent to those of ordinary skill in this art area that there are alternate methods to synchronize the Slaves to a Master such that the required sync pulse is derived from the common clock, hclk, in the implementation of embodiments of the invention. For example, if the hclk signal is, instead, a triangular oscillating waveform with a predetermined period, then the cyclically recurring time of occurrence of a specified voltage level, say, on the falling slope of hclk, may be used as the parameter for communicating periodicity. In such a case, a Slave may derive the periodicity information from hclk simply by using a threshold comparator, and then generate its sync pulses based on that.
According to a preferred embodiment of the present invention, in one aspect a feedforward path is added, for example to the above-described PWM converter system, so as to support a wide input voltage range. This is particularly important in voltage-mode control. In another aspect, a Master/Slave PWM switching converter power supply system is provided that can support “stacking,” i.e., multiple individual supplies that work in concert with one another to provide a single power supply, so as to providing a wide current range.
A Master PWM SPS, or, converter, must also be allowed to stand on its own; i.e., to provide a single-phase power supply; therefore, an internal oscillator is used in the Master PWM converter. To simplify the circuitry, the internal oscillator is also the RAMP signal, i.e., m_ramp, generator. FIG. 3( a ) shows preferred circuitry for the generating the RAMP signal, while FIG. 3( b ) shows the RAMP signal generated by the circuit of FIG. 3( a ). A “window” voltage ΔV is set up to place a boundary on the oscillating RAMP signal. A current source 20 sourcing current I RAMP , from a power supply at voltage V DD , is connected to one terminal of a switch SW 1 , with the other terminal of switch SW 1 is connected to one terminal of a second switch SW 2 and to one plate of a capacitor C, the other plate of capacitor C being connected to ground. The other terminal of switch SW 2 is connected to a current sink 21 sinking current αI RAMP , which is greater than current I RAMP , to ground.
Current source 20 charges capacitor C until the capacitor voltage reaches the top of the window voltage. At that time, switch SW 2 is turned on and switch SW 1 is turned off and the RAMP signal voltage falls until hitting the bottom of the voltage window, and the cycle repeats. As explained in more detail below, the RAMP signal voltage passes the bounding voltage levels of the voltage window, due to comparator propagation delay. The fact that, in this embodiment, the discharge current is selected to be to αI RAMP is also significant; this is discussed in more detail below.
To further simplify the circuitry, the feedforward path is wrapped into the RAMP generator. According to a preferred embodiment, this is accomplished by setting the charge/discharge current I RAMP proportional to the input voltage (V IN ). For example, for a factoring constant k, and assuming a termination resistance of R T ,
I RAMP = k V in R T . Eq . ( 1 ) FIG. 4 shows a simple method of deriving such a current. The resistor R T may be an external resistor, which allows the user to select the frequency of the RAMP signal oscillation. The input voltage V IN is divided by a resistive voltage divider consisting of two resistors, R 1 and R 2 , connected in series between VIN and ground, with k being determined by the ratio of the resistors. The common connection node of resistors R 1 and R 2 is connected to the non-inverting input of an operational amplifier A 1 . The output of amplifier A 1 is connected to the gate of an NMOS transistor T 1 . The source of transistor T 1 is connected to receive the RAMP signal, while the drain is connected to one port of a termination resistor R T , the other port of which is connected to ground. In this way, I RAMP =kV IN /R T is generated.
Given a RAMP signal period of Δt, as shown in FIG. 2( b ), the period of oscillation, neglecting comparator delay, is
T = Δ t = C Δ V I RAMP + C Δ V α I RAMP . Eq . ( 2 )
By creating the window voltage, ΔV:
ΔV=kV IN , Eq. (3)
the oscillator is able to maintain a constant frequency even with changes in V IN . Combining Equations (1)-(3) yields Equations (4) and (5):
T
=
CkV
IN
k
V
IN
/
R
T
+
CkV
IN
α
k
V
IN
/
R
T
,
and
Eq
.
(
4
)
f
=
[
R
T
C
(
1
+
α
)
α
]
-
1
.
Eq
.
(
5
)
Table I shows appropriate component values for the circuit of FIG. 4 , and the resulting frequencies. Note that comparator delay causes the resulting frequency to be longer than desired. It is therefore considered preferred to use a high speed comparator, so as to reduce this effect.
TABLE 1
FREQUENCIES FOR C = 13.3 pF and α = 2
R T [kΩ]
f [kHz]
25
2000
50
1000
100
500
200
250
Each Slave PWM converter should be synchronized with the Master PWM converter, in order to avoid multiple phases drawing current from V IN at the same time. Ways of accomplishing this are known, and can be found, for example, in “Dual or 2 Phase, Stackable Buck Controller,” by John Li, Norman Mosher, Vwodek Wiktor, Second TI Integrated Power Conference ( IPC 05), poster presentation, October 2005, and in U.S. Pat. No. 6,819,577, “Distributing Clock and Programming Phase Shift in Multiphase Parallelable Converters,” which issued on Nov. 16, 2005, to Stefan Wlodzimierz Wiktor and Vladimir Alexander Muratov, and is commonly assigned, in addition to the system described above in connection with FIGS. 2( a ) and 2 ( b ). The following description assumes that such a system is provided, i.e., with a Master PWM converter and one or more Slave PWM converters, such that communication from the Master PWM converter provides a pulse, SYNC (e.g., sync in FIG. 2( b )), that causes the Slave PWM converter's RAMP (e.g., s_ramp in FIG. 2( b )) signal slope to turn negative. FIG. 5 is a diagram for a Slave PWM converter similar in form to that of FIG. 1 , but showing also the SYNC signal and a low voltage swing limit voltage V BTM . Signal voltage waveforms are shown, graphed voltage versus time, vertically aligned to show relative timing between the waveforms. The figure shows the RAMP waveform bounded at the bottom by the V BTM voltage, which is the same voltage that the Master PWM converter uses for the bottom of its window voltage, and at the top by the rising edge of SYNC. The Master PWM converter ensures that the SYNC rising edge occurs at such time to cause the Slave's RAMP amplitude to be equal to ΔV; this passes the frequency V IN cancellation on to each Slave PWM converter.
Because SYNC effects a resetting of the RAMP period, it is considered preferred to design the PWM converters such that subharmonic oscillations are minimized or avoided completely. FIGS. 6( a ) and 6 ( b ) show two different RAMP rise/fall ratios. Signal voltage waveforms are shown, graphed voltage versus time, vertically aligned to show relative timing between the waveforms. In both FIGS. 6( a ) and 6 ( b ) waveform (A) is the Master RAMP signal (solid line), with the horizontal dotted lines showing the respective upper and lower voltage boundaries, waveform (B) is the Slave SYNC signal, waveforms (C) are the Slave RAMP signal (solid line) and the ideal Slave RAMP signal (dashed line), with the upper dotted line showing the COMP signal, and the lower dotted line showing the lower voltage boundary in the Slave, and waveform (D) is the Slave PWM signal.
In FIG. 6( a ) a RAMP signal rise/fall ratio of 1:1 (α=1) is used, and subharmonic oscillating is evident in that t 1 is not equal to t 2 . In FIG. 6( b ) a RAMP signal rise/fall ratio of 5:3 (α=5/3) is used, and subharmonics are suppressed.
Stacking PWM converters or power supply modules allows a great amount of flexibility. When the filter inductor of each supply is connected to the same output, a synchronized, multi-phase converter is created. FIG. 7 shows the respective RAMP signals and PWM signals for a 2-phase example, while FIG. 8 shows the same signals for an 8-phase example.
If each supply is rated at 20 amps maximum, then the user can stack eight supplies to enable 160 amps maximum output current. This topology also allows vertical stacking, i.e. supplies with a 0° phase shift, to provide high current outputs when there is a limit to the number of PWM time slots.
It should also be noted that separate output power supplies can be synchronized with this topology. Synchronizing separate power supplies can be useful when there is a need to suppress possible beat frequencies in a larger system.
Thus, an inventive PWM control method has been presented which uses a triangle, or, sawtooth, oscillating RAMP signal waveform to provide double-edge modulation. Feedforward is combined in the RAMP signal generation to allow voltage-mode control and a wide V IN range. A technique was also presented that allows the PWM converters to be stacked, thus making it easy for the user to scale supply capabilities to meet a variety of applications.
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. | A method and apparatus for use in a multi-phase power system. The power system is of the type having a plurality of Pulse Width Modulation (PWM) controllers including a first PWM controller and at least one second PWM controller. The first PWM controller generates at least one first PWM output signal based on a cyclic signal having a cyclically recurring parameter, and provides the cyclic signal including the cyclically recurring parameter to the second PWM controller. The second PWM controller generates at least one second PWM output signal based on the cyclic signal, and synchronizes the generation of the first and second output signals using the cyclically recurring parameter within the cyclic signal, thereby maintaining a predetermined phase relationship between the first and second output signals. The second PWM controller generates a cyclic, triangular RAMP waveform signal having a series of periods, the RAMP waveform having in each period a signal rising portion and a signal falling portion, and compares the RAMP waveform against an error signal to generate the second PWM signal, the RAMP waveform rising portion and falling portion being generated by charging and discharging, respectively, a capacitor. A feedforward path is provided by setting a charging current for the capacitor that is proportional to an input voltage. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit, pursuant to 35 U.S.C. §120, as a continuation of U.S. patent application Ser. No. 09/640,219, now U.S. Pat. No. 6,527,068, filed on Aug. 16, 2000 and of U.S. patent application Ser. No. 10/352,490, filed Jan. 28, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates generally to the field of drill bits used to drill-earth formations. More specifically, the invention relates to methods for designing, and to designs, for drill bits having improved drilling performance.
[0004] 2. Description of the Related Art
[0005] Roller cone drill bits used to drill wellbores through earth formations generally include a plurality of roller cones rotatably mounted to a bit body. The bit body is turned by a drilling apparatus (drilling rig) while axial force is applied to the bit to drill through the earth formations. The roller cones include a plurality of cutting elements disposed at selected locations thereon. The types, sizes and shapes of the cutting elements are generally selected to optimize drilling performance of the drill bit in the particular earth formations through which the formation is to be drilled.
[0006] The cutting elements may be formed from the same piece of metal as each of the roller cones, these being so-called “milled tooth” bits. Other types of cutting elements consist of various forms of “inserts” (separate bodies formed from selected materials) which can be affixed to the roller cones in a number of different ways.
[0007] Some types of cutting elements, both milled tooth and insert type, have cutting edges (“crests”) which are not symmetric with respect to an axis within the body of the cutting element. These are called non-axisymmetric cutting elements. Some types of roller cone drill bits have non-axisymmetric cutting elements oriented so that the crests are oriented in a selected direction. The purpose of such crest orientation is to improve the drilling performance of the roller cone bit.
[0008] One such method for improving drill bit performance by orienting cutting element crests along a particular direction is described in published patent application PCT/US99/19992 filed by S. Chen. The method disclosed in this application generally includes determining an expected trajectory of the cutting elements as they come into contact with the earth formation. The expected trajectory is determined by estimating a rotation ratio of the roller cones, this ratio being the cone rotation speed with respect to the bit rotation speed. The crests of the cutting elements are then oriented to be substantially perpendicular to, or along, the expected trajectory. Whether the crests are oriented perpendicular or along the expected trajectory depends on the type of earth formation being drilled.
[0009] Yet another method for orienting the crests of the cutting elements on a roller cone bit is described in U.S. Pat. No. 5,197,555 issued to Estes. As explained in the Estes '555 patent, the crests of the cutting elements are oriented within angle ranges of 30 to 60 degrees (or 300 to 330 degrees) from the axis of rotation of the cone.
[0010] It is desirable to provide a drill bit wherein non-axisymmetric cutting elements are oriented to optimize a rate at which the drill bit cuts through earth formations.
SUMMARY OF THE INVENTION
[0011] One aspect of the invention is a roller cone drill bit having roller cones rotatably attached to a bit body. Each of the cones includes a plurality of cutting elements, at least one of the cutting elements being non-axisymmetric and oriented so that a value of at least one drilling performance parameter is optimized. In one embodiment, the at least one parameter include rate of penetration of the drill bit.
[0012] In one embodiment, the crest of the at least one cutting element is oriented at an angle of about 10 to 25 degrees from the direction of movement of the cutting element as it contacts the earth formation when the cutting element is disposed in a position outboard of the drive row location on the cone. In another embodiment, the angle is about 350 to 335 degrees when the cutting element is disposed in a position inboard of the drive row location.
[0013] Another aspect of the invention is a method for designing a roller cone drill bit including simulating the bit drilling earth formations. The drill bit includes roller cones rotatably attached to a bit body. Each of the cones includes a plurality of cutting elements, at least one of the cutting elements being non-axisymmetric. In the method, an orientation of the cutting element is adjusted, and the drilling is again simulated. The adjustment and simulation are repeated until the value of at least one drilling performance parameter is optimized. In one embodiment, the at least one performance parameter includes the rate of penetration of the drill bit.
[0014] Other aspects and advantages of the invention will be apparent from the description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 shows one example of a prior art roller cone drill bit having non-axisymmetric cutting elements.
[0016] FIG. 2 shows a bottom view of one example of a roller cone bit having cutting elements oriented according to the invention.
[0017] FIG. 3 shows one example of how to approximate a location of a drive row on a cone.
[0018] FIG. 4 shows one embodiment of a cutting element which has more than one direction of a long dimension.
DETAILED DESCRIPTION OF THE INVENTION
[0019] Referring to FIG. 1 , a typical prior art roller cone drill bit 20 includes a bit body 22 having an externally threaded connection at one end 24 , and a plurality of roller cones 26 (usually three as shown) attached to the other end of the bit body 22 and able to rotate with respect to the bit body 22 . Attached to the cones 26 of the bit 20 are a plurality of cutting elements 28 typically arranged in rows about the surface of the cones 26 . The cutting elements 28 can be any type known in the art, including tungsten carbide inserts, polycrystalline diamond compacts, or milled steel teeth. The cutting elements shown in FIG. 1 at 28 are non-axisymmetric, meaning that the crest 28 A of the cutting element is not symmetric with respect to an axis (not shown) of the cutting element 28 . Typically, the crest 28 A of a non-axisymmetric cutting element such as shown at 28 will define a long dimension, shown along line L. An orientation of the long dimension L is generally defined as an angle subtended between the direction of the long dimension L and a selected reference. In this example the reference is the rotational axis of the cone, shown at A. Any other suitable reference can be used to define the orientation of the cutting element. The non-axisymmetric cutting elements 28 on the bit 20 shown in FIG. 1 are arranged so that the long dimension L is substantially parallel (at zero degrees subtended angle) with respect to the axis rotation A.
[0020] It should be noted that the long dimension L for the crest 28 A shown in FIG. 1 is substantially parallel to the crest 28 A because the crest 28 A is linear. Other shapes of crest are known in the art which will have different definitions of the long dimension. For example, crescent shaped crests on some cutting elements may have the long dimension defined as along a line connecting the endpoints of the crescent. Referring briefly to FIG. 4 , for example, a special type of cutting element 28 has a long dimension L 2 across its crest which as shown in this example is oriented differently than the long dimension L 1 of the base of the cutting element 28 . For the description of the invention which follows, the orientation of the crest of such cutting elements will be determined by the direction of L 2 . As will be further explained, the individual orientation of both L 2 and of L 1 can be optimized to provide improved drilling performance.
[0021] Referring back to FIG. 1 , although the bit 20 has been shown wherein substantially all the cutting elements 28 include the long dimension L, it is within the scope of this invention if only one such cutting element, or any other number of such cutting elements, is non-axisymmetric and includes long dimension L. The rest of the cutting elements may be axisymmetric. Therefore, the number of non-axisymmetric cutting elements is not intended to limit the invention.
[0022] It has been determined that the orientation of the long dimension L with respect to the axis of the cone A has an effect on drilling performance of the bit 20 . In one aspect of the invention, drilling with the bit 20 through a selected earth formation is simulated. The simulation typically includes determination of a rate at which the bit penetrates through the selected earth formation (ROP), among other performance measures. In this aspect of the invention, the angle of the long dimension L with respect to the selected reference is adjusted, the drilling simulation is repeated, and the performance of the bit is again determined. The adjustment to the angle and simulation of drilling are repeated until the drilling performance is optimized. In one embodiment of the invention, optimization is determined when the rate of penetration (ROP) is determined to be maximum.
[0023] One such method for simulating the drilling of a roller cone drill bit such as shown in FIG. 1 is described in U.S. Pat. No. 6,516,293, filed on Mar. 13, 2000, and assigned to the assignee of this invention. The method of the '293 patent is hereby incorporated by reference. The method for simulating the drilling performance of a roller cone bit drilling an earth formation may be used to optimize the design of roller cone drill bits, and to optimize the drilling performance of a roller cone bit. The method includes selecting bit design parameters, selecting drilling parameters, and selecting an earth formation to be drilled. The bit design parameters generally include at least the shape of the cutting elements on the drill bit. The method further includes calculating, from the bit design parameters, drilling parameters and earth formation, the parameters of a crater formed when one of the cutting elements contacts the earth formation. The method further includes calculating a bottomhole geometry, wherein the crater is removed from a bottomhole surface. The method also includes incrementally rotating the bit and repeating the calculating of crater parameters and bottomhole geometry based on calculated roller cone rotation speed and geometrical location with respect to rotation of said roller cone drill bit about its axis.
[0024] In the present embodiment, the simulation according to the previously described program is performed. At least one drilling performance parameter, which can include the rate of penetration, is determined as a result of the simulation. The angle of the long dimension L of the at least one non-axisymmetric cutting element is adjusted. The simulation is repeated, typically including maintaining the values of all the other drilling control and drill bit design parameters, and the value of the at least one drilling performance parameter is again determined. This process is repeated until the value of the drilling performance parameter is optimized. In one example, as previously explained, the drilling performance parameter is optimized when rate of penetration is determined to be at a maximum.
[0025] For the special cutting element 28 shown in FIG. 4 , the orientation of the crest long dimension L 2 and the orientation of the base long dimension L 1 can both be adjusted, the simulation repeated, and the results compared until the value of the at least one drilling performance parameter is optimized. It is believed that in some drill bits, the direction of the velocity vector may be different at the crest of the cutting elements than at the base of the cutting elements. Specially shaped cutting elements such as shown at 28 in FIG. 4 provide the bit designer with the ability to optimize the orientation of the long dimension at both the crest and at the base of the cutting elements to further improve drilling performance. As for the other embodiments of a bit according to the various aspects of the invention, the number of such special cutting elements as shown in FIG. 4 is not meant to limit the scope of the invention.
[0026] Another aspect of non-axisymmetric cutting elements is that some types of such cutting elements may not be symmetric with respect to a bisecting plane. Other types of such cutting elements may be symmetric with respect to a bisecting plane. Referring briefly to FIG. 1 , typical prior art cutting elements such as 28 A which are not axisymmetric nonetheless have a bisecting plane about which the cutting element is symmetric. In the prior art, such cutting elements 28 A are oriented such that the bisecting plane is substantially perpendicular to the surface of the roller cone. Another aspect of the invention is that in addition to orienting the cutting element crest at a selected angle with respect to the cone axis, the bisecting plane is oriented at a selected angle with respect to the surface of the cone. An example of this orientation is shown in FIG. 2 , where bisecting plane P subtends an angle θ 4 with respect to perpendicular to the surface of the cone 26 . As with other aspects of the invention, the orientation of the subtended angle θ 4 is preferably determined by selecting an initial value of the subtended angle, simulating performance of the bit, adjusting the angle, and repeating the simulating performance until an optimal value of the at least one drilling performance parameter is determined.
[0027] Referring to FIG. 2 , through drilling simulation according to the method described in the '088 patent application, it has been determined that drilling performance of a certain type of roller cone bit known as a tungsten carbine insert (TCI) bit having “chisel” shaped inserts, is optimal when the angle, shown as θ 1 , of the long dimension L is in a range of about 10 to about 25 degrees with respect to the axis A, when the cutting element 28 is disposed in a position on the cone radially outboard (away from the center of the cone) of the radial position of a “drive row” on the cone. If the cutting element, for example, as shown at 29 , is disposed in a row radially interior to the drive row position, it has been determined that drilling performance is improved when the angle, shown in FIG. 2 as θ 2 , is within a range of about 350 to 335 degrees. The definition of the size of the angle used herein is that the angle increases in a direction of the “leading” edge (toward the direction of rotation of the cone).
[0028] It has been determined through simulation of drilling with the bit that a more preferred value for the angle θ 1 is about 25 degrees, and that a more preferred value for angle θ 2 is about 335 degrees.
[0029] In the event that the cutting element is radially positioned at the drive row location, the angle may be either approximately 10 to 25, or 350 to 335 degrees, (or more preferably 25 or 335 degrees) depending on which value of the angle provides a more optimized value of the drilling performance parameter, such as higher rate of penetration.
[0030] One method for estimating the position of the drive row is illustrated in FIG. 3 . The rotation ratio of each of the cones 26 can be determined, for example, using force calculations such as described in the '293 patent referred to earlier, or by simulating the drilling of the bit as in the '293 patent. Having determined or otherwise estimated the rotation ratio of the cone 26 , a ratio of drive row distance r 2 from the axis of the bit B with respect to effective cone radius r 1 will be approximately related to the position of the drive row. The drive row position for purposes of this invention will be located approximately at the position along the cone axis A where the ratio r 2 /r 1 is approximately the same as the rotation ratio of the cone 26 . In any particular bit design, there may or may not be a row of cutting elements disposed at the drive row location. The angle for orienting the at least one cutting element can be selected, as previously explained, by considering the location of the at least one cutting element with respect to the drive row location estimated according to the previously described method.
[0031] Referring again to FIG. 3 , a particular feature of the invention is shown which has as its purpose further improvement of drilling performance. At least one of the cutting elements 30 , in a row in which all the other cutting elements are oriented at the preferred angle θ 1 , preferably is oriented at a different angle θ 3 so that the row of cutting elements will resist “tracking”. The magnitude of the difference in the angles is not important, but only need be selected to avoid tracking. In particular, whether the selected difference in angle between the at least one cutting element and the other cutting elements on the same row is enough to avoid tracking can be determined, among other methods, by using the drilling simulation technique described in the '293 patent referred to earlier.
[0032] This feature of the invention can work with other embodiments of a drill bit. For example, substantially all of the cutting elements on the bit may have long dimension L parallel to the respective axis A of the cone on which each cutting element is disposed. At least one cutting element on any one row of cutting elements on the bit may be disposed so that its long dimension L subtends an angle other than parallel to the cone axis. In another example, at least one cutting element on each row on one cone can be disposed so that its long dimension is other than parallel to the respective cone axis. In yet another example, at least one cutting element on each cone, or alternatively, at least one cutting element on each row of each cone can be oriented so that its long dimension is other than parallel to the cone axis. In each of the foregoing examples, orienting the at least one cutting element so that its long dimension other than parallel to the cone, when all the other cutting elements in the same row are parallel to their respective cone axis is intended to reduce tracking. This aspect of the invention will also work where the other ones of the cutting elements on the same row are not parallel to the cone axis but are disposed at some selected angle (such as the previously described preferred angle). As long as at least one cutting element is disposed at a different angle than all the other cutting elements on one row of cutting elements on the bit, such configuration is within the contemplation of this aspect of the invention. In another example, each row of cutting elements on each of the cones includes at least one cutting element disposed at an angle different from all the other cuffing elements on the row to avoid tracking.
[0033] The invention has been described with respect to particular embodiments. It will be apparent to those skilled in the art that other embodiments of the invention can be devised which do not depart from the spirit of the invention as disclosed herein. Accordingly, the invention shall be limited in scope only by the attached claims. | A method for designing a drill bit that involves simulating a drill bit having cutting elements disposed thereon is provided. In particular, the method involves determining the axial forces acting on at least one of the cutting elements at a first orientation | 4 |
FIELD OF THE INVENTION
The present invention relates to a cooling machine driven for example by solar energy, useful for air conditioning, refrigeration, ice production, or the like. More particularly, the invention is directed to a device known as a generator forming part of the cooling machine which utilizes an aqueous solution of ammonia as the working fluid in an absorption type refrigeration thermodynamic cycle.
BACKGROUND OF THE INVENTION
The references referred to hereinafter, each of which are hereby incorporated by reference, disclose the state of the art.
Refrigeration machines of the absorption type utilizing ammonia as the refrigerant fluid and water as the absorbent, have been known for many years. These machines have been used for example in household refrigerators and air conditioners and utilize a burner of natural gas or electricity as the source of energy for heating the aqueous solution of ammonia. An example of this type of absorption heat pump, not used for cooling or as a chiller, is described in U.S. Pat. No. 4,573,330 to van der Sluys et al. This patent describes a particular design of generator (integrated to a rectifier) wherein fins are provided internally within the generator vessel to promote the formation of liquid drops. The heat is provided by a burner (63) and is not intended to operate with solar energy or other heat source of low temperature and low heat density, therefore this patent does not teach or suggest in any way a solution to the problem of transferring heat with sufficient efficiency from an energy source, such as a solar collector, to the ammonia solution in the generator.
U.S. Pat. No. 4,744,224 gives as a general background of solar driven ammonia absorption refrigerators. This patent describes an intermittent cycle system where the structure of the solar energy collector functions directly as the generator by day and as the absorber by night. The solar radiation directly heats up the ammonia solution circulating through the solar collector. Although this proposal may seem more efficient than the customary practice of heating water in the collectors and then using said hot water to heat the ammonia solution, it has several drawbacks. For example, it does not make use of commercially available solar collectors, because those commercial collectors would have to be operated at high pressures (approximately 14 bars). Also, implicitly it would require conduits for ammonia of considerable length with the consequent increase in risk of leaks. This system is also limited with respect to the temperature that can be reached by the solution and consequently also with respect to the cooling capacity of the machine as well as in its general operation. A machine operating according to this patent would not work at all if the temperature in the generator is not sufficiently high (of the order of 100° C. when the ambient temperature is about 30° C.); as can be derived from a pressure-temperature diagram for aqueous ammonia solutions.
U.S. Pat. No. 4,763,488 discloses a heat exchanger made of parallel plates, which can be utilized as a generator in an ammonia based solar driven absorption system. The generator structure disclosed in this patent however is of complex manufacture and also has the disadvantage of not fitting in the preferred design of existing refrigeration machines.
The present invention overcomes the disadvantages of the prior art and renders commercially possible the more effective utilization of solar energy for cooling purposes as air conditioning and ice making. One of the main reasons why the solar energy has not been yet widely applied for air conditioning, refrigeration or ice making is that the density of energy available from the sun radiation is very low, therefore, a combination of sufficiently high temperatures and energy density has to be obtained to operate a commercially available cooling machine.
The applicant has found that by combining an ammonia based absorption machine, of the type commercially available, and that has been already optimized both in its thermodynamic process and mechanical components, with a suitable solar collector and a generator modified to incorporate this invention (with little or no change in the size or bulk of the generator), the solar energy can be effectively and efficiently utilized for these purposes. This invention also makes it possible to utilize other low temperature energy sources, as for example waste heat carried by fluid streams in many industrial processes, which heat is usually thrown away to the environment, contributing to thermal pollution.
Many attempts have been made in the past in order to find an effective way of transferring the amount of necessary heat to the ammonia solution and at the same time to reach sufficiently high temperatures in the generator in order to effectively separate the ammonia from the water. The simplest way of combining a solar collector with an absorption cooling machine is to circulate water through a solar collector and then pass the hot water through heat exchange pipes in the generator where the ammonia solution contacts said pipes. This simple combination however does not work because the amount of heat per unit area to be transferred through the heat-exchange pipes can not flow through the practically-available heat transfer area under such conditions.
It is therefore an object of the invention to provide a device useful as a generator in an ammonia-absorption cooling machine which may be operated utilizing relatively low temperature energy sources, and especially which can be used with commercially available components of high-temperature driven cooling machine of the ammonia-absorption type by substituting for the burner unit yet without increasing the size of the generator core.
It is another object of the invention to provide a solar driven ammonia-absorption cooling machine.
Other objects of the invention will be pointed out hereafter or will be evident to those skilled in the art.
The objects of the invention are generally achieved by an apparatus combining a source of low temperature energy, of the type which can heat a liquid to temperatures in the range of 120° C. to 150° C., for example a solar energy collector, and an ammonia-absorption type cooling machine which comprises a generator vessel where an aqueous solution of ammonia is heated to separate absorbed ammonia from the solvent water by a multi-stage equilibrium separation; a hot water circulation vessel, coaxially enclosing at least a portion of and cooperating with said generator vessel to define a hot water circulation chamber through which water is caused to circulate in direct contact with the wall of said generator vessel, thus transferring heat from said hot water to said ammonia solution; characterized by the fact that said generator vessel has a multitude of heat transfer fins protruding into and preferably substantially filling said hot water circulation chamber arranged in staggered series along the wall of said generator vessel so that the hot water circulating in contact with said fins is subject to frequent direction changes resulting in heat transfer enhancing. Without intending to link the effectiveness of the present invention to the following explanation, the applicant believes that the efficiency of the heat transfer fins having the dimensions herein claimed, particularly the length, measured in the direction of the circulation of hot water through said hot water circulation chamber, is effective for this application because the many abrupt changes in direction cause turbulence breaking up establishment of thicker more steady-state boundary layers that inhibit efficient convection heat transfer at the fin surfaces. Said fin length is shorter than the length where the thick steady state boundary layers would be formed by the water circulating straight through said chamber at each side of the heat transfer fins. In other words, as the fins length is increased much beyond 50 mm there is a significent decrease in the heat transfer efficiency thereafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In this specification and in the accompanying drawings, some preferred embodiments of the invention are shown and described and various alternatives and modifications thereof have been suggested; but it is to be understood that other changes and modifications can be made within the scope of the invention. The suggestions herein are selected and included for purposes of illustration in order that others skilled in the art will more fully understand the invention and the principles thereof and will thus be enabled to modify it in a variety of forms, each as may be best suited to the conditions of a particular use.
FIG. 1 is a schematic diagram in the vertical section of a generator for a solar based cooling system operating with an aqueous ammonia solution;
FIG. 2 is a schematic perspective view of the internal vessel of the generator, showing the heat transfer fins according to the present invention;
FIG. 3 is a schematic perspective view on an enlarged scale of the structure in FIG. 2 to show the relative disposition of the heat transfer fins; and
FIG. 4 is a schematic diagram of a preferred embodiment of the cooling machine incorporating the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring first to FIG. 1, the generator is generally designated by numeral 10, and comprises an outer vessel in the form of a water jacket 12, adapted to withstand pressures on the order of about 4 to 6 bars, and an internal vessel forming the generator core 14 provided with a plurality of internal semicircular plates 16 which increase the contact between the heat source and the ammonia solution to promote heating and also facilitate the contact of the vapor phase and the liquid phase of the aqueous ammonia solution wetting the plates thus causing ammonia to better concentrate in the vapor phase.
Liquid water is heated by solar radiation 25 in solar collectors 23 to a temperature in the range between 120° C. and 150° C. From there, it flows via pipe 20 to vessel 12 (entering through inlet 22). The circulating solar-heated water then exits through outlet 26 and flows via pipe 21 by means of pump 27 back to the solar collectors 23 to receive more energy from said solar collectors.
The strong ammonia solution enters the generator core 10 through pipe 48 from the absorber 29 of the cooling machine 9. The solar-heated water circulating through the annular space 24 of the generator water jacket 12 transfers heat from such hot water stream across the wall of generator core 14 to the ammonia solution therein to accomplish the required separation of ammonia from water. The resulting weak ammonia solution exits generator core 14 via pipe 40 to feed the absorber 29 (after first passing through a pressure reducing valve 33, which compensates for the pressure differential between the generator core 14 and the absorber 29). The amount of heat required to separate the required ammonia vapor is of the order of 7000 watts (23886 B.T.U. per hour) per ton of refrigeration (one ton of refrigeration=3517 watts=12,000 BTU per hour) for a machine to operate satisfactorily. Therefore, the heat transfer area must be on the order of 1.5 square meters, per ton of refrigeration (which surface must be constructed in contact with the vessel wall of the generator core 14, with such wall being dimensioned for the predetermined desired capacity of the cooling machine).
Although many attempts have been made in the past to extend the heat transfer surface of the generator core 14 by means of heat exchange fins, these have not been successful because the characteristics of the heat transfer boundary layer on such fins have not been taken into account. The applicant has found that the heat density required can be effectively transferred by constructing the fins 28 with the following approximate dimensions: length 30 mm to 50 mm; width 12.7 mm to 19.1 mm; and about 2.38 mm to 3.18 mm of thickness. Consequently, the length 31 of the fins in the direction of the hot water flow is shorter than the length where the boundary layers formed by the water circulating through said chamber along the sides of said heat transfer fins meet between adjacent fins. According to the present invention, the heat-transfer fins 28 are arranged in a staggered pattern, as better seen in FIG. 2, so as to present frequent directional changes to the flow of hot water annular space 24, as can be seen in FIG. 3. This arrangement for the heat transfer fins is sufficiently effective to allow for operation of a cooling machine 9 operated by a low temperature heat source as for example solar collectors 23.
The annular space 24 for hot water flow in the claimed generator also has the advantage that the generator jacket 12 can be insulated, so that the heat loss from the hot water is minimized, in contrast with the prior art generators where most of the energy is applied as a direct flame from a gas burner only to the bottom of the generator and the heat content of the products of combustion is carried away by the fumes of the burner.
As a result of the heating the ammonia solution, the refrigerant vapor, ammonia, rises to the top of the generator core 14. There the vapor 36 enters a leveling chamber 30, through passage 32. A stream of high concentration ammonia solution at a relatively lower temperature of about 45° C. is circulated at high pressure by means of a pump 43 via pipe 44 to coil 42, which latter forms a rectifier zone in said leveling chamber 30. This rectifier zone is simply a heat exchanger. The coil 42 exchanges heat with the refrigerant vapor passing through passage 32. When the hot vapor contacts the cooler coil 42, any water vapor which might have been carried out from the generator core 14 into the leveling chamber 30 will condense and drain to the bottom of said chamber 30 and return to the generator core 30 through the condensate line 34. After the high concentration solution is heated in the rectifier zone 42, it flows to through pipe 46 to the absorber 29 of the cooling machine 9 and leads said strong solution at a higher temperature through pipe 48 into the generator core 14. The refrigerant vapor (ammonia) leaves the rectifier zone via line 50 in chamber 30 at a high pressure and temperature and is circulated through a thermodynamic cycle portion of the cooling machine, as known in the art (a typical example of which is shown in FIG. 4).
More specifically, the high-pressure high-temperature ammonia vapor is passed via pipe 50 to condenser 54 (wherein the vapor is liquified by heat dissipation to the outer environment, e.g. from condenser coils). The liquid ammonia flows via pipes 56 and 57 to expansion valve 58. Cold gaseous ammonia from valve 58, cooled by loss to the heat of vaporization, flows via pipe 59 into the cooling coils 61 of the evaporator 60. There, typically, water circulated in a closed loop 62 by pump 64 is chilled by heat exchange contact with coils 61 and in turn cools air (arrows 66) by heat exchange flow through remote coils 68. The still somewhat cool ammonia gas issuing from the evaporator flows via pipe 69 to the absorber 29 (advantageously through heat exchanger 70) where the low pressure ammonia vapor is absorbed in the weak water-ammonia solution received in the absorber 29 from the generator core 14 via pipe 40 (through pressure reducing valve 33). Pump 43 draws a strong solution from the absorber 29 and delivers that cool solution at high pressure through the rectifying chamber 30 and on via line 46, heat exchange coils in absorber 29, and line 48 to generator core 48.
Referring now to FIG. 2, the generator core 14 is shown in a perspective view illustrating the preferred arrangement of the heat transfer fins 28 which are formed in staggered series surrounding the vessel 14, so that the water circulating through the annular space 24 within the water jacket 12 is in contact with such fins 28 (which latter fill most of such space 24) and thus is subject to frequent changes in the direction of its flow. This detail is more explicitly shown in FIG. 3 where a schematic amplified view of the fins 28 has been illustrated and where the flow of the hot water is indicated by the arrows 52 passing through the spaces between each pair of adjacent fins 28. The fins preferably are oriented radially as illustrated in FIG. 2, in horizontal rows closely spaced and alternatively axially staggered. The array of fins could also be in a wound overlapping spiral and spaced such that such space between adjacent fins is obstructed longitudinally by a fin in the next winding.
The following example of an operating air conditioning machine 9, having a capacity of 3 tons of refrigeration and driven by solar radiation, illustrates the invention:
______________________________________Dimensions of fins 28: length width thickness 50 mm 19.1 mm 3.18 mmOuter diameter of core 14: 152 mmInner diameter of water jacket 12: 195 mmVertical spacing between staggered 1 mmrows of fins:Vertical height of stacked fins (17 867 mmrows):______________________________________
From this it can be seen that the fins 28 substantially fill the annular space 24, leaving about 1/8 inch expansion spacing). The effective length for heat transfer where the boundary layer does not present great resistance to the heat flow from the hot water to the fins, for a hot water flow rate of about 1 liter/sec in a flow annular area of 0.01 square meters measured without the fins, is about 50 mm. This finding makes the construction and operation of a cooling machine 9, having a generator 10 incorporating the invention, of practical use when the energy source is for example heat obtained from solar collectors.
The hot water stream had a temperature of about 145° C. during the operation of the cooling machine 9 of the example and was heated by vacuum solar collectors of the type known as evacuated heat pipes which concentrate solar heat in a stream of water which then heated said hot water stream. The separation of the ammonia is very effective, having only a minimum amount of water in the outgoing stream of about 0.4 % wt. of water in the solution of ammonia exiting the generator. The chiller for chilling water to be used in air conditioning was a modified commercially-available 3 tons absorption unit, and the load was a two-floors experimental house with a total floor area of about 120 square meters. The outside ambient temperature was on the order of 30° C. to 35° C.
The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. The invention which is intended to be protected herein, however, is not to be construed as limited to the particular forms disclosed, since these are to be regarded as illustrative rather than restrictive or limitative. Variations and changes may be made by those skilled in the art without departing from the spirit of the invention in its broader aspects, for example the shape of the heat-exchange fins in the generator may be different (non-rectangular, especially if needed for mass production, such as might result from the formation of multiple fins from a continuous metal strip), or the heat for driving the cooling machine may be taken from a hot stream in an industrial process instead of from solar collectors. | A cooling machine, useful for air conditioning, refrigeration, ice production, or the like, based on the ammonia absorption thermodynamic cycle, and operated by a heat source of relatively low temperature, as for example a set of solar heat collectors, wherein the generator of said cooling machine comprises a first vessel through which said ammonia solution is circulated and is subject to separation of ammonia from water in the solution by raising its temperature through heat exchange relationship with a stream of a hot liquid, heated in the set of solar collectors; and a second vessel coaxially disposed surrounding said first vessel, whereby the walls of said first and second vessels define an annular hot water circulation chamber; said first vessel having a plurality of staggered series of heat transfer fins of predetermined dimensions so as to optimize the heat transfer from said hot liquid to the ammonia solution in said generator. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Pursuant to 35 U.S.C. §119 and the Paris Convention Treaty, this application claims the benefit of Chinese Patent Application No. 201110162713.4 filed Jun. 17, 2011, the contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to an aeration ship used in sewage purification and biological treatment for rapidly and effectively increasing oxygen in a deep-water area by aeration for improving the content and saturation of dissolved oxygen in sewage.
[0004] 2. Description of the Related Art
[0005] Methods of treating the organic matters in wastewater by microorganisms have the advantages of less investment, high efficiency, stable operation, low operating cost, good effluent quality, and good sludge settleability. In biological treatment methods, because there is almost no odor, the activated sludge process plays an extremely important role due to its characteristics of shorter processing time and high treatment efficiency. In the activated sludge process, aeration is necessary for supplying sufficient oxygen to sewage, and activated sludge is fully mixed with sewage, and further kept in suspension, so that the oxygen in air is effectively dissolved in sewage.
[0006] Conventional aeration equipment mostly adopts a single machine body, and freely moves on water when in use. An aeration ship as shown in FIG. 1 includes an air compressor 206 , an air cylinder 204 , submersible hollow shaft motors 602 , and a propeller 604 . A base 6 having a hollow structure is arranged between the air cylinder 204 and the submersible hollow shaft motors 602 , and a plurality of openings are formed on the side surface of the base 6 and simultaneously connected with the submersible hollow shaft motors 602 . By adopting the structure, aeration can be carried out in a plurality of directions at the same time, and the aeration efficiency is improved, however, the aerator freely navigates on water with uncontrollable aeration direction, thus it's not suitable for uniform aeration on water on a large scale.
[0007] Conventional aerators generally have a fixed aerator and a movable aerator, and in both the fixed aerator and movable aerator, air is conveyed to sewage through an air guide tube, and the introduced air is mixed with sewage through a sewage mixing device. The length of the air guide pipe is fixed, thus the aerator is only suitable for working near a pool with a smooth water bottom, and for the waters in a natural environment such as lakes and rivers required to be treated, due to the different depths of the water bottom, when the aerator with the air guide tube with fixed length works, the sewage in the deep-water area fails to be mixed, and the aerator fails to move in the shallow-water area, therefore, the aeration efficiency and quality are greatly limited.
[0008] Conventional aerators can be used for sewage aeration, however, for those seriously polluted waters, for example, the water in an earthquake-stricken area, besides the normal aeration, disinfection is also needed or chemical substances are required. However, the disinfection fails to be carried out in the polluted waters through the aerator in the prior art.
SUMMARY OF THE INVENTION
[0009] In view of the above-described problems, it is one objective of the invention to provide an aeration ship provided with controllable direction and free navigation and capable of stably and evenly performing large-area aeration. In the aeration ship, the underwater penetration of the aerator can be adjusted according to different water depths, the aeration depth is adjusted, and the disinfection is carried out during the aeration, or chemical substances are added to sewage.
[0010] To achieve the above objective, in accordance with one embodiment of the invention, there is provided an aeration ship comprising a ship body, a ship bottom, and an aerator, wherein the aerator comprises an air cylinder having an upper section and a lower section, the upper section of the air cylinder is fixed on the ship body, and the lower section of the air cylinder penetrates the ship bottom and extends downwards.
[0011] The moving direction of the ship body of the aeration ship is controllable and thus stable large-area aeration in large-scale water can be performed. Thus, the aeration efficiency is improved.
[0012] In a class of this embodiment, the aerator is a submerged aerator.
[0013] In a class of this embodiment, the aerator comprises an air compressor, and an output port of the air compressor is connected with the upper part of the air cylinder.
[0014] In a class of this embodiment, the aerator comprises a compressed air pipe, and the output port of the air compressor is connected with the upper part of the air cylinder via the compressed air pipe.
[0015] The air compressor is connected with the air cylinder via the compressed air pipe, and the compressed air pipe is controllable in length and shape, thus the air compressor is more flexibly placed.
[0016] In a class of this embodiment, the aerator comprises a submersible hollow shaft motor, a propeller, and a base; the air cylinder is connected with the submersible hollow shaft motor through the base, and the propeller is coaxially connected with the submersible hollow shaft motor.
[0017] In a class of this embodiment, the base is a multidirectional base, an opening at an upper part of the base is connected with the air cylinder, and an opening on a side surface of the base is connected with the submersible hollow shaft motor.
[0018] In a class of this embodiment, three uniformly distributed openings are formed on the side surface of the base.
[0019] The multidirectional base is used as a channel for uniformly distributing a compressed air source, and air is simultaneously sprayed and diffused around the aerator through shaft holes of a hollow transmission shaft of the submersible hollow shaft motor, so that the aeration is more uniform and more stable, and the aeration efficiency is improved.
[0020] In a class of this embodiment, the aeration ship further comprises an aeration system lifting device for controlling the ascending or descending of the air cylinder.
[0021] In a class of this embodiment, the aeration system lifting device comprises an electric generator, a hydraulic station, a hydraulic pipe, a lifting oil cylinder, and a piston; the lifting oil cylinder is fixed on the ship body, the electric generator drives the hydraulic station to work, the hydraulic station is connected with the lifting oil cylinder via the hydraulic pipe, the air cylinder penetrates the inside of the lifting oil cylinder, the piston is arranged between an outer wall of the air cylinder and an inner wall of the lifting oil cylinder, and oil is filled between the outer wall of the air cylinder and the inner wall of the lifting oil cylinder.
[0022] In a class of this embodiment, the aeration system lifting device comprises a lead screw, a lifter, a lifting handle, a protective sleeve of the lead screw, a lifting guide pipe, and a connecting plate; the lifting guide pipe and the protective sleeve of the lead screw are fixed on the ship body, the air cylinder penetrates the inside of the lifting guide pipe, the connecting plate is used for connecting the upper end of the air cylinder and the upper end of the lead screw, the lead screw penetrates the inside of the protective sleeve of the lead screw via the lifter, and the lifting handle drives the lead screw to ascend or descend through a worm and gear system in the lifter.
[0023] Because the lifting mechanism is used for controlling the ascending or descending of the air cylinder, the underwater penetration of the aerator is adjusted according to different water depths, and the aeration depth is adjusted.
[0024] In a class of this embodiment, the aeration ship further comprises a disinfectant generator arranged in the ship body, and an output port of the disinfectant generator is communicated with the upper part of the air cylinder.
[0025] In a class of this embodiment, the aeration ship further comprises a three-way pipe and a disinfectant delivery pipe, an output port of the three-way pipe is communicated with the upper part of the air cylinder, a first input port of the three-way pipe is communicated with the air compressor through the compressed air pipe, and a second input port of the three-way pipe is communicated with the disinfectant generator through the disinfectant delivery pipe.
[0026] The disinfectant generator is additionally arranged, thus the disinfection is carried out during the aeration, or chemical substances are added to sewage.
[0027] The term “is connected with” as used herein respective any embodiment of the invention encompasses the terms “is directly connected to” and “is directly connected with.”
[0028] Advantages of the invention are summarized below. The aerator is combined with the ship, thus when the aeration ship works, the aeration is stable, the direction is controllable, the large-area aeration can be performed, and the aeration efficiency is improved. Meanwhile, through controlling the ascending or descending of the air cylinder, the underwater penetration of the aerator is adjusted according to different water depths, and the aeration depth is adjusted, so that the aeration can be carried out in a broader and more complicated water. In addition, the sterilizing device is also arranged in the aeration ship, so that disinfectant or chemical substances can be put in water during the aeration, and sewage is disinfected.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a front view of a multifunctional submerged aerator in the prior art;
[0030] FIG. 2 is a front view of an aeration ship in accordance with one embodiment of the invention;
[0031] FIG. 3 is a left view of an aeration ship in accordance with one embodiment of the invention;
[0032] FIG. 4 is a right view of an aeration ship in accordance with one embodiment of the invention;
[0033] FIG. 5 is a schematic diagram of an aeration system lifting device of a first example of the invention;
[0034] FIG. 6 is a schematic diagram of an aeration system lifting device of a second example of the invention; and
[0035] FIG. 7 is a schematic diagram of a steering device of an aeration ship in accordance with one embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0036] An aeration ship as shown in FIGS. 2 , 3 , and 4 comprises a ship body, a ship bottom, a pilot instrument cabin 1 , an integrated cabin 2 , a power distribution cabin 3 , a power cabin 4 , a left ship body 502 , and a right ship body 503 . A steering wheel 101 , a manual hydraulic pump 102 , a steering gear oil pipe 103 , a frequency-conversion control cabinet 104 , and a cockpit door 105 are arranged in the pilot instrument cabin 1 ; an air compressor 206 , a hydraulic station 207 , a disinfectant generator 209 , an air cylinder 204 , and a lifting oil cylinder 210 are arranged in the integrated cabin 2 ; a power distribution control cabinet 302 , a power distribution cabin door 303 , and a window 304 are arranged in the power distribution cabin 3 ; an electric generator 405 and a power cabin door 404 are arranged in the power cabin 4 . An air inlet of the air compressor 206 arranged in the ship body is introduced outside the cabin via an air inlet pipe 205 , and an air outlet is connected with one end of a three-way pipe 203 positioned at the upper part of the air cylinder 204 through an compressed air pipe 201 . An output port of the disinfectant generator 209 is connected with another end of the three-way pipe 203 positioned at the upper part of the air cylinder 204 through a disinfectant delivery pipe 202 .
[0037] As shown in FIGS. 3 and 4 , the ship in the example is a double-bottom ship, the aerator is installed between the two ship bottoms at the bottom of the ship, and the aerator sinks in water for aeration. For any ship (e.g., a single-bottom ship) with the similar structure, as long as one part of the aerator is fixed on the ship, and the other part sinks in water for work, all should fall within the protection range of the invention.
[0038] In combination with FIG. 1 , the base 6 is a multifunctional base and connected with the bottom of the air cylinder 204 , an opening at the upper part of the base 6 is connected with the air cylinder 204 , and openings on the side surface of the base 6 are connected with submersible hollow shaft motors 602 respectively. A propeller 604 is coaxially connected with each of the submersible hollow shaft motors 602 . A hollow structure is adopted inside the base 6 , the openings on the side surface of the base 6 are used as the channel for uniformly distributing a compressed air source, and the number of the openings can be 2-4 or more. The air pressurized through the air compressor 206 flows through the air cylinder 204 via the three-way pipe 203 , and then is simultaneously sprayed and diffused around through shaft holes of hollow transmission shafts of the submersible hollow shaft motors 602 connected with the openings on the side surface of the base 6 respectively, so that the uniform aeration is carried out in sewage, the aeration is more uniform and more stable, and the serration efficiency is improved.
[0039] The aeration ship further comprises an aeration system lifting device, a disinfectant generator, a ship body propulsion apparatus, and a ship body steering device.
[0040] In a first embodiment of the aeration system lifting device, as shown in FIG. 5 , the aeration system lifting device comprises the hydraulic station 207 , hydraulic pipes 208 , the lifting oil cylinder 210 , a piston 211 , an upper connecting plate 212 , and a lower connecting plate 213 . The electric generator 405 drives the hydraulic station 207 to work. The hydraulic station 207 is connected with the lifting oil cylinder 210 through two hydraulic pipes 208 . The upper part of the air cylinder 204 is connected with the three-way pipe 203 , and the lower part of the air cylinder 204 is connected with the base 6 . The air cylinder 204 penetrates the inside of the lifting oil cylinder 210 , and oil is filled between the outer wall of the air cylinder 204 and the inner wall of the lifting oil cylinder 210 . The piston 211 is arranged between the outer wall of the air cylinder 204 and the inner wall of the lifting oil cylinder 210 . The upper connecting plate 212 is arranged at the upper end of the outer wall of the lifting oil cylinder 210 , and the lower connecting plate 213 is arranged at the lower end of the outer wall of the lifting oil cylinder 210 , so that the lifting oil cylinder 210 is fixed on the ship body. The hydraulic station 207 drives the hydraulic oil in the hydraulic pipes 208 to enter the lifting oil cylinder 210 , and the piston 211 is further pushed to drive the air cylinder 204 to ascend or descend, so as to achieve the purpose of regulating and controlling the aeration depth.
[0041] In a second embodiment of the aeration system lifting device, as shown in FIG. 6 , the aeration system lifting device comprises a lead screw 227 , a lifter 239 , a lifting handle 220 , a protective sleeve 221 of the lead screw, a lifting guide pipe 226 , an upper connecting plate 222 , a lower connecting plate 223 , and a connecting plate 228 . The air cylinder 204 penetrates the inside of the lifting guide pipe 226 . The upper connecting plate 222 is arranged at the upper end of the outer wall of the lifting guide pipe 226 . The lower connecting plate 223 is arranged at the lower end of the outer wall of the lifting guide pipe 226 . The connecting plate 228 is used for connecting the upper end of the air cylinder 204 and the upper end of the lead screw 227 , and the protective sleeve 221 of the lead screw is fixed through the upper connecting plate 222 , so that both the lifting guide pipe 226 and the protective sleeve 221 of the lead screw are fixed on the ship body. The lead screw 227 penetrates the inside of the protective sleeve 221 of the lead screw, the lifting handle 220 drives the lead screw 227 to ascend or descend through a worm and gear system (not shown in the figure) in the lifter 239 , and the lead screw 227 drives the air cylinder 204 to ascend or descend, so as to achieve the purpose of regulating and controlling the aeration depth.
[0042] Certainly, other similar devices in the prior art can be installed on the aeration ship for controlling the ascending or descending of the aerator, so all these should fall within the protection range of the invention.
[0043] As for the disinfectant generator, as shown in FIG. 2 , the air inlet of the air compressor 206 is introduced outside the cabin via the air inlet pipe 205 , and the air outlet is connected with one end of the three-way pipe 203 positioned at the upper part of the air cylinder 204 through the compressed air pipe 201 . The output port of the disinfectant generator 209 is connected with another end of the three-way pipe 203 positioned at the upper part of the air cylinder 204 through the disinfectant delivery pipe 202 . The disinfectant generator is additionally arranged, thus the disinfection is carried out during the aeration, or chemical substances are added to sewage.
[0044] As shown in FIG. 2 , the ship body propulsion apparatus comprises the electric generator 405 , a submergible hollow shaft propulsion motor 7 and a propulsion propeller 703 . The electric generator 405 is installed in the power cabin 4 . The submergible hollow shaft propulsion motor 7 is hung between the left ship body 502 and the right ship body 503 , and a cable 701 of the submergible hollow shaft propulsion motor 7 is connected with the frequency-conversion control cabinet 104 in the pilot instrument cabin 1 . The power distribution control cabinet 302 in the power distribution cabin 3 is connected with the frequency-conversion control cabinet 104 through an output cable 301 , and the power distribution control cabinet 302 is connected with the electric generator 405 in the power cabin 4 through a generator output cable 402 ; a water inlet hole 702 is formed at the front part of the submergible hollow shaft propulsion motor 7 , and the propulsion propeller 703 is arranged at the rear part of the submergible hollow shaft propulsion motor 7 and coaxially connected with the submergible hollow shaft propulsion motor 7 .
[0045] As shown in FIG. 7 , the ship body steering device comprises a steering wheel 101 , a manual hydraulic pump 102 , steering gear oil pipes 103 , a steering gear oil cylinder 803 , an oil cylinder support 805 , a rudder stock 801 , a rudder stock bearing bracket 804 , a tiller 802 , and a rudder blade 8 . The steering wheel 101 is connected with the manual hydraulic pump 102 . The steering gear oil cylinder 803 is connected with the manual hydraulic pump 102 through the two steering gear oil pipes 103 . The steering gear oil cylinder 803 is positioned on the oil cylinder support 805 . The upper part of the steering gear oil cylinder 803 is connected with one end of the tiller 802 through a piston rod 806 , and the other end of the tiller 802 is connected with the upper end of the rudder stock 801 . The rudder stock 801 penetrates the rudder stock bearing bracket 804 to connect with the rudder blade 8 .
[0046] The steering gear adopts a reciprocating steering mechanism, and mainly comprises the steering gear oil cylinder 803 (fixed on the oil cylinder support 805 ) and the piston rod 806 (capable of making reciprocating motion in the steering gear oil cylinder 803 ). The steering wheel 101 manually rotates left or right to drive the manual hydraulic pump 102 . Oil is forced into the steering gear oil cylinder 803 by the manual hydraulic pump 102 via the steering gear oil pipe 103 . The piston rod 806 moves left or right under the action of oil pressure and is connected with one end of the tiller 802 through a movable connector at the top end of the piston rod 806 . The other end of the tiller 802 is fixed at the upper end of the rudder stock 801 through a key. The deflecting direction of the rudder blade 8 can be changed through the reciprocating motion of the piston rod 806 , so that the direction of travel of the ship is changed.
[0047] In the aeration ship, as shown in FIG. 2 , an electric slip ring 9 is arranged at the tail part of the ship body, a rain shield 904 is arranged at the upper part of the electric slip ring 9 , and the electric slip ring 9 is connected with an external input cable 902 and an external output cable 906 respectively. The external input cable 902 penetrates via a cable duct tube 901 and is connected with the electric slip ring 9 . A plurality of floating balls 903 are tied at the position where the external input cable 902 is positioned on water. The external output cable 906 is also connected with the power distribution control cabinet 302 .
[0048] The hydraulic station 207 is connected with the frequency-conversion control cabinet 104 through a hydraulic station cable 214 . One end of the power distribution control cabinet 302 is connected with the electric generator 405 through a generator output cable 402 , and the other end of the power distribution control cabinet 302 is connected with the frequency-conversion control cabinet 104 through an output cable 301 , and further connected with the air compressor 206 and the disinfectant generator 209 respectively. Two frequency converters are arranged in the frequency-conversion control cabinet 104 and connected with the submergible hollow shaft propulsion motor 7 and the submergible hollow shaft motors 602 through cables.
[0049] When the aeration ship works, the air compressor 206 is driven by the power distribution control cabinet 302 to output compressed air under the action of electric power of the electric generator 405 , the disinfectant generator 209 is also driven to spray disinfectant, and meanwhile, the electric power is input to the frequency-conversion control cabinet 104 through an electrical cabinet and drives the submergible hollow shaft propulsion motor 7 connected with the frequency-conversion control cabinet 104 to work. Thus, the motor transmission shaft rotates to drive the propulsion propeller 703 to rotate, so as to push the ship body to move forwards. The electric power of the electric generator 405 drives the hydraulic station 207 to work or drives the aerator lifting device to work through the lifting handle 220 .
[0050] In conclusion, the application of the ship avoids the inconvenience caused by installing plurality of aerators in the large-area water, and the movable aeration can be carried out according to the specific anoxic zone and demand of water body. Meanwhile, the seriously polluted water can be disinfected during the aeration or chemicals are put in the seriously polluted water.
[0051] While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. | An aeration ship including a ship body, a ship bottom, and an aerator. The aerator includes an air cylinder having an upper section and a lower section. The upper section of the air cylinder is fixed on the ship body, and the lower section of the air cylinder penetrates the ship bottom and extends downwards. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to an apparatus for crushing motor vehicle oil filters and simultaneously recovering residual or waste oil from the filters.
The Environmental Protection Agency of the United States has promulgated rules declaring that waste oil constitutes a hazardous material. As such, waste oil must be carefully collected and then recycled or disposed of in accord with stringent disposal procedures. Heretofore, a significant source of waste oil has been the residual oil retained in used motor vehicle oil filters. Thus, appropriate techniques are required to recover the waste oil from such filters for purposes of recycling, proper disposal or other treatment. It is estimated that approximately half of the oil in such filters can be recovered by simply draining the filter after it is removed from the motor vehicle. The remaining oil in the filter cannot normally be recovered by draining and thus other techniques must be used.
It has been suggested that such additional techniques include the crushing of the filter and the collection of the oil during the crushing operation will result in the recovery of an additional 38% of the oil originally contained in the filter. The remaining amount (12%) does not appear to be recoverable.
In any event, the recovery of a significant amount of used motor vehicle oil can be effected by crushing of the filters. Recently various proposed structures for the crushing of oil filters and recovery of the oil released during the crushing operation have appeared in the marketplace. Typically, such oil filter crusher apparatus are comprised of a platform or anvil with a piston positioned over the anvil. A hydraulic operated piston is then positioned to descend onto the filter, crushing the filter and thereby extracting significant amounts of residual oil retained in the filter. The use of such crushing apparatus has been greeted with acceptance especially among those businesses responsible for changing the oil in motor vehicle engines. There has remained a need, however, for an improved oil filter crushing apparatus which is compact, efficient, durable, safe to operate and less costly.
SUMMARY OF THE INVENTION
In a principal aspect, the present invention comprises an improved oil filter crushing apparatus that generally includes a horizontal platform with vertical support members projecting therefrom upward through a base plate and connected to a piston of an operating cylinder. The underside of the base plate of the cylinder serves as an anvil against which an oil filter supported on the platform is driven by the vertical upward movement of the piston within the cylinder. The platform is retained within a protective housing for collecting the residual oil that is removed from an oil filter during the crushing operation. A drain at the bottom of the housing directs residual oil into a collection container. An access door is provided in the housing with an interlock that precludes operation of the crushing mechanism unless the door is closed. The anvil which is incorporated as part of the base plate of the cylinder includes a unique configuration to enhance the filter crushing operation. The entire assembly is especially compact, durable and relatively inexpensive.
Thus, it is an object of the invention to provide an improved oil filter crusher apparatus.
It is a further object of the invention to provide an improved oil filter crusher apparatus of the type wherein a platform for driving an oil filter against an anvil is movable vertically upward in response to actuation of a cylinder within a piston positioned over the platform.
It is a further object of the invention to provide an improved oil filter crusher apparatus having a base plate which includes an integral anvil and further includes a cylinder construction having a design which permits an elongated stroke.
Yet another object of the invention is to provide an improved oil filter crusher apparatus comprised of a minimum number of components and parts.
Yet another object of the invention is to provide an improved oil filter crusher apparatus which can easily collect and direct oil removed from a crushed oil filter to a central drain.
Yet another object of the invention is to provide an improved oil filter crusher apparatus wherein the oil filter can be easily and properly positioned within the apparatus to facilitate the crushing operation.
These and other objects, advantages and features of the invention will be set forth in the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWING
In the detailed description which follows, reference will be made to the drawing comprised of the following figures:
FIG. 1 is a front elevation view of the improved oil filter crusher apparatus of the invention positioned to receive a filter which is to be crushed;
FIG. 2 is a front elevation view illustrating the manner in which an oil filter is positioned within the apparatus of FIG. 1;
FIG. 3 is a front elevation view illustrating the initiation of the operation of the crusher of FIG. 1;
FIG. 4 is a front elevation view illustrating partial crushing of an oil filter in the crusher of FIG. 1;
FIG. 5 is a front elevation view after a cycle of operation of the apparatus of FIG. 1 is completed and also depicts further a crushed oil filter;
FIG. 6 is an exploded elevation of the component parts of the apparatus of FIG. 1;
FIG. 7 is a bottom plan view of the lower surface of the base member of the apparatus of FIG. 1;
FIG. 8 is a top plan view of the platform for supporting oil filter in the crusher apparatus of FIG. 1;
FIG. 9 is a front elevation of the platform of FIG. 8;
FIG. 10 is a plan view of the lower surface of the top or cover of the cylinder of the apparatus of FIG. 1;
FIG. 11 is a side elevation of the top cover illustrated in FIG. 10;
FIG. 12 is a top plan view of the piston of the cylinder of the apparatus of FIG. 1;
FIG. 13 is a section of the piston FIG. 12 taken along the line 13--13; and
FIG. 14 is an enlarged cut away section view of a safety interlock feature.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-6, there is illustrated the improved oil filter crusher apparatus of the present invention. Generally, the apparatus comprises a cylinder 20 which includes a lower cylinder head or base plate 22, a top cylinder head, dome or cover 24 spaced from the base plate 22, a cylinder or tube 26 which defines the cylinder assembly in combination with the base plate 22 and dome or cover 24, and a series of spaced tie rods 28 about the periphery of the tube 26 for connecting the base plate 22 to the dome 24. Attached to the lower side of the base plate 22 is a housing 30 having a sliding door 32. The housing 30 has a floor and encloses the region or space beneath the base plate 22. As shown in FIG. 6, a horizontal platform or ram 34 which is attached to two spaced rods or support members 36 is positioned beneath the base plate 22. The rods 36 slidably project upwardly through congruent passages 38 in the base plate 22 and are rigidly connected to a piston 40 by means of bolts 42. Similarly, the rods 36 are affixed by means of bolts 44 to the platform or filter support member 34.
A manifold or control valve 46 with a control button 48 is also attached to the base member 22 and interfaces with fluid flow channels (not shown) milled or drilled in the base 22. Valve 46 controls connection of pressurized air from an inlet or fitting 49 to either the region 50 beneath the piston 40 or the region 52 above the piston 40. Thus, the manifold or valve 46 will provide for air flow or pressurized air flow through plate or member 22 into region 50 to drive the piston 40 and thus the platform 34 vertically upward. Alternatively, the control valve 46 will connect through the base plate 22 to a line 54 that connects to a passage (not shown) in the dome or cover 24 and thence to the region 52 above the piston 40.
In operation, when the button 48 is depressed, pressurized air flow is directed to the region 50. Then the piston 40 is driven vertically upward the maximum stroke. The button 48 may then be released and a spring return on a valve member (not shown) associated with the button 48 causes the valve 46 to return to an unactivated position to direct flow through the line 54 and thence region 52. This causes the platform 34 to respond to movement of the piston 40 downward thereby returning the platform 34 to its original down position.
Positioned within the housing 30 at the mid point of the floor or base in the preferred embodiment is a drain 60. As can be seen by reference to FIGS. 1 through 5 the drain 60 permits the draining of oil from the housing 30 into some type of container 61 for purposes of collection.
The access door or sliding door 32 is preferably made from a clear acrylic or plastic material. Additionally, the door 32 optionally interlocks with button control 48 and valve 46. That is, the button 48 is precluded from inward movement unless the door 32 is in the fully closed position. This arrangement insures that the button 48 is in the extended position so that the piston 40 and platform are in the pressurized down position and cannot be otherwise operated unless the door 32 is closed.
One method of such interlocking arrangement is depicted by reference to FIG. 6. The upper edge 33 of door 32 coacts with the underside of button 48 preventing button 48 from being depressed unless the door 32 is closed so that the edge 33 is out of engagement with button 48. Further, as shown in FIG. 14, as button 48 is depressed to permit pressurized air to flow into reservoir or region 50, the pressurized air also actuates a plunger 35 positioned in a passage 37 in plate 22. Note passage 37 extends through plate 22 from reservoir 50, and that the pressurized air to the reservoir 50 is provided through fitting 49 and drilled passageway in plate 22. Plunger 35 is sealed to the wall of passage 37 by an O-ring seal 43 and is normally spring biased by spring 39 into a retracted position as shown in FIG. 14 against a retainer collar 45. A retainer plug 41 coacts with spring 39 to bias plunger 39 and to retain plunger 39 in passage 37. Upon air actuation, however, the plunger 35 extends (as shown in phantom) into the trackway for door 32, preventing door 32 from movement to the open position. The plunger 35 remains extended until the pressure in reservoir 50 is reduced to ambient pressure which occurs only when the piston 40 is returned to its full lowered position. The interlock associated with the plunger 35 is in addition to and independent of the mechanical interlock associated with button 48 and door edge 33. Thus the interlock associated with edge 33 may be omitted as may that associated with plunger 35. However, a safety interlock is preferred.
The rods 36 are sealed with respect to the base plate 22 by means of O-ring seals 62. The platform 34 includes a projecting center pin 64 which cooperates with and is designed to engage the center port of an oil filter so as to appropriately align the oil filter on the platform 34. As illustrated in FIGS. 8 and 9, the platform includes a plurality of generally radially extending drain slots 66, 68 and 70 which permit oil that is driven from a crushed oil filter to flow into the housing 30 and thence into the drain 60.
In operation, the rods 36 are equally radially spaced from the center point of the platform 34 which is generally congruent with the pin 64. The rods 36 are also equally spaced from one another. In the embodiment shown, only two rods 36 are depicted as being utilized. The symmetrical arrangement of the rods 36 prevents binding of the apparatus during its operation. More than two rods may be utilized. It is preferred, however, that the arrangement of the rods 36 remain symmetrical.
As another important feature of the invention, the base plate 22 serves a multiplicity of purposes. First, it acts as the lower head of the cylinder 20. Second, it provides the passageways for directing air flow into the region 50 and, in part, the region 52. Thirdly, it defines an anvil 70 and more particularly, a shaped anvil surface 72 which enhances the crushing operation for an oil filter. As depicted in FIG. 7, the anvil surface 72 is comprised of a plurality of radially extending ribs 74 which are equally spaced about the center point of the anvil 70. The ribs 74 are spaced from the center point and extend radially outward therefrom.
Another important feature of the invention is the construction of the cover or dome 24 in conjunction with the configuration of the piston 40. That is the dome 24 as illustrated in FIGS. 10 and 11 includes an inner concave surface 80 with a cross rib 82 that connects the opposite diametrical sides of the surface 80 to enhance the structural integrity of the dome or cover 24. The top surface of the piston 40 is compatible therewith as illustrated in FIGS. 12 and 13. The piston 40 thus includes a groove 88 which is cooperative with the rib 82 or in other words receives the rib 82. This particular construction enables the piston 40 to fit completely into the cover or dome 24 thereby enhancing the length of the stroke of the piston 40. Of course the bolts 42 are positioned in counterbores in the cover 40 thereby further enhancing clearance for movement of the piston 40.
FIGS. 1 through 5 illustrate the sequence of operation of the crusher apparatus shown in FIG. 1, the apparatus is in a rest position. An air line 51 is attached to hose fitting 49. With the platform 34 in the lowered position, it is possible to open the door 32 for access to the interior of housing 30 for insertion of a filter to be crushed. Because door 32 is open, it is not possible to depress the button 48 to activate the air flow into the region 50. Door handle 31 limits sliding movement of the door 31 to the open position as shown in FIG. 2. Note that the dome or crown of the oil filter is extended upwardly and the oil filter centerport is centered on pin 64.
Next referring to FIG. 3, the access door 32 is closed and the button 48 is depressed. This initiates upward movement of the platform 34 as illustrated in FIG. 4. Note, it is necessary to maintain manual pressure on the button 48 for continued pressurized air flow to region 50 and operation and movement of the platform 34.
After the oil filter is fully crushed, the button 48 is released. This automatically causes the valve 48 to direct return air to the region 52 thereby moving the platform 34 vertically downward as depicted in FIG. 5. The access door 32 may then be opened for removal of the crushed filter. Oil has, in the interim, drained down the drain slots 66, 68, 70 into the drain 60 of the housing 30. Note that with the invention, by providing upward movement of the oil filter as it is being crushed, oil may be more easily drained and observed draining into the housing 30 for free flow out of the drain 60.
In the foregoing description, there has been described a single embodiment of the invention. However, numerous changes or alterations may be made to the described structure. Thus, other alternative embodiments of the invention are considered to be within the scope of the invention. Among the features which are considered important are the upward movement of the platform 34 during the crushing operation, the construction of the anvil 72 and the platform 34 and the construction of the base member 22 in combination with the cylinder tube 26 and cover 24. These particular elements may be altered in configuration and shape and to some extent, may be juxtaposed. The invention is therefore to be limited by the following claims and equivalents. | An improved oil filter crusher, includes a cylinder positioned over a movable platform. Upon initiation of operation of the crusher, the platform moves upwardly toward a base member of the cylinder to crush the oil filter and discharge oil therefrom. | 8 |
The present application is the national phase of International Application No. PCT/CN2012/071203, titled “HYDRAULIC CONTROL VALVE, DUAL-CYLINDER EXTENSION SYSTEM AND AERIAL WORK ENGINEERING MACHINE,” filed on Feb. 16, 2012, which claims the benefit of priority to Chinese Patent Application No. 201110286496.X, titled “HYDRAULIC CONTROL VALVE, DUAL-CYLINDER TELESCOPIC SYSTEM AND AERIAL WORK ENGINEERING MACHINE,” filed with the Chinese State Intellectual Property Office on Sep. 23, 2011, both of which applications are herein incorporated by reference in their entireties.
TECHNICAL FIELD
The present application relates to the technical field of engineering machines, and particularly to a dual-cylinder telescopic control valve of an aerial work engineering machine having a dual-cylinder telescopic system. The present application further relates to a dual-cylinder telescopic system having the control valve and an aerial work engineering machine having the control valve.
BACKGROUND
An aerial work engineering machine, such as an elevating fire engine, is a product having a specialized chassis and mounted with a lifting arm frame, and may be operated by a professional operator to rise to a certain height for aerial rescuing or working.
The lifting arm frame may be divided into several types according to the lifting operation manner, such as a folding arm type, a telescopic arm type, a combined arm type and a self-propelled type. The telescopic arm is formed by two or more sections of box-shaped arms sleeved together, and may be driven by a telescopic cylinder or pulled by a flexible wire rope or a leaf chain to make linear reciprocating motion, and may transport an aerial operator to a higher place for working via a bucket mounted on a head of the telescopic arm.
For example, a fire water cannon is arranged at a top end of the telescopic arm of the elevating fire truck, and mechanisms, such as a working platform, is arranged at the top end of the telescopic arm of the aerial work platform. The operator can control the telescopic arm on the controlling platform to realize aerial work functions, such as spraying water, transporting working personnel, or rescuing.
With the rapid development of the social economy of China, the number of high-rise and super-high-rise buildings is growing rapidly, resulting in unprecedented tremendous challenges in fire extinction and emergency rescue of the high-rise buildings. In China, the development of the elevating fire truck has a tendency of pursuing a higher and higher working altitude, and at the same time, the high-altitude and super-high-altitude elevating fire trucks has higher requirements on the performances of the telescopic system, such as safety, reliability and smoothness.
The telescopic arm of the high-working-altitude elevating fire truck has a long stroke and has large numbers of sections, thus a single-cylinder and multi-stage telescopic-chain-type synchronous telescopic control system has been unable to meet the requirements for safety and stability. And for a telescopic system having two or more telescopic cylinders, the telescopic cylinders have to be controlled synchronously so as to reach the maximum working height in the shortest action time to perform the rescue operation quickly.
None of the existing elevating fire trucks using a dual-cylinder telescopic system are provided with a synchronous control valve, and the motion of the telescopic cylinders is controlled directly by a solenoid directional valve group.
Reference is made to FIG. 1 , which is a hydraulic schematic diagram of the solenoid directional valve group of the existing dual-cylinder telescopic system.
As shown in the Figure, an upper telescopic cylinder 1 is controlled by a first solenoid directional valve 3 - 1 , and a lower telescopic cylinder 2 is controlled by a second solenoid directional valve 3 - 2 . A solenoid directional valve group 3 is formed by the first solenoid directional valve 3 - 1 and the second solenoid directional valve 3 - 2 , and has oil ports A 1 and B 1 connected to a larger chamber and a smaller chamber of the upper telescopic cylinder 1 respectively, and oil ports A 2 and B 2 connected to a larger chamber and a smaller chamber of the lower telescopic cylinder 2 respectively. Theoretically, the upper telescopic cylinder 1 and the lower telescopic cylinder 2 can be controlled to extend or retract synchronously as long as the first solenoid directional valve 3 - 1 and the second solenoid directional valve 3 - 2 are synchronously switched to the left position or the right position.
However in fact, since the load on the lower telescopic cylinder 2 is much larger than the load on the upper telescopic cylinder 1 , the extending and retracting motion of the two cylinders may have two circumstances. Taking the extending motion as an example, if the system flow is large enough, the two cylinders may extend synchronously, but the upper telescopic cylinder 1 will have an extending speed faster than the lower telescopic cylinder 2 and will reach the end of the stroke earlier. In contrast, if the system flow is small, the pressure oil will firstly push the upper telescopic cylinder 1 with a smaller load to extend via the directional valve, and after the upper telescopic cylinder 1 reaches the end, the system pressure increases, and then the pressure oil will continue to push the lower telescopic cylinder 2 to extend till the lower telescopic cylinder 2 reaches the end.
This kind of control systems have disadvantages that, the synchronous extension and retraction of the two cylinders can not be realized, and the two telescopic cylinders are controlled separately to extend to the end of the stroke in sequence, which may cause an overlong action time of the telescopic system, and further affect efficiencies of rescue operation and work.
Therefore, a technical problem to be solved by those skilled in the art is to control two cylinders of the dual-cylinder telescopic system to extend and retract synchronously so as to shorten the action time of the telescopic system and improve the working efficiency.
SUMMARY
The present application provides a hydraulic control valve, which may control two cylinders of a dual-cylinder telescopic system to extend and retract synchronously so as to shorten the action time of the telescopic system and improve the working efficiency.
The present application further provides a dual-cylinder telescopic system having the hydraulic control valve.
The present application further provides an aerial work engineering machine having the hydraulic control valve.
A hydraulic control valve according to the present application includes a flow divider and combiner, wherein
a valve body of the hydraulic control valve has a first oil port, a second oil port and a third oil port;
the flow divider and combiner has a first oil port, a second oil port and a third oil port which are respectively communicated with the first oil port, the second oil port and the third oil port of the valve body; and
the control valve has a first operating state and a second operating state:
in the first operating state, an oil path between the second oil port and the third oil port of the valve body is blocked; and in the second operating state, the oil path between the second oil port and the third oil port of the valve body is opened.
Preferably, the valve body of the control valve has a fourth oil port, and the control valve has a third operating state and a fourth operating state:
in the third operating state, the third oil port and the fourth oil port of the valve body are communicated with each other; and
in the fourth operating state, the second oil port and the fourth oil port of the valve body are communicated with each other.
Preferably, the valve body has a directional valve and a stop valve;
in the second operating state, the oil path between the second oil port and the third oil port of the valve body is opened via the directional valve; in the third operating state, the third oil port and the fourth oil port of the valve body are communicated with each other via the directional valve; and in the fourth operating state, the second oil port and the fourth oil port of the valve body are communicated with each other via the stop valve.
Preferably, the directional valve has a first oil port, a second oil port and a third oil port which are respectively communicated with the fourth oil port, the second oil port and the third oil port of the valve body; and
the directional valve has first, second and third operating positions: in the first operating position, each of the first oil port, the second oil port and the third oil port of the directional valve is closed; in the second operating position, the first oil port of the directional valve is closed, and the second oil port and the third oil port of the directional valve are communicated with each other; and in the third operating position, the second oil port of the directional valve is closed, and the first oil port and the third oil port of the directional valve are communicated with each other.
Preferably, the directional valve is a three-position three-way solenoid directional valve.
Preferably, the directional valve has a first oil port, a second oil port and a third oil port, which are respectively communicated with the fourth oil port, the second oil port and the third oil port of the valve body, and a closed fourth oil port; and
the directional valve has first, second and third operating positions: in the first operating position, each of the first oil port, the second oil port, the third oil port and the fourth oil port of the directional valve is closed; in the second operating position, the first oil port and the fourth oil port of the directional valve are communicated with each other, and the second oil port and the third oil port of the directional valve are communicated with each other; and in the third operating position, the first oil port and the third oil port of the directional valve are communicated with each other, and the second oil port and the fourth oil port of the directional valve are communicated with each other.
Preferably, the directional valve is a three-position four-way solenoid directional valve.
The present application further provides a dual-cylinder telescopic system, including an upper telescopic cylinder and a lower telescopic cylinder, and further including the hydraulic control valve described above, wherein a valve body of the hydraulic control valve has a first oil port acting as a control oil port, and a second oil port and a third oil port which are respectively communicated with rodless chambers of the upper telescopic cylinder and the lower telescopic cylinder.
The present application further provides an aerial work engineering machine, including a chassis, a lift arm, an upper telescopic cylinder and a lower telescopic cylinder, and further including the hydraulic control valve described above, wherein a valve body of the hydraulic control valve has a first oil port acting as a control oil port, and a second oil port and a third oil port which are respectively communicated with rodless chambers of the upper telescopic cylinder and the lower telescopic cylinder.
Preferably, the aerial work engineering machine is an elevating fire truck or an aerial work platform.
The hydraulic control valve according to the present application includes a flow divider and combiner, wherein a valve body of the hydraulic control valve has a first oil port, a second oil port and a third oil port; the flow divider and combiner has a first oil port, a second oil port and a third oil port which are respectively communicated with the first oil port, the second oil port and the third oil port of the valve body; and the control valve has a first operating state and a second operating state: in the first operating state, an oil path between the second oil port and the third oil port of the valve body is blocked;
and in the second operating state, the oil path between the second oil port and the third oil port of the valve body is opened.
The control valve has a simple structure, good stability and high safety. In operation, the first oil port of the valve body of the control valve acts as a control oil port, and the second oil port and the third oil port thereof are respectively communicated with rodless chambers of the upper telescopic cylinder and the lower telescopic cylinder of the dual-cylinder telescopic system.
When the upper telescopic cylinder and the lower telescopic cylinder extend or retract, the control valve is in the first operating state, i.e., the oil path between the second oil port and the third oil port of the valve body is blocked, and the flow divider and combiner in the control valve can keep the flow inputted into (or outputted from) the second oil port equal to the flow inputted into (or outputted from) the third oil port without considering errors and other external interference factors, thus the two telescopic cylinders may be driven to extend or retract synchronously so as to enable the telescopic system to complete the extension or retraction in the shortest time, thereby greatly improving the working efficiency.
When the two cylinders can not extend to the end or retract to the starting point synchronously due to various flow error factors such as load difference, error of the flow divider and combiner, the control valve is in the second operating state, wherein the oil path between the second oil port and the third oil port of the valve body is opened, such that the lag telescopic cylinder may extend to the end of the stroke or retract to the starting point quickly, thereby ensuring that each of the telescopic cylinders may move in place accurately.
In an embodiment, the valve body of the control valve has a fourth oil port, and the control valve has a third operating state and a fourth operating state: in the third operating state, the third oil port and the fourth oil port of the valve body are communicated with each other; and in the fourth operating state, the second oil port and the fourth oil port of the valve body are communicated with each other.
The fourth oil port of the valve body acts as an oil returning port, and the second oil port or the third oil port of the valve body is communicated with the oil returning circuit so as to separately supply oil for the upper telescopic cylinder and the lower telescopic cylinder, thereby controlling the telescopic cylinders to extend or retract separately. In this way, the control valve has functions for controlling the two cylinders to extend or retract synchronously and controlling the two cylinders to extend or retract separately, which may meet the requirements for various operating conditions, such as vehicle debugging, fault diagnosis, or single cylinder stress calculation.
The dual-cylinder telescopic system and the aerial work engineering machine according to the present application are both provided with the hydraulic control valve described above. Since the hydraulic control valve has the above technical effects, the dual-cylinder telescopic system and the aerial work engineering machine with the hydraulic control valve also have the corresponding technical effects.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a hydraulic schematic diagram of a solenoid directional valve group of an existing dual-cylinder telescopic system;
FIG. 2 is a hydraulic schematic diagram of a hydraulic control valve according to a first embodiment of the present application;
FIG. 3 is a hydraulic schematic diagram of a hydraulic control valve according to a second embodiment of the present application;
FIG. 4 is a hydraulic schematic diagram of a hydraulic control valve according to a third embodiment of the present application;
FIG. 5 is a hydraulic schematic diagram of a hydraulic control valve according to a fourth embodiment of the present application;
FIG. 6 is a hydraulic schematic diagram of a hydraulic control valve according to a fifth embodiment of the present application;
FIG. 7 is a hydraulic schematic diagram of a hydraulic control valve according to a sixth embodiment of the present application; and
FIG. 8 is a hydraulic schematic diagram of the hydraulic control valve in FIG. 6 being connected to an upper telescopic cylinder and a lower telescopic cylinder of a dual-cylinder telescopic system.
Reference numerals in FIG. 1 :
1
upper telescopic cylinder,
2
lower telescopic cylinder,
3
solenoid directional valve group,
3-1
first solenoid directional
3-2
second solenoid directional valve;
valve,
Reference numerals in FIGS. 2 to 8 :
10
valve body,
V
first oil port,
C1
second oil port,
C2
third oil port,
T
fourth oil port;
10-1
flow divider and combiner;
10-2
two-position two-way solenoid
directional valve;
10-3
three-position three-way
solenoid directional valve,
T
first oil port,
P
second oil port,
B
third oil port;
10-4
three-position four-way
solenoid directional valve,
T
first oil port,
P
second oil port,
B
third oil port,
A
fourth oil port;
10-5
first stop valve,
10-6
second stop valve,
10-7
third stop valve,
10-8
fourth stop valve;
20-1
upper telescopic cylinder, and
20-2
lower telescopic cylinder.
DETAILED DESCRIPTION
The present application provides a hydraulic control valve, which may control two cylinders of a dual-cylinder telescopic system to extend and retract synchronously so as to shorten the action time of the telescopic system and improve the working efficiency.
The present application further provides a dual-cylinder telescopic system having the hydraulic control valve, and an aerial work engineering machine having the hydraulic control valve.
For those skilled in the art to better understand technical solutions of the present application, the present application is described in detail in conjunction with drawings and embodiments hereinafter.
Reference is made to FIG. 2 , which is a hydraulic schematic diagram of a hydraulic control valve according to a first embodiment of the present application.
In the first embodiment, the hydraulic control valve according to the present application is a combination valve, which includes a flow divider and combiner 10 - 1 and a two-position two-way solenoid directional valve 10 - 2 , and a valve body 10 of the hydraulic control valve has a first oil port V, a second oil port C 1 and a third oil port C 2 . The flow divider and combiner 10 - 1 has a first oil port (i.e. an oil inlet), a second oil port and a third oil port which are respectively communicated with the first oil port V, the second oil port C 1 and the third oil port C 2 of the valve body 10 .
The control valve has a first operating state and a second operating state.
In the first operating state, an oil path between the second oil port C 1 and the third oil port C 2 of the valve body 10 is blocked.
In the second operating state, the oil path between the second oil port C 1 and the third oil port C 2 of the valve body 10 is opened via the two-position two-way solenoid directional valve 10 - 2 .
In operation, the first oil port V of the valve body 10 is a control oil port, and the second oil port C 1 and the third oil port C 2 communicate with rodless chambers of an upper telescopic cylinder and a lower telescopic cylinder of a dual-cylinder telescopic system, respectively. The operating process is as follows.
When the telescopic cylinders are required to extend, the hydraulic control valve is in the first operating state. The control oil port of the hydraulic system supplies oil to the first oil port V, and after being divided by the flow divider and combiner 10 - 1 in the valve body 10 , the oil enters into the two telescopic cylinders via the second oil port C 1 and the third oil port C 2 respectively, then the two telescopic cylinders extend. Here, the flow divider and combiner 10 - 1 has a flow dividing function for dividing the system flow into two equal parts, which are supplied to the two telescopic cylinders to drive the two cylinders to extend synchronously.
In actual process, the flows distributed to the two telescopic cylinders are not completely equal due to several factors, such as different forces applied on the two telescopic cylinders, uneven load frictions, the error of the flow divider and combiner. Thus, one of the telescopic cylinders will reach the end of the stroke firstly. Due to the construction features of the flow divider and combiner 10 - 1 , a build-up pressure of the hydraulic cylinder may be caused when one telescopic cylinder reaches the end of the stroke, then the pressure increases sharply, and the oil port (the second oil port C 1 or the third oil port C 2 ), through which the oil is supplied to a lag cylinder by the flow divider and combiner, will be sharply reduced or closed, thus the lag cylinder will stop action and can not fully extend. If such situation happens in an elevating fire truck, the arm of the elevating fire truck cannot reach the specified operating height.
At this time, the hydraulic control valve is in the second operating state. When one of the telescopic cylinders reaches the end of the stroke, the two-position two-way solenoid directional valve 10 - 2 is energized to connect the left position (i.e. ports P and A are connected), such that the second oil port C 1 and the third oil port C 2 of the flow divider and combiner 10 - 1 are communicated with each other and have equal pressures, and the second oil port C 1 and the third oil port C 2 return to the normal open state, and the flow from the flow divider and combiner 10 - 1 will be completely supplied to the lag cylinder to drive it to reach the end of the stroke quickly.
When the telescopic cylinders are required to retract, the hydraulic control valve is in the first operating state. The second oil port C 1 and the third oil port C 2 are oil returning ports, and after being combined by the flow divider and combiner 10 - 1 in the valve body, the oil flows back to the control oil port of the hydraulic system via the first oil port V, and the telescopic cylinders retract. Here, the flow divider and combiner 10 - 1 has a flow combining function for keeping the flows inputted in the second oil port C 1 and the third oil port C 2 equal, thereby driving the two cylinders to retract synchronously.
Similarly, in actual process, the flow rates of the oils flowing into the second oil port C 1 and the third oil port C 2 are not completely equal due to several factors, such as different forces applied on the two telescopic cylinders, uneven load frictions, the error of the flow divider and combiner. Thus, one of the telescopic cylinders will retract to the starting point of the stroke firstly, and at this time, an outlet pressure of the telescopic cylinder will be reduced to zero sharply, and the oil port (the second oil port C 1 or the third oil port C 2 ), through which the oil in the lag telescopic cylinder enters the flow divider and combiner 10 - 1 , will be sharply reduced or closed, thus the lag telescopic cylinder will stop action and can not fully retract. If the above situation happens to the elevating fire truck, the arm thereof cannot retract to the original position and the truck cannot return to the original state normally.
At this time, the hydraulic control valve is in the second operating state. When one of the telescopic cylinders returns to the starting point, the two-position two-way solenoid directional valve 10 - 2 is energized to connect the left position (i.e. ports P and A are connected), such that the pressures at the second oil port C 1 and the third oil port C 2 of the flow divider and combiner 10 - 1 are equal, and the second oil port C 1 and the third oil port C 2 may return to the normal open state, thus the oil in the telescopic cylinder, which is not fully retracted, will flow through both the second oil port C 1 and the third oil port C 2 and be combined in the first oil port V via the flow divider and combiner 10 - 1 to flow back, thus the telescopic cylinder, which is not fully retracted, may retract to the starting point of the stroke quickly.
Reference is made to FIG. 3 , which is a hydraulic schematic diagram of a hydraulic control valve according to a second embodiment of the present application.
Since the two-position two-way solenoid directional valve 10 - 2 in the hydraulic control valve of the first embodiment functions to open or close the second oil port C 1 and the third oil port C 2 (i.e. the second oil port and the third oil port of the flow divider and combiner) of the valve body, in the second embodiment, a first stop valve 10 - 5 is used to replace the two-position two-way solenoid directional valve 10 - 2 . The first stop valve 10 - 5 and the two-position two-way solenoid directional valve 10 - 2 have basically the same function of controlling the oil path, thus both can drive the two cylinders to extend or retract in place.
Reference is made to FIG. 4 , which is a hydraulic schematic diagram of a hydraulic control valve according to a third embodiment of the present application.
In the third embodiment, the control valve according to the present application is a combination valve, which includes a flow divider and combiner 10 - 1 , a second stop valve 10 - 6 and a three-position three-way solenoid directional valve 10 - 3 , and the valve body 10 of the control valve has a first oil port V, a second oil port C 1 , a third oil port C 2 and a fourth oil port T.
The flow divider and combiner 10 - 1 has a first oil port (i.e. an oil inlet), a second oil port and a third oil port which are respectively communicated with the first oil port V, the second oil port C 1 and the third oil port C 2 of the valve body.
The second stop valve 10 - 6 has two oil ports which are respectively communicated with the second oil port C 1 and the fourth oil port T of the valve body 10 .
The three-position three-way solenoid directional valve 10 - 3 has a first oil port T, a second oil port P and a third oil port B which are respectively communicated with the fourth oil port T, the second oil port C 1 and the third oil port C 2 of the valve body 10 .
The control valve has the following four operating states.
In a first operating state, the second stop valve 10 - 6 is disconnected, the three-position three-way solenoid directional valve 10 - 3 is in a middle position, and an oil path between the second oil port C 1 and the third oil port C 2 of the valve body 10 is blocked.
In a second operating state, the second stop valve 10 - 6 is disconnected, the three-position three-way solenoid directional valve 10 - 3 is in a left position, and the oil path between the second oil port C 1 and the third oil port C 2 of the valve body 10 is opened through the third oil port B and the second oil port P of the three-position three-way solenoid directional valve 10 - 3 .
In a third operating state, the second stop valve 10 - 6 is disconnected, the three-position three-way solenoid directional valve 10 - 3 is in a right position, the oil path between the second oil port C 1 and the third oil port C 2 of the valve body 10 is blocked, and the third oil port C 2 of the valve body 10 communicates with the fourth oil port T of the valve body 10 through the first oil port T and the third oil port B of the three-position three-way solenoid directional valve 10 - 3 .
In a fourth operating state, the second stop valve 10 - 6 is connected, the three-position three-way solenoid directional valve 10 - 3 is in the middle position, the oil path between the second oil port C 1 and the third oil port C 2 of the valve body 10 is blocked, and the second oil port C 1 of the valve body 10 communicates with the fourth oil port T of the valve body 10 through the second stop valve 10 - 6 .
In operation, the first oil port V of the valve body 10 is a control oil port, and the second oil port C 1 and the third oil port C 2 of the valve body 10 respectively communicate with rodless chambers of an upper telescopic cylinder and a lower telescopic cylinder of a dual-cylinder telescopic system. The operating process is as follows.
When the telescopic cylinders are required to extend, the hydraulic control valve is in the first operating state. The control oil port of the hydraulic system supplies oil to the first oil port V, and after being divided by the flow divider and combiner 10 - 1 in the valve body, the oil enters into the two telescopic cylinders via the second oil port C 1 and the third oil port C 2 respectively, thereby driving the two cylinders to extend synchronously.
When one of the telescopic cylinders reaches the end of the stroke, the hydraulic control valve is in the second operating state. At this time, the three-position three-way solenoid directional valve 10 - 3 is energized to connect the left position (i.e. ports P and B are connected), such that the second oil port and the third oil port of the flow divider and combiner 10 - 1 are communicated with each other and have equal pressures, and the second oil port and the third oil port return to the normal open state, thereby driving the lag telescopic cylinder to reach the end of the stroke quickly.
When the telescopic cylinders are required to retract, the hydraulic control valve is in the first operating state. The second oil port C 1 and the third oil port C 2 are oil returning ports, and after being combined by the flow divider and combiner 10 - 1 in the valve body 10 , the oil flows back to the control oil port of the hydraulic system via the first oil port V, thereby driving the two cylinders to retract synchronously.
When one of the telescopic cylinders returns to the starting point, the hydraulic control valve is in the second operating state. At this time, the three-position three-way solenoid directional valve 10 - 3 is energized to connect the left position, thus the second oil port and the third oil port of the flow divider and combiner 10 - 1 have equal pressures, and return to the normal open state, thereby driving the telescopic cylinder, which is not fully retracted, to retract to the starting point of the stroke quickly.
The two cylinders may be required to extend or retract separately for debugging, fault diagnosis, single cylinder stress calculation or other reasons. For example, when it needs to run an loaded experiment test or a stress test on the lower telescopic cylinder moving separately, the three-position three-way solenoid directional valve 10 - 3 in the hydraulic control valve is energized to connect the right position, then the first oil port T communicates with the third oil port B, and the pressure oil flowing from the third oil port of the flow divider and combiner 10 - 1 flows through the first oil port T and the third oil port B and flows back to an oil tank directly via the fourth oil port T of the valve body 10 , which is equivalent to short-circuit the upper telescopic cylinder in the hydraulic oil path, while the pressure oil flowing from the second oil port of the flow divider and combiner 10 - 1 still enters into the lower telescopic cylinder to push it to extend, thereby realizing the separate action of the lower telescopic cylinder.
When the upper telescopic cylinder is required to move separately, the second stop valve 10 - 6 in the hydraulic control valve is connected, and the three-position three-way solenoid directional valve 10 - 3 is de-energized. In this way, the pressure oil flowing from the second oil port of the flow divider and combiner 10 - 1 flows back to the oil tank directly via the second stop valve 10 - 6 , which is equivalent to short-circuit the lower telescopic cylinder in the hydraulic oil path, and the pressure oil flowing from the third oil port of the flow divider and combiner 10 - 1 still enters into the upper telescopic cylinder to push it to extend, thereby realizing the separate action of the upper telescopic cylinder.
Reference is made to FIG. 5 , which is a hydraulic schematic diagram of a hydraulic control valve according to a fourth embodiment of the present application.
Unlike the third embodiment, the directional valve in the hydraulic control valve according to the fourth embodiment of the present application is a three-position four-way solenoid directional valve 10 - 4 , which has a first oil port T, a second oil port P and a third oil port B respectively communicated with a fourth oil port T, a second oil port C 1 and a third oil port C 2 of the valve body 10 , and a closed fourth oil port A.
The three-position four-way solenoid directional valve 10 - 4 has the following three operating positions. In a first operating position, the first oil port T, the second oil port P, the third oil port B and the fourth oil port A are all closed; in a second operating position, the first oil port T communicates with the fourth oil port A, and the second oil port P communicates with the third oil port B; and in a third operating position, the first oil port T communicates with the third oil port B, and the second oil port P communicates with the fourth oil port A.
Other structures and operating principle of the fourth embodiment are substantially the same as that of the third embodiment, which will not be repeated herein for simplicity.
Reference is made to FIG. 6 , which is a hydraulic schematic diagram of a hydraulic control valve according to a fifth embodiment of the present application.
Since the directional valves of the third and fourth embodiments in the hydraulic control valve function to connect or disconnect the second oil port C 1 and the third oil port C 2 of the valve body 10 , and to connect or disconnect the third oil port C 2 and the fourth oil port T, a two-position two-way solenoid directional valve 10 - 2 and a third stop valve 10 - 7 can be used to replace the three-position three-way solenoid directional valve 10 - 3 or the three-position four-way solenoid directional valve 10 - 4 .
As shown in the Figure, two oil ports of the two-position two-way solenoid directional valve 10 - 2 communicate with the second oil port C 1 and the third oil port C 2 of the valve body 10 respectively, and two oil ports of the third stop valve 10 - 7 communicate with the third oil port C 2 and the fourth oil port T of the valve body 10 respectively, thereby also realizing objects of driving the two cylinders to extend or retract in place synchronously and driving the two cylinders to extend or retract separately.
The hydraulic control valve described above is only a preferable solution, and the specific structure thereof is not limited to this and can be adjusted according to actual requirements to obtain different embodiments. For example, the two-position two-way solenoid directional valve 10 - 2 of the fifth embodiment may be replaced by a fourth stop valve 10 - 8 (see FIG. 7 ).
Therefore, in order to make the hydraulic control valve to be in respective operating states accurately, the directional valve can be of various types, and the stop valve and the directional valve also have various combination manners in a hydraulic oil path, which will not be illustrated herein for simplicity since there are various implementations.
Reference is made to FIG. 8 , which is a hydraulic schematic diagram of the hydraulic control valve in FIG. 6 being connected to an upper telescopic cylinder and a lower telescopic cylinder of a dual-cylinder telescopic system.
The present application further provides a dual-cylinder telescopic system, including an upper telescopic cylinder 20 - 1 and a lower telescopic cylinder 20 - 2 , and further including the hydraulic control valve of the fifth embodiment. A valve body 10 of the hydraulic control valve has a first oil port V acting as a control oil port, a second oil port C 1 and a third oil port C 2 respectively communicated with rodless chambers of the upper telescopic cylinder 20 - 1 and the lower telescopic cylinder 20 - 2 , and a fourth oil port T acting as an oil returning port. Other structures of the dual-cylinder telescopic system may be referred to the prior art.
It is to be explained that, since each of the upper telescopic cylinder 20 - 1 and the lower telescopic cylinder 20 - 2 of the dual-cylinder telescopic system is a single-acting cylinder, the hydraulic control valve according to the present application is only arranged in the oil path of the rodless chamber thereof. If each of the upper telescopic cylinder 20 - 1 and the lower telescopic cylinder 20 - 2 is a double-acting cylinder, the hydraulic control valve can also be arranged in the oil path of the rod chamber thereof.
In addition to the hydraulic control valve and the dual-cylinder telescopic system described above, the present application further provides an aerial work engineering machine, which includes a chassis, a lift arm, an upper telescopic cylinder 20 - 1 and a lower telescopic cylinder 20 - 2 , and further includes the hydraulic control valve described above. A valve body 10 of the hydraulic control valve has a first oil port V acting as a control oil port, a second oil port C 1 and a third oil port C 2 respectively communicated with rodless chambers of the upper telescopic cylinder 20 - 1 and the lower telescopic cylinder 20 - 2 , and a fourth oil port T acting as an oil returning port. Other structures of the aerial work engineering machine may be referred to the prior art.
The aerial work engineering machine is an elevating fire truck or an aerial operation platform.
A hydraulic control valve, a dual-cylinder telescopic system and an aerial work engineering machine according to the present application are described in detail hereinbefore. The principle and the embodiments of the present application are illustrated herein by specific examples. The above description of examples is only intended to help the understanding of the concept of the present application. It should be noted that, for the person skilled in the art, many modifications and improvements may be made to the present application without departing from the principle of the present application, and these modifications and improvements are also deemed to fall into the protection scope of the present application defined by the claims. | A hydraulic control valve, a dual-cylinder extension system and an aerial work engineering machine. The control valve comprises a flow distributing and collecting valve, and control valve body is provided with a first oil opening, a second oil opening and a third oil opening. A first oil opening, a second oil opening and a third oil opening of said flow distributing and collecting valve are respectively communicated with the first oil opening, the second oil opening and the third oil opening of the valve body. The control valve has two working states, wherein, in the first working state, the oil path between the second oil opening and the third oil opening of the valve body is blocked; and in the second working state, the oil path between the second oil opening and the third oil opening of the valve body is opened. | 5 |
BACKGROUND OF THE INVENTION
The subject matter disclosed herein relates to a patient monitoring system with a health status indicator.
Multi-patient displays enable a single technician to generally simultaneously monitor a plurality of patients. Multi-patient displays are commonly implemented in centralized patient monitoring systems wherein a plurality of technicians collectively monitor a large number of patients from a single location, and in hallway display systems wherein patient data pertaining to a plurality of different patients is visually conveyed in a hospital hallway.
Some conventional multi-patient displays are configured to enable a single technician to monitor as many as 96 patients. One problem with such conventional multi-patient displays is that it can be difficult to efficiently evaluate all the displayed information and identify those specific patients requiring attention.
BRIEF DESCRIPTION OF THE INVENTION
The above-mentioned shortcomings, disadvantages and problems are addressed herein which will be understood by reading and understanding the following specification.
In an embodiment, a system includes a computer adapted to assess the health of a patient, and to generate a health status indicator for the patient. The health status indicator comprising a visual gradient adapted to visually convey the assessed health of the patient. The system also includes a display operatively connected to the computer. The display is configured to display the health status indicator comprising the visual gradient.
In another embodiment, a patient monitoring system includes a computer adapted to generate a health status indicator for each of a plurality of patients. The health status indicator includes a color gradient configured to visually convey a patient health assessment with a variable range of color saturation and/or intensity. The patient monitoring system also includes a multi-patient display operatively connected to the computer. The multi-patient display is configured to generally simultaneously display the health status indicator for each of the patients.
In another embodiment, a method includes obtaining patient data from each of a plurality of patients. The method also includes implementing a computer to assess the health of each of the patients based on the patient data, and to generate a health status indicator for each of the patients. The health status indicator is configured to visually convey the health assessment with a variable range of color saturation and/or intensity. The method also includes generally simultaneously displaying the health status indicator for each of the patients.
Various other features, objects, and advantages of the invention will be made apparent to those skilled in the art from the accompanying drawings and detailed description thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic representation of a centralized patient monitoring system in accordance with an embodiment; and
FIG. 2 is a schematic representation of a multi-patient display of the centralized patient monitoring system of FIG. 1 in accordance with an embodiment.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration specific embodiments that may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments, and it is to be understood that other embodiments may be utilized and that logical, mechanical, electrical and other changes may be made without departing from the scope of the embodiments. The following detailed description is, therefore, not to be taken as limiting the scope of the invention.
Referring to FIG. 1 , a patient monitoring system 10 is shown in accordance with one embodiment. The patient monitoring system 10 includes a computer 12 and a display 14 . The patient monitoring system 10 will hereinafter be described in accordance with an embodiment as a centralized patient monitoring system 10 adapted to enable a single technician 16 to generally simultaneously monitor a plurality of patients 18 a - 18 n , however, it should be appreciated that other monitoring systems may be envisioned. Similarly, the display 14 will hereinafter be described in accordance with an embodiment as a multi-patient display 14 , however, other display types may also be envisioned. According to one alternate embodiment, the display 14 may comprise a single-patient display.
The computer 12 is connected to a plurality of discrete patient monitoring systems 20 a - 20 n . The discrete patient monitoring systems 20 a - 20 n are each configured to monitor one of the patients 18 a - 18 n , to generate patient data based on the specific characteristics being monitored, and to transmit the patient data to the computer 12 . In a non-limiting manner, the discrete patient monitoring systems 20 a - 20 n may each comprise an electrocardiograph, a blood pressure monitor, a thermometer, and/or a pulse oximeter. Correspondingly, the patient data generated by the patient monitoring systems 20 a - 20 n may comprise electrocardiogram (ECG) data, blood pressure data, temperature data, and/or pulse data.
The computer 12 is configured to evaluate the patient data from the patient monitoring systems 20 a - 20 n in order assess each patient's health. In a non-limiting manner, the computer 12 may be configured to assess patient health by analyzing the magnitude of the patient data and/or the data's rate of change. As an example, heart rate data falling below a first predetermined value may indicate moderate patient health and the need for attention in the near future, whereas heart rata data falling below a second predetermined value may indicate poor patient health and the need for immediate attention.
The computer 12 is also configured to generate a user interface for each monitored patient. According to one embodiment, each user interfaces comprises raw patient data and a visual health status indicator. A plurality of exemplary user interfaces 100 - 130 and health status indicators 132 - 138 are shown in FIG. 2 . As will be described in more detail hereinafter, each health status indicator may be implemented to visually convey a wide range of patient health assessments such as, for example, the range extending from very good health to critically poor health.
The multi-patient display 14 is connected to the computer 12 , and is configured to visually convey a user interface for each of a plurality of different patients. According to the embodiment depicted in FIG. 2 , the multi-patient display 14 is partitioned into sixteen distinct regions that are each adapted to visually convey a different user interface such that the technician 16 can generally simultaneously monitor sixteen different patients with a single display. It should, however, be appreciated that alternate multi-patient display configurations may be envisioned.
Having described the operation of the centralized patient monitoring system 10 to assess patient health, the implementation of the multi-patient display 14 to visually convey such information will now be described in detail. Referring to FIG. 2 , the multi-patient display 14 is shown in accordance with an embodiment. The multi-patient display 14 is configured to generally simultaneously display sixteen user interfaces 100 - 130 based on input from the computer 12 . According to one embodiment, each user interface comprises raw patient data (not shown) and a visual health status indicator (e.g., status indicators 132 - 138 ). The raw patient data is generally provided to enable a more detailed analysis of each patient. The visual health status indicator is configured to enable an observer to quickly assess patient health from a more remote location than would otherwise be possible. The following will describe several different visual health status indicator embodiments in more detail.
The health status indicators 132 - 138 implement a color gradient adapted to convey patient health with a variable degree of color hue, saturation or intensity. For purposes of this disclosure, a color gradient should be defined as a spectrum or range of one or more colors. As an example, a red gradient may comprise a range extending from pure black (the complete absence of color) to bright red. Also for purposes of this disclosure, the term hue refers to a pure color (e.g., red, yellow, green, blue, etc.), the term saturation refers the level of color purity with respect to white, and the term intensity refers to the level of color purity with respect to black.
It should be appreciated that each color gradient may comprise numerous visually distinct degrees of saturation or intensity such that a correspondingly large range of patient health assessments (e.g., including but not limited to good health, moderate health, poor health and critical health) can be visually conveyed. It should also be appreciated that the color gradient enables a technician to quickly identify the patients in need of immediate attention, and to do so from a greater distance than would otherwise be possible.
For illustrative purposes, a more intense color is graphically depicted in FIG. 2 with a greater degree of stipple density. Accordingly, the health status indicator 132 without any stippling represents the absence of color (i.e., black), and the health status indicator 134 with a minimal range of stippling density represents a minimal range of color intensity. Similarly, the health status indicator 136 with a moderate range of stippling density represents a moderate range of color intensity, and the health status indicator 138 with the widest range of stippling density represents the maximum range of color intensity.
According to one embodiment, the color gradients may implement a single color hue to visually convey information pertaining to a given patient's health. As an example, the color gradients 132 may represent the absence of coloration in order to convey the fact that the monitored patients are in good health. Similarly, the color gradient 134 may represent a minimal color range from no intensity (i.e., black) to a red with very little intensity (i.e., dark red) adapted to convey moderate patient health. The color gradient 136 may represent a moderate color range from no intensity (i.e., black) to a mid range intensity red coloration adapted to convey poor patient health, and the color gradient 138 may represent the widest range of red coloration from no intensity (i.e., black) to high intensity red (i.e., bright red) adapted to convey critical patient health requiring immediate attention.
According to another embodiment, the color gradients may implement multiple color hues in order to convey both a patient health assessment and the specific type of patient data on which the health assessment is based. As an example, the color gradients 132 - 138 may implement varying degrees of red saturation or intensity to convey a patient health assessment based on heard rate, and varying degrees of blue saturation or intensity to convey a patient health assessment based on blood pressure.
Alternatively, the previously described color gradient may be replaced by or implemented in combination with other visual gradients such as a contrast gradient or an illumination gradient. As an example, a black and white display may implement a gray scale gradient with a variable degree of contrast or illumination to convey a patient health assessment. These alternative visual gradients may, for example, be implemented to ensure that colorblind technicians are able to readily and conveniently identify patient health.
According to another embodiment, the health status indicators 132 - 138 implement a visual gradient adapted to convey patient health based on shape and/or relative size. As an example, the health status indicator 134 covering only a relatively small percentage of the user interface 102 may represent moderate patient health. Similarly, the health status indicator 136 covering an intermediate percentage of the user interface 112 may represent poor patient health, and the health status indicator 138 covering a relatively large percentage of the user interface 128 may represent critical patient health requiring immediate attention.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention 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 if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. | A patient monitoring system is disclosed herein. The patient monitoring system includes a computer adapted to assess the health of a patient, and to generate a health status indicator for the patient. The health status indicator comprising a visual gradient adapted to visually convey the assessed health of the patient. The system also includes a display operatively connected to the computer. The display is configured to display the health status indicator comprising the visual gradient. | 6 |
[0001] This application claims the benefit of the Korean Application Nos. P2003-0017195 filed on Mar. 19, 2003, and P2003-0018449 filed on Mar. 25, 2003, which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to microwave ovens, and more particularly, to a door assembly for a microwave oven, having an improved structure.
[0004] 2. Background of the Related Art
[0005] In general, the microwave oven (MWO) cooks food with intermolecular friction heat generated when molecular array of food is disturbed by a high frequency wave (approx. 2,450 MHz).
[0006] [0006]FIG. 1 illustrates a perspective view of a related art microwave oven.
[0007] Referring to FIG. 1, the related art microwave oven is provided with a body 10 , an inner case 20 , and an outfit chamber.
[0008] The body 10 is provided with a front case 11 , an outer case 12 , and a frame 13 . The inner case 20 is provided inside of the body 10 for holding the food therein. The front case 11 is in a front part of the microwave oven, with a door 14 at one side thereof for opening/closing a front part of the inner case 20 . The outer case 12 covers top and side surfaces of the microwave oven, with front edges thereof fastened to the front case 11 .
[0009] The frame 13 covers a bottom and rear surfaces of the body 10 , to protect the inner case 20 and the outfit chamber 30 from an external environment together with the outer case 12 and the front case 11 .
[0010] In the meantime, the outfit chamber is formed on a side of the inner case 20 for providing various electric components thereto, including a magnetron 31 , a high voltage transformer 32 , and a fan 33 .
[0011] The magnetron 31 provides a microwave to an inside of the inner case 20 for heating food. The high voltage transformer 32 provides a high voltage power to the magnetron 31 . The fan 33 blows air into an inside of the body 10 , for cooling various electric components.
[0012] In the meantime, there are brackets 15 fixed to a front surface of the frame 13 , and the door 14 rotatably fixed to the brackets 15 opens/closes a front surface of the inner case 20 . As described later, when the door 14 is closing, a latch on a door panel 141 pushes a lever on a latch board in the body 10 , to operate a switch.
[0013] [0013]FIG. 2 illustrates a side view of a latch board in a related art microwave oven, and FIG. 3 illustrates a diagram showing operation of an actuator ‘A’ of a switch ‘S’ when the latch 142 of the door is inserted into a latch board 101 . The frame 13 is on a front surface of the inner case 20 , and the latch board 101 is on the frame 13 .
[0014] The latch board 101 has three levers L 1 , L 2 , and L 3 , and 3˜5 switches ‘S’ fitted therein. The switches ‘S’ include a first safety switch S 1 , a second safety switch S 2 , and a monitor switch S 3 .
[0015] Referring to FIG. 2, the first safety switch ‘S 1 ’ is in a lower part of the latch board 101 , the monitor switch ‘S 3 ’ is in a central part, and the second safety switch ‘S 2 ’ in an upper part. Each of the switches ‘S’ is fastened to the latch board 101 with two fastening pins ‘P’ and a hook ‘H’.
[0016] There are two holes 102 in a diagonal direction of each of the switches ‘S’. After the fastening pins ‘P’ are aligned with the holes 102 , the switches ‘S’ are pressed down, to insert the switch ‘S’ into the hook ‘H’ and fasten the switch ‘S’.
[0017] A related art door latch structure will be described.
[0018] Referring to FIG. 2, there are latch inlets 103 in a front part of the latch board 101 for inserting the latch 142 a . An upper latch inlet 103 has a sloped surface 104 for guiding an upper latch 142 a to upward.
[0019] Referring to FIG. 3, the upper latch 142 is engaged with one end of the first lever L 1 as the upper latch 142 a moves up along the sloped surface 104 and drops at an end of the sloped surface 104 . In this instance, the upper latch 142 a pushes the first lever L 1 .
[0020] In the meantime, a lower latch 142 b is inserted into a lower latch inlet 103 . In this instance, the lower latch 142 b pushes both one end of the second lever L 2 and one end of the third lever L 3 below the second lever L 2 .
[0021] In this instance, other end of the first lever L 1 pushes an actuator A 2 of the second safety switch S 2 , and the second lever L 2 and the third lever L 3 push the monitor switch S 3 and actuators A 1 and A 3 of the first safety switch S 1 , respectively.
[0022] According to this, the first lever L 1 operates the second safety switch S 2 , the second lever L 2 operates the monitor switch S 3 , and the third lever L 3 operates the first safety switch S 1 .
[0023] In the meantime, when the door is opened, a door handle is operated, to lift the latches 142 a upward, so that the latches 142 are pulled out of the latch inlets 103 . Thereafter, as the levers L, respectively turned by the latches 142 , are restored by the springs 107 respectively, the actuators ‘A’ on the switches ‘S’ are released, respectively.
[0024] A related art assembly structure of the door will be described. FIG. 4 illustrates fitting of the pin to the related art door, and FIG. 5 illustrates fastening of the pin.
[0025] Referring to FIG. 4, there are horizontal members 50 on an upper part and a lower part of an inside of the door 14 . The horizontal member 50 is extended form an edge of the door 14 . The horizontal member 50 has a pin 55 fastened thereto for serving as a rotation shaft of the door 14 .
[0026] Referring to FIG. 5, the horizontal member 50 has a hole 51 formed therein, for inserting the pin 55 therein. The pin 55 has a flange at a middle part thereof.
[0027] According to this, when the pin 55 is inserted into the hole 51 by a predetermined length, the flange 50 is held by a lower surface of the horizontal member 50 , when an extension 57 from a rear end of the pin 55 is projected by a length beyond the horizontal member 50 . The extension 57 is flattened by caulking.
[0028] Thus, as the horizontal member 50 is clamped between the flange 56 and the extension 57 , the pin 55 is fastened to one side of the horizontal member 50 .
[0029] In the meantime, as shown in FIG. 1, the brackets 15 are on one side of the frame 13 . The bracket 15 has a hole 15 a in one end part thereof, to which the pin 55 is inserted. Thus, the door 14 is rotatably mounted on the frame 13 . The pin 55 serves as a rotation shaft of the door.
[0030] As described, the related art door latch board has the following problems.
[0031] First, the many levers and springs required as many as a number of switches increase a number of components, and results in a complicated assembly process.
[0032] Second, the holes, fastening pins, and hooks required for fastening the switches to the latch board requires complicated switching fastening process.
[0033] Third, since the pin fitted to the door is a separate component, a fitting process increases, and the extension of the pin is damaged in the caulking.
SUMMARY OF THE INVENTION
[0034] Accordingly, the present invention is directed to a door assembly for a microwave oven that substantially obviates one or more of the problems due to limitations and disadvantages of the related art.
[0035] An object of the present invention is to provide a door assembly for a microwave oven that has a simple and convenient assembly structure.
[0036] Additional features and advantages of the invention will be set forth in the description which follows, and in part will be apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0037] To achieve these objects and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, the door assembly for a microwave oven includes a door panel at one side of the door, having a push bar and a latch both projected from one side toward a body, and a latch board including levers each fitted rotatable at contact with the latch or the push bar, and switches each operable at contact with the lever.
[0038] At least one of the levers has at least three arms. The levers include a first lever for being brought into contact with the push bar, and a second lever for being brought into contact with the latch.
[0039] The second lever includes a third arm for being brought into contact with the latch, and a second arm, and a first arm for operating the switches respectively when the third arm is pushed and rotated by the latch. The first lever includes a second arm for being brought into contact with the push bar, and a first arm for operating the switch when the second arm is pushed and rotated by the push bar.
[0040] The door panel is preferably formed as one unit with the door. The latch board includes a push bar hole and a latch hole for inserting the push bar and the latch, respectively.
[0041] The latch has a sloped surface at an end part for inserting the latch into the latch hole as the sloped surface slides the latch hole. The latch hole includes a projection on an inside edge for hooking the latch. The lever is held by an upper side of the projection.
[0042] The door assembly further includes a spring having one end hooked at a hook at one side of the latch, and the other end held in an upper part of the door panel. The spring provides a restoring force for rotating the latch, which pushes the arm of the lever.
[0043] Preferably, the switches are fitted on a front surface and a rear surface of the latch board in parallel. The latch board has a fastening pin and boss, and the switch has holes for inserting the fastening pin and the boss, for fastening the switch to the latch board with screw fastened to the boss.
[0044] The levers rotate to original positions when the levers are disengaged from the latch or the push bar. The latch board has stoppers for holding the levers at preset positions, respectively.
[0045] The levers are fitted to rotation shafts projected from the door panel respectively, and the levers fitted to the rotation shafts are held by hooks, respectively. The lever has a sloped surface at a part the lever is brought into contact with the hook in fitting the lever to the rotation shaft.
[0046] In other aspect of the present invention, there is provided a door assembly for a microwave oven including a door panel at one side of the door, having a push bar and a latch both projected from one side toward a body, and a latch board including levers each fitted rotatable at contact with the latch or the push bar, a board wall for dividing a front surface and a rear surface, and switches fitted on the front and rear surfaces of the board wall in parallel.
[0047] The board wall has pass through holes formed therein, and the levers have extensions rotatable along the pass through holes, respectively. The levers operate switches on the front surface respectively, and the extensions operate the switches on the rear surfaces respectively.
[0048] The switches include a first safety switch, a second safety switch, and a monitor switch, and switches are fitted parallel to, and on opposite side of the switches.
[0049] In another aspect of the present invention, there is provided a door assembly for a microwave oven including horizontal members each extended from an upper part, or a lower part of an edge of the door, pins each formed as one unit with one of the horizontal members, and brackets on a frame of the microwave oven, each having a hole for rotatably inserting the pin.
[0050] The pin is a projection from the horizontal member formed by pressing. The horizontal members are formed as one unit with the door.
[0051] In further aspect of the present invention, there is provided a door assembly for a microwave oven including a latch assembly including a door panel at one side of a door for the microwave oven, a push bar projected from the door panel toward a body, a latch rotatably fitted to the door panel spaced a distance away from the push bar, a spring having one end held at an upper part of the door panel, and the other end connected to the latch, and a fastening pin fastened through the door panel and the latch to serve as a rotation shaft of the latch, and a latch board including levers rotatable at contact with the latch and the push bar respectively, and switches operable at contact with the levers respectively.
[0052] The door assembly further includes a handle linked with the latch, and fitted rotatable around the fastening pin. The fastening pin has a head clamped between the door and the door panel.
[0053] The spring provides a restoring force for rotating the latch in one direction. The door assembly further includes a projection on one side part of the door panel for holding the latch such that the latch rotates no more than a desired angle.
[0054] It is to be understood that both the foregoing description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention claimed.
BRIEF DESCRITPION OF THE DRAWINGS
[0055] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention.
[0056] In the drawings;
[0057] [0057]FIG. 1 illustrates a perspective view of a related art microwave oven;
[0058] [0058]FIG. 2 illustrates a side view of a latch board in a related art microwave oven;
[0059] [0059]FIG. 3 illustrates a diagram showing latches inserted in a related art latch board to operate actuators of switches;
[0060] [0060]FIG. 4 illustrates a diagram showing a fastening structure of a pin to one side of a related art door;
[0061] [0061]FIG. 5 illustrates a diagram showing a related art pin fastening method;
[0062] [0062]FIG. 6 illustrates a diagram showing latches and a latch board in a microwave oven in accordance with a preferred embodiment of the present invention;
[0063] [0063]FIGS. 7 and 8 illustrate diagrams each showing operation between latches and a latch board following operation of a door handle of the present invention;
[0064] [0064]FIG. 9 illustrates a diagram showing a latch board in accordance with a second preferred embodiment of the present invention;
[0065] [0065]FIG. 10 illustrates a side view of a latch board in accordance with a second preferred embodiment of the present invention;
[0066] [0066]FIGS. 11 and 12 illustrate perspective views showing a first lever and a second lever to be fitted to a latch board in accordance with a second preferred embodiment of the present invention, respectively;
[0067] [0067]FIG. 13 illustrates a structure employed in each of embodiments for holding a lever on a latch board with a hook;
[0068] [0068]FIG. 14 illustrates a diagram of a pin formed at one side of a door in accordance with a preferred embodiment of the present invention;
[0069] [0069]FIG. 15 illustrates a section of a pin in accordance with a preferred embodiment of the present invention;
[0070] [0070]FIG. 16 illustrates a side view of a latch assembly in accordance with a preferred embodiment of the present invention; and
[0071] [0071]FIG. 17 illustrates a section of a latch assembly in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0072] Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings FIGS. 6 ˜ 17 . In describing the embodiments, same parts will be given the same names and reference symbols, and repetitive description of which will be omitted. FIG. 6 illustrates a diagram showing latches and a latch board in a microwave oven in accordance with a preferred embodiment of the present invention.
[0073] Referring to FIG. 6, there are a latch board 201 provided to one side of a frame (reference numeral 13 in FIG. 1), and first and second levers L 1 and L 2 rotatably fitted to upper part and lower part of the latch board 201 , respectively.
[0074] The first lever L 1 has two arms, and the second lever L 2 has three arms. There is a door panel 241 at one side of a door, having a push bar 244 and a latch 242 fitted thereto. The door panel 241 may be fabricated as one unit with the door.
[0075] The latch board 201 has a bar hole 208 and a latch hole 209 . When the door is closed, the push bar 244 and the first lever L 1 are inserted into the bar hole 208 and the latch hole 209 , respectively. In this instance, the push bar 244 pushes an arm of the first lever L 1 , and the latch 242 pushes an arm of the second lever L 2 .
[0076] In the meantime, the head part 242 a of the latch 242 has a hook 242 b , and the latch hole 209 has a projection 201 a from an inside of an upper edge thereof. The hook 242 b is hooked at the projection 201 a.
[0077] [0077]FIGS. 7 and 8 illustrate diagrams showing different states of engagement of the latch with the latch board following operation of the door handle when the door is closed.
[0078] Referring to FIG. 7, the latch 242 is fitted rotatable around a rotation shaft 305 , and the rotation shaft 305 has a rear end having a door handle fixed thereto. An upper side of the latch 242 and one side of the door panel 241 are connected with a spring 306 . The door handle 243 is rotated in a clockwise direction in opening the door.
[0079] When the door handle 243 is rotated in the clockwise direction, the latch 242 also rotates in the clockwise direction, and disengaged from the projection 201 a . In this instance, a restoring force is provided from the spring 306 to the latch 242 for rotating the latch 242 in a counter clockwise direction.
[0080] [0080]FIG. 8 illustrates a diagram showing engagement of the latch with the latch board when the door is closed.
[0081] Referring to FIG. 8, when the door is closed, the latch 242 is inserted in the latch hole 209 as a sloped surface of the latch head 242 a slides along an edge of the latch hole 209 , and rotates in the counter clockwise direction by the spring 306 until the hook 242 b on the latch 242 is hooked at the projection again, when the door is locked.
[0082] The latch board 201 has three switches ‘S’ each of which is operable when an actuator thereon is pressed. The switches includes a monitor switch ‘S 3 ’, a second safety switch ‘S 2 ’, and a first safety switch ‘S 1 ’. The monitor switch ‘S 3 ’ is in an upper part of the latch board 201 , the second safety switch ‘S 2 ’ is in a lower part the latch board 201 , and the first safety switch ‘S 1 ’ is in a central part the latch board 201 . The actuator ‘A 3 ’ of the monitor switch ‘S 3 ’ is positioned adjacent to the arm of the first lever L 1 , and the actuators A 1 and A 2 of the first safety switch ‘S 1 ’ and the second safety switch S 2 are positioned adjacent to arms of the second lever L 2 , respectively.
[0083] The operation of the monitor switch ‘S 3 ’ with the first lever ‘L 1 ’ will be described.
[0084] Referring to FIG. 8, when the door on the microwave oven is closed, the push bar 244 inserted through the bar hole 208 pushes a lower arm L 12 of the first lever L 1 downward, when the first lever L 1 rotates in the counter clockwise direction until an upper arm L 11 thereof presses an actuator ‘A’ on a bottom of the monitor switch ‘S 3 ’.
[0085] In the meantime, referring to FIG. 6, when the door is opened, the push bar 244 moves back, to release a force pushing the lower arm L 12 of the first lever L 1 . According to this, the first lever L 1 rotates in a clockwise direction by gravity of the upper arm L 11 . After rotated at a certain angle, the upper arm L 11 is held at a stopper 210 thereunder, to hold the first lever L 1 in a substantial ‘ ’ position.
[0086] Next, the operation of the first safety switch ‘S 1 ’ and the second switch ‘S 2 ’ with the second lever ‘L 2 ’ will be described.
[0087] Referring to FIG. 6, in opening the door, arms of the second lever L 2 move away from the actuators respectively. In this instance, the first arm L 21 positions over the actuator ‘A 1 ’ of the first safety switch ‘S 1 ’, the second arm L 22 positions over the actuator ‘A 2 ’ of the second safety switch 'S 2 , and the third arm L 23 is held at the projection 201 a on one side of the latch hole 209 .
[0088] In the meantime, referring to FIG. 8, in closing the door, the latch 242 is inserted through the latch hole 209 . Then, the latch 242 is hooked at the projection 201 a by the restoring force provided from the spring 306 .
[0089] In this instance, the latch head 242 a pushes the third arm L 23 to rotate in the clockwise direction L 23 . The first arm L 21 presses down the actuator ‘A 1 ’ of the first safety switch S 1 , and the second arm L 22 presses down the actuator ‘A 2 ’ of the second safety switch S 2 .
[0090] According to this, the latch board 201 in accordance with a first preferred embodiment of the present invention can operate three switches S 1 , S 2 , and S 3 only with two levers L 1 , and L 2 . Moreover, since the levers L 1 and L 2 are restored by own gravity, respectively, no separate spring is required.
[0091] Structures for fitting the monitor switch 'S 3 , the first safety switch ‘S 1 ’, and the second safety switch ‘S 2 ’ to the latch board 201 respectively will be described.
[0092] Each of the switches has two holes in a diagonal direction, and the latch board 201 has fastening pins 381 and bosses (not shown) at positions corresponding to positions of the holes Sh. The fastening pins 381 and the bosses are inserted in the holes Sh in the switches, respectively. By fastening screw 309 to the bosses, the switch ‘S’ is fastened to the latch board 201 .
[0093] The switches ‘S’ may be fastened by two in parallel, when the switches ‘S’ are fastened to the latch board 201 with screws 309 and fastening pin as long as a width of the switches overlapped in parallel.
[0094] [0094]FIG. 9 illustrates a side section of a latch board in accordance with a second preferred embodiment of the present invention, and FIG. 10 illustrates a rear view of a latch board in accordance with a second preferred embodiment of the present invention.
[0095] Referring to FIGS. 9 and 10, the latch board 301 is divided into a front surface part and a rear surface part by a board wall. The front surface part has a first lever L 1 , a second lever L 2 , a monitor switch S 3 , a first safety switch S 1 , and a second safety switch S 2 fitted thereto, and the rear surface part has the other monitor switch S 3 ′ and the other first safety switch S 1 ′. The other monitor switch S 3 ′ and the other first safety switch S 1 ′ may be substituted with switches having different functions, respectively. For simultaneous operation of the one pair of switches fitted in parallel in front and rear of the board wall 319 , the levers ‘L’ are passed through the board wall 319 .
[0096] [0096]FIGS. 11 and 12 illustrate perspective views showing a first lever L 1 ′ and a second lever ‘L 2 ’ to be fitted to a latch board in accordance with a second preferred embodiment of the present invention, respectively.
[0097] As shown in the drawings, the first lever L 1 ′ and the second lever L 2 ′ have extensions W 1 and W 2 passed through the board wall 319 respectively, and the latch board 301 has lever pass through holes 391 , and 392 the extensions W 1 and W 2 pass therethrough. Actuators of the switches fitted parallel to each other are pressed at the same time with the extensions W 1 , and W 2 .
[0098] For an example, two monitor switches S 3 , and S 3 ′, and actuators A 3 , and A 3 ′ thereof are fitted in parallel respectively, and the extension W 1 pass through the lever pass through hole 391 so that the first lever L 1 ′ presses the two actuators at the same time. When the push bar 144 presses the first lever L 1 ′, the extension W 1 from the upper arm is rotated. According to this, the actuators A 3 , and A 3 ′ of the monitor switches S 3 and S 3 ′ positioned in front and rear surfaces of the latch board 301 are pressed at the same time with the upper arm and the extension of the first lever L 1 ′.
[0099] Alikely, the extension W 2 from the second lever L 2 ′ also passes through the lever pass through hole 392 in the latch board 201 . When the latch 142 presses the second lever L 2 ′, the extension W 2 from the second lever L 2 ′ rotates. According to this, the actuators A 1 , and A 2 of the first safety switches S 1 , and S 2 positioned on the front and rear surfaces of the latch board 301 are pressed at the same time by the arm and the extension of the second lever L 2 ′.
[0100] [0100]FIG. 13 illustrates a structure employed in each of embodiments for holding a lever L 1 , L 1 ′, L 2 , or L 2 ′ on a board wall of a latch board.
[0101] Referring to FIG. 13, the lever L is rotatably fitted to a rotation shaft 201 c of a latch board. The lever L is held with a hook 201 d after the lever L is inserted in the rotation shaft 201 c for preventing break away of the lever L from the rotation shaft 201 c.
[0102] When the lever L is inserted into the rotation shaft 201 c , the hook 201 d deforms elastically, and after insertion of the lever 101 c is finished, the hook 201 d is restored, to hold an upper part of the lever L. For preventing deformation or breakage of the hook 201 d in contact with the lever L, a sloped surface 55 is formed at the lever L in contact with the hook 201 d . That is, since a head of the hook 201 d slides along the sloped surface 255 when the hook 201 d fastens the lever L, the lever L can be fitted to the latch board more stably without any damage to the lever L or the hook 201 d.
[0103] Moreover, it is preferable that the rotation shaft 201 c and the hook 201 d are formed as one unit with the latch board 201 for simplifying an assembly structure of the latch board 201 .
[0104] In the meantime, a mounting structure of the door on the microwave oven of the present invention will be described. FIG. 14 illustrates a diagram of a pin formed at one side of a door as one unit with the door in accordance with a preferred embodiment of the present invention, and FIG. 15 illustrates a section of the pin.
[0105] Referring to FIG. 14, there is a horizontal member 250 on an inside surface of the door 114 . The horizontal member 250 has a pin 250 a formed as one unit with the horizontal member 250 for serving as a rotation shaft of the door 114 . Also, it is preferable that the horizontal member 250 is formed as one unit with the door 114 .
[0106] Referring to FIG. 15, the pin 250 a is formed as one unit with the horizontal member 250 at one side part of the horizontal member by pressing. Therefore, it is preferable that the horizontal member 250 of the door is formed of a metal for easy pressing. Since the pin 250 a is formed as one unit with the horizontal member 250 , fitting of the pin 250 a is easy and damage to the pin 250 a is prevented in comparison to a case the pin is fitted as a separate component.
[0107] In this instance, as the pin 250 a is inserted to the hole 15 a at an end part of the bracket 15 , the door 114 is rotatably mounted on the frame 13 .
[0108] A fitting structure of the latch of the present invention will be described. FIG. 16 illustrates a side view of a latch assembly in accordance with a preferred embodiment of the present invention, and FIG. 17 illustrates a section of the fitting structure.
[0109] Referring to FIG. 16, the latch assembly includes a door panel 241 , a push bar 244 , a latch 242 , a handle 243 , a spring 306 , and a fastening pin 218 . The door panel 241 is provided to one side of the door. The push bar 244 is in an upper part of the door panel 241 , and the latch 242 is in a lower part of the door panel 241 . The handle 243 has one end connected to the latch 242 .
[0110] The spring 306 has one end connected to an upper part of the door panel 241 , and the other end connected to a hook 242 a on the latch 242 , so that the spring 306 provides a restoring force for rotating the latch 242 in a counter clockwise direction.
[0111] The latch 242 has an extension 242 c in a lower part, and the door panel 241 has a projection 241 a formed thereon. Since the extension 242 c is held by the projection 241 a at a desired angle, any further rotation of the latch 242 is prevented.
[0112] In the meantime, the fastening pin 218 is fastened to the door panel, passing through the door handle 243 and the latch 242 . According to this, the door handle 243 and the latch 242 turn around the fastening pin 218 .
[0113] The latch 242 and a link part 203 of the handle 243 are on the same rotation shaft, so that the handle 243 and the latch 242 rotate together.
[0114] Referring to FIG. 16, when the handle 243 is rotated in a clockwise direction for opening the door, the latch 242 also rotates in a clockwise direction. In this instance, the hook 242 b at the end of the latch 242 is disengaged from the projection (reference numeral 201 a in FIG. 7).
[0115] Opposite to this, what is required for closing the door is just pushing the door forward in a state the handle 5 is at a regular position. In this instance, the latch 2 is inserted into the latch board, and engaged with the projection.
[0116] Referring to FIG. 17, the fastening pin 218 is fitted such that a head 218 a thereof is clamped between the door panel 241 and the door 114 , and the other end directed to an open surface of the door panel 241 . The door panel 241 is fastened to one side of the door 114 rigidly with screws or the like.
[0117] Thus, since the head 218 a of the fastening pin is clamped between the door panel 241 and the door 114 , break away of the fastening pin 218 is prevented.
[0118] As has been described, the microwave oven of the present invention has the following advantages.
[0119] First, the restoration of the levers fitted to the door for the microwave oven of the present invention by gravity permits to dispense with springs, to reduce a number of required components.
[0120] Second, the fastening of the switches to the latch board only with screws simply without the hook permits to simplify the switch fastening structure.
[0121] Third, the formation of at least three arms on the lever such that one lever can operate at least two switches permits to simplify a lever fitting structure.
[0122] Fourth, the formation of the pin, serving as a rotation shaft of the door, as one unit with the door permits to simplify an assembly process. Moreover, breakage of the pin taken place when the pin is formed separately can be prevented.
[0123] Fifth, the employment of the fastening pin instead of bolt-nut as an operational rotation shaft of the latch and the door handle permits to simplify assembly, and prevents break away of the operational rotation shaft.
[0124] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | Door assembly for a microwave oven including a door panel at one side of the door, having a push bar and a latch both projected from one side toward a body, and a latch board including levers each fitted rotatable at contact with the latch or the push bar, and switches each operable at contact with the lever, thereby providing a simple and convenient assembly structure. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional application serial No. 60/450,477, filed Feb. 27, 2003, the disclosures and teachings of which are herein incorporated by reference.
BACKGROUND AND SUMMARY OF THE INVENTION
[0002] This invention relates to a brake system, and more particularly to an arrangement for preventing adverse effects which can occur when the brake system experiences excessive fluid pressure.
[0003] Brake systems, as hydraulic systems, rely significantly on precise pressures that translate into precise movements of the components parts. This is particularly significant in the precise caliper piston movements required in disc brake systems. The thermal expansion of fluid in the system or from contact between the brake disc and the brake pads may translate into knock-back of the brake actuating piston.
[0004] A disc brake system typically includes a master cylinder assembly which is responsive to an operator-controlled lever or pedal to control operation of a caliper, and thereby application and release of the brake. The master cylinder assembly includes a body defining a fluid reservoir, and a piston mounted within the master cylinder body. The piston is movable relative to the master cylinder body between an extended position and a retracted position. Typically, the master cylinder piston is moved to the extended position in response to actuation of the brake lever or pedal by an operator. Such extension of the piston is operable to displace a quantity of fluid from the master cylinder which causes movement of the caliper so as to apply the brake. When the operator releases the brake pedal or lever, the piston is moved to the retracted position under the influence of a spring. The piston includes a seal arrangement, and is exposed to fluid within the valve body. The seal arrangement is configured to cut off communication between the interior of the valve body and the fluid reservoir when the piston is moved to the extended position, and to establish communication between the reservoir and the interior of the valve body when the piston is moved to the retracted position. In this manner, the quantity of fluid that is displaced upon extension of the piston returns to the reservoir through the interior of the valve body when the piston is retracted.
[0005] One problem is known as “knock-back”, in which the dynamic effects of a vehicle can tend to push the caliper pistons into their respective bores forcing fluid into the master cylinder reservoir. In most instances, this results in partial or complete loss of braking capability. The loss of fluid in the pressure circuit causes increased lever/pedal movement and in effect decreases the ability to achieve system pressure. Another result of knockback is an unnatural braking sensitivity, in which this increased lever/pedal travel reduces the ability to modulate braking power.
[0006] In general, brake calipers that are hard mounted to a vehicle versus floating automotive type calipers experience this knock-back. More specifically, this occurs when caliper pistons are pushed into their respective bores due to the dynamic effects of a vehicle. When enough fluid is displaced to the master cylinder reservoir during this event, the brake lever/pedal can be completely actuate with little or no braking of vehicle.
[0007] Under certain circumstances, an increase in pressure in the fluid flow path can result in undesirable effects on the brake system. For example, when the disc comes into contact with the brake pads, which is caused by an increase in pressure from thermal expansion of a fluid in the brake line, it tends to move the piston inwardly beyond its normal retracted position. This condition is commonly known as thermal lock, and creates the potential for the caliper piston to be moved such that premature braking can occur without actuation of the brake lever/pedal. In addition, thermal expansion of the brake fluid may cause extension of the piston even when the brake is not applied, resulting in drag on the brake disc.
[0008] It is an object of the present invention to provide a pressure relief arrangement for a disc brake system, which prevents the adverse effects that can result from excessive pressure in the brake system caused by contact between the brake disc and the brake pads or thermal expansion of brake fluid in the system. It is a further object of the invention to provide such a pressure relief arrangement which is incorporated in the master cylinder body. A further object of the invention is to provide such a pressure relief arrangement that controls the flow of fluid between the fluid flow path and the fluid reservoir upon movement of the piston between the extended and retracted positions.
[0009] A still further object of the invention is to provide such a pressure relief arrangement which functions as a valve that selectively establishes communication between the valve interior and the fluid reservoir when pressure in the fluid flow path exceeds a predetermined threshold. Yet another object of the invention is to provide such a pressure relief arrangement which allows the brake to be operated in the same manner as in the prior art while preventing the adverse effects that can occur from excessive pressure in the system. A still further object of the invention is to provide such a pressure relief arrangement which is relatively simple in its components, construction and operation, yet which is effective to control the flow of fluid between the valve interior and the fluid reservoir while preventing the adverse effects that can occur from excessive pressure in the valve interior.
[0010] In accordance with one aspect of the present invention, a disc brake system includes a brake disc and a caliper, and an actuator for selectively moving the caliper to apply and release the brake. The brake actuator includes a master cylinder body defining a fluid reservoir, and a valve body mounted within a passage defined by the master cylinder body. A piston is mounted for movement between an extended position and a retracted position. In a typical configuration, movement of the piston to the extended position displaces a quantity of fluid from the interior to operate the caliper so as to apply the brake, and movement of the piston toward the retracted position returns a quantity of fluid toward the fluid reservoir through the interior, to release the brake. A pressure relief valve arrangement is interposed between the interior and the reservoir, for controlling the flow of fluid upon movement of the piston between the extended and retracted positions. The pressure relief valve arrangement is configured and arranged to selectively vent fluid from the to the fluid reservoir in the event pressure in the fluid flow path exceeds a predetermined threshold. In the disclosed embodiment, the pressure relief valve arrangement includes a valve body defining an internal cavity in communication with the interior, and the valve body includes a relief port in communication with the fluid reservoir. The pressure relief valve arrangement further includes a biased valve member movably mounted with the internal cavity, which normally seals the relief port to prevent communication between the internal cavity and the reservoir. During normal operation, brake release causes the piston to move from the extended position to the retracted position to return fluid to the interior, which causes fluid to be displaced into the internal cavity and results in movement of the valve member to move to an expanded position against the bias. When the brake is applied, the piston is moved toward the extended position to displace fluid from the interior, and the valve member is opened to the reservoir and is moved to an exhaust position under the influence of the bias to discharge fluid from the internal cavity into the fluid reservoir through a series of ports associated with the master cylinder body. The valve body is configured such that the valve member normally prevents communication between the internal cavity and the fluid reservoir through the relief port when the valve member is in both the expanded position and the exhaust position. The valve member is further movable from the expanded position to a relief position against the bias when pressure in the fluid flow path exceeds the predetermined threshold. When in the relief position, the valve member is positioned such that the relief port is opened so as to establish communication between the internal cavity and the fluid reservoir. This functions to relieve pressure in the internal cavity and thereby in the interior, to prevent movement of the piston beyond its normal retracted position in the event of contact between the brake disc and the brake pads which otherwise may result in knock-back of the piston, and to prevent piston extension which may otherwise result from thermal expansion of fluid in the system.
[0011] The invention contemplates a brake actuator or master cylinder assembly incorporating a pressure relief arrangement, as well as a method of relieving excessive pressure in a brake system, substantially in accordance with the foregoing summary.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A preferred exemplary embodiment of the invention is illustrated in the accompanying drawings in which like reference numerals represent like parts throughout, and in which:
[0013] [0013]FIG. 1 is a sectional view schematically illustrating a brake system that includes a master cylinder assembly incorporating the pressure relief valve arrangement of the present invention, in which the piston of the master cylinder assembly is shown in a retracted position and the valve member of the pressure relief valve arrangement is shown in an expanded position;
[0014] [0014]FIG. 1A is an exploded view of the pressure relief valve arrangement in accordance with one aspect of the present invention;
[0015] [0015]FIG. 2 is a sectional view showing the master cylinder assembly as in FIG. 1, in which the piston of the master cylinder assembly is shown in an extended position for applying the brake and the valve member of the pressure relief valve arrangement is shown in an at rest position; and
[0016] [0016]FIG. 3 is a sectional view similar to FIG. 2, showing the piston in the retracted position and the valve member of the pressure relief arrangement moved to a relief position for relieving excessive pressure in the master cylinder assembly.
DETAILED DESCRIPTION OF THE INVENTION
[0017] [0017]FIG. 1 schematically illustrates a disc-type brake system incorporating an actuator in the form of a master cylinder assembly 10 which includes the pressure relief valve arrangement of the present invention. In accordance with conventional construction of a brake system of this type, master cylinder assembly 10 is interconnected with an operator-controlled actuating lever shown at 12 , and functions to control movement of a caliper shown schematically at 14 . Caliper 14 closes upon brake application to apply pressure to a brake disc or rotor 16 , and opens upon release to relieve pressure on rotor 16 . Master cylinder assembly 10 is particularly well suited for use in a fixed caliper or hard-mounted (vs. floating automotive type) application, such as is commonly incorporated in a vehicle such as a motorcycle, snowmobile or all terrain vehicle (ATV), although it is understood that master cylinder assembly 10 may be used in other types of braking arrangements.
[0018] Master cylinder assembly 10 includes a body 18 that defines a passage 20 within which a piston 22 is mounted. Master cylinder body 18 further includes a fluid reservoir 24 sealed by a cap 26 which includes a diaphragm 28 , in a known manner. Reservoir 24 is defined by side walls such as shown at 30 and a bottom wall 32 , a portion of which defines passage 20 .
[0019] In accordance with known construction, piston 22 is reciprocally movable within a cartridge 34 located within passage 20 , between a retracted position as shown in FIGS. 1 and 3 in which brake caliper 14 is released, and an extended position as shown in FIG. 2 in which brake caliper 14 is applied.
[0020] Cartridge 34 includes a passage 36 defined by an annular cartridge side wall 38 , and piston 22 is movably mounted within passage 36 . A timing port 40 is formed in cartridge side wall 38 , and establishes communication between cartridge passage 36 and a recess 42 formed in the outer surface of cartridge side wall 38 . In addition, a backup port 44 is formed in cartridge side wall 38 at a location spaced from timing port 40 , and establishes communication between cartridge passage 36 and recess 42 . Cartridge 34 further includes a reservoir port 46 that communicates between cartridge passage 36 and a recess 48 formed in the outer surface of cartridge side wall 38 . An O-ring seal 50 is seated within a groove formed in cartridge side wall 38 between recesses 42 and 48 , and engages the inwardly facing surface of cartridge side wall 38 to establish a fluid-tight seal therebetween.
[0021] Piston 22 includes a spool section 52 having a recess 54 located between a pair of cup-type seals 56 , 58 that contact the inwardly facing surface of cartridge side wall 38 to establish a fluid-tight seal therebetween. In addition, piston 22 includes a forward extension section 60 that extends from spool section 52 . A cup-type seal 62 is mounted to extension section 60 , and engages the inwardly facing surface of cartridge side wall 38 to form a fluid-tight seal therebetween.
[0022] Piston 22 defines a passage 64 within which a return spring 66 is mounted. The forward end of return spring 66 is supported by a collar 68 , in accordance with known construction. Return spring 66 is operable to bias piston 22 toward the retracted position, in a manner as known in the art.
[0023] Bottom wall 32 of master cylinder body 18 , which forms a part of fluid reservoir 24 , is formed with a return opening 64 that communicates between fluid reservoir 24 and master cylinder passage 20 . Forwardly of return opening 64 , a pressure relief valve assembly 66 is mounted to bottom wall 32 . In a manner to be explained, pressure relief valve assembly 66 is operable to control fluid flow into and out of reservoir 24 , and to relieve excessive pressure that may be experienced in the pressure vessel or chamber located in the forward portion of cartridge passage 36 forwardly of piston seal 62 .
[0024] Pressure relief valve assembly 72 includes a valve body or cylinder 74 having a side wall 76 and an end wall 78 that cooperate to define an internal cavity 80 . A valve member 82 is movably mounted within internal cavity 80 . Valve member 82 includes a body section 84 that carries a cup-type seal 86 which contacts the inner surface of side wall 76 to form a fluid-tight seal therebetween. Valve member 82 further includes a shoulder section 88 which is configured to maintain seal 86 in position, and a head section 90 that extends from shoulder section 88 .
[0025] Side wall 76 of pressure relief valve cylinder 74 is formed with a valve relief opening or port 92 , and seal 86 is normally engaged with the area of cylinder side wall 76 below the lowermost extent of relief port 92 .
[0026] A cap 94 is secured to the upper end of valve cylinder 74 . Cap 94 includes an outwardly extending flange 96 engaged within a groove 98 formed in the inner surface of side wall 76 , which functions to mount cap 94 to valve cylinder 74 .
[0027] Cap 94 is formed with a recess 100 in its inner surface, which faces and is in communication with internal cavity 80 of valve cylinder 74 . Recess 100 is formed to define an inner mounting boss 102 , and one end of a low-force inner spring 104 is engaged with mounting boss 102 . The opposite end of low-force inner spring 104 is engaged with head section 90 of valve member 82 . Inner spring 104 is operable to apply a biasing force on valve member 82 that tends to urge valve member 72 toward end wall 78 of valve cylinder 74 .
[0028] An outer, high force preloaded spring 106 is seated within cap recess 100 outwardly of mounting boss 102 . The lowermost extent of outer spring 106 , shown at 108 , is provided with an elongated configuration, and the ends of lower turn 108 of outer spring 106 are engaged with opposed seat surfaces 110 which are formed in the inner surface of valve cylinder side wall 76 . With this construction, outer spring 106 is preloaded when cap 94 is engaged with valve cylinder 74 , via seating of the lower turns 108 of outer spring 106 in seat surfaces 110 and compression that is applied to outer spring 106 when cap 94 is secured to valve cylinder 74 .
[0029] Valve cylinder 74 is mounted within reservoir 24 via an extension 112 of end wall 78 that is received within an opening 114 formed in bottom wall 32 . Representatively, a threaded connection may be provided between extension 112 and opening 114 , although it is understood that any other satisfactory mounting arrangement may be employed. A passage 116 , which includes a frustoconical inlet, is formed in end wall 78 and extension 112 , and establishes communication between internal cavity 80 of valve cylinder 74 and recess 42 defined by cartridge 34 .
[0030] [0030]FIG. 1A is an exploded view of the pressure relief valve arrangement 200 in accordance with one aspect of the present invention. The valve arrangement 200 includes a valve body 202 , a piston 204 , and a generally u-shaped cup seal 206 , with these items defining a pressure vessel 208 . The valve arrangement further includes a cap 210 , a small, low installed force, spring 212 and a larger, higher installed force spring 214 .
[0031] In one embodiment, a pressure relief valve assembly and a master cylinder combination is disclosed. On such master cylinder for use in the combination is the master cylinder shown and described with respect to FIGS. 1-3. The combination comprises: a master cylinder having a master cylinder reservoir; and a pressure relief valve assembly positioned within the master cylinder reservoir. The pressure relief valve assembly itself comprises: a pressure vessel for displacing a fluid. The pressure vessel itself comprises: a valve body; a generally u-shaped cup seal disposed adjacent the valve body; and a piston in sealing contact with the generally u-shaped cup seal. The valve arrangement further comprises: a first spring located adjacent the pressure vessel piston; a second spring adjacent the pressure vessel piston and concentric with the first spring; and a cap in engagement with the first spring. The second spring is preloaded to have a higher installed force and a higher spring rate than the first spring. When the piston moves to contact the first spring, compress the first spring, and compress the second spring, fluid is drawn into the pressure vessel, thereby relieving pressure from the master cylinder reservoir.
[0032] A method of reducing caliper piston knockback using a brake master cylinder is also disclosed. The method comprises: displacing a pressure relief valve assembly piston to contact and compress a first spring and a second spring concentric with the first spring, thereby increasing the pressure required to force caliper pistons into their respective bores, thereby reducing caliper piston knockback.
[0033] During every braking event the system stabilizes itself when the valve discharges all its fluid on a brake application. The valve is designed to release pressure before caliper pistons can be actuated due to thermal expansion of the fluid.
[0034] In operation, valve member 82 is normally in an expanded position as shown in FIG. 1 when the brake is released and piston 22 is in the retracted position. The brake is applied by operating brake actuating lever 12 in a known manner, to move piston 22 from the retracted position of FIG. 1 to the extended position of FIG. 2. Such movement of piston 22 displaces a quantity of fluid from the pressure chamber of cartridge passage 36 outwardly to brake caliper 14 , to apply pressure on brake disc 16 in a known manner. Such movement of piston 22 to the extended position functions to cut off communication of timing port 40 with the pressure chamber of cartridge passage 36 , and also positions the rearward cup seal 58 forwardly of both timing port 40 and backup port 44 .
[0035] During such movement of piston 22 to the extended position, internal cavity 80 of valve cylinder 74 is open to reservoir 24 via passage 116 , backup port 44 , spool recess 54 , reservoir port 46 , cartridge recess 48 and return opening 70 . Such communication between valve cylinder internal cavity 80 and reservoir 24 allows valve member 82 to be moved under the influence of inner spring 104 from its expanded position of FIG. 1 to its exhaust position of FIG. 2, to discharge fluid from valve cylinder internal cavity 80 . When the operator releases actuating lever 12 , piston 22 returns to the retracted position of FIG. 1 under the influence of retraction spring 66 , which causes introduction of a volume of fluid into the pressure chamber of cartridge passage 36 and movement of cartridge seals 58 , 62 to the position as shown in FIGS. 1 and 3, in which timing port 40 is opened to the pressure chamber of cartridge passage 36 and backup port 44 is sealed. In this manner, fluid that is introduced to cartridge passage 36 upon retraction of piston 22 is supplied through timing port 40 to cartridge recess 42 , and through passage 116 of valve cylinder 74 into internal cavity 80 . The fluid pressure is sufficient to cause valve member 82 to return to the expanded position of FIG. 1, against the bias of inner spring 104 .
[0036] In the event brake disc 16 contacts the brake pads of caliper 14 during rotation of brake disc 16 , which presents the potential for knock-back of piston 22 , an increase in fluid pressure is experienced in the pressure chamber of cartridge passage 36 . The pressure increase is transferred through timing port 40 and cartridge recess 42 into valve cylinder internal cavity 80 through passage 116 , to engage valve member 82 with the lower end of outer spring 106 . If the increase in pressure is above a predetermined threshold at which knock-back normally occurs, as governed by the preload on outer spring 106 , the increased pressure is operable to force valve member 82 upwardly against the bias of outer spring 106 , as shown in FIG. 3, to a relief position in which the lip of valve seal 86 is located above the lowermost extent of relief port 92 . Such movement of valve member 82 functions to establish communication between valve internal cavity 80 and reservoir 24 through relief port 92 . In this manner, the fluid pressure in the pressure chamber of cartridge passage 36 is relieved. When pressure in the pressure chamber of cartridge passage 36 falls below the threshold established by the force of outer spring 106 , valve member 82 is returned to the expanded position as shown in FIGS. 1 and 3 under the influence of both inner spring 104 and outer spring 106 .
[0037] Valve member 82 can also be moved to the relief position of FIG. 3 when pressure in the pressure chamber of cartridge passage 36 increases above the predetermined threshold for any other reason, e.g. as a result of thermal expansion of the brake fluid which otherwise may result in drag of the pads of caliper 14 on brake disc 16 .
[0038] Generally, when the system is first assembled its “at rest” assembled state is where the piston is fully extended within the valve. The “at rest” operational state (i.e., when the system is attached to the vehicle) is with the piston compressing the small spring but not contacting the large spring.
[0039] During a braking event, the valve works in the following manner (assuming the valve starts from its “at rest” position on vehicle): When the brake lever/pedal is actuated, the master cylinder piston and primary cup travel forward, thereby closing off the port timing hole and creating pressure in the brake caliper. At the same time, fluid in the valve is directed into the master cylinder reservoir through the backup port, over the primary backup cup, and through the reservoir port. When the brake is released, fluid travels over the primary cups (the amount dependant upon return velocity) and the master cylinder piston stops at its home position. With both cups behind their respective ports, the last event is the retraction of the caliper pistons into their bores. When this occurs, the fluid displaced in the caliper pushes the piston in the valve back to its home (at rest) position. The retraction of the caliper pistons is the last event in the braking sequence.
[0040] This occurs every braking event. It is important that the valve be able to fully discharge during a braking event, otherwise the valve will pump up until the valve piston hits the large spring, which eliminates the calipers ability to retract the pistons and will cause the brake pads to drag.
[0041] During a knock back event, the valve works in the following manner: the caliper piston experiences an external force wanting to push it into its respective bore. The valve piston moves slightly contacting the large preloaded spring. Due to the increased pressure needed to move the valve piston further against the spring, the force needed to push the piston into the bore is increased. If the force is great enough, with enough displacement to overcome the large spring force in the valve, the valve can dump this pressure to the master cylinder reservoir as the valve U-cup pass this port. This pressure relief is also used in thermal expansion of the liquid.
[0042] While the invention has been shown and described with respect to a specific embodiment, it is understood that various alternatives and modifications are contemplated as being within the scope of the invention. For example, and without limitation, while valve cylinder 74 is illustrated as being a separate member that is mounted to the valve body, it is also understood that the valve cylinder may be formed integrally with the material of the master cylinder body during manufacture. Moreover, it is important to note that the placement of the valve body and associated valve arrangement components described herein are shown in a particular region of the master cylinder shown and described. However, it is contemplated that the location or placement of the arrangement can vary depending on a number of constraints, for example, the size and dimension (and in general the make and model) of the master cylinder utilized. Thus, the changes in the exact location of the valve arrangement are contemplated, provided that the fluid flow and pressure relief objectives are met. The preferred location disclosed herein is chosen for its ability to be easily bled with the system (versus separately) and to provide a direct path for the fluid to be dumped from the valve into the master cylinder reservoir, reducing the need for extra lines and to reduce overall complexity.
[0043] Various alternatives and embodiments are contemplated as being within the scope of the following claims particularly pointing out and distinctly claiming the subject matter regarded as the invention. | A pressure relief arrangement for a disc-type brake system in which a master cylinder assembly applies and releases the brake. The pressure relief arrangement is in the form of a pressure relief valve located between the piston and reservoir of the master cylinder assembly. The pressure relief valve provides normal operation of the brake upon extension and retraction of the piston when fluid pressure remains below a predetermined threshold. When fluid pressure exceeds the predetermined threshold, the pressure relief valve establishes communication between the reservoir and the fluid flow path, to relieve the excessive pressure. In this manner, the pressure relief valve reduces or eliminates the brake calipers from functioning improperly when the brakes are applied, which can result from the excess pressure caused by fluid expansion and dynamic braking effects that tend to move the caliper pistons. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application 61/661,701 filed Jun. 19, 2012, which is hereby incorporated by reference to the extent not inconsistent with the disclosure herein.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was made with government support under contract number N00014-12-1-0014 awarded by the Office of Naval Research. The government has certain rights in the invention.
BACKGROUND
[0003] For a liquid droplet on a solid substrate, the contact angle may be defined as the interior angle formed by the substrate and the tangent to the interface between the liquid and gas or vapor at the apparent intersection of the substrate, liquid and gas or vapor phases (see FIG. 1 a ). The dimension of the droplet is often comparable to or smaller than the capillary length of the liquid. The contact angle may be measured or calculated from images of the droplet on the substrate. The substrate is characterized as being wetted if the contact angle between the droplet and the substrate is less than 90°; or non-wetted if the contact angle between the droplet and the substrate is greater than 90°. When the liquid is water, the surface is considered hydrophobic when the contact angle between the water droplet and the substrate is greater than 90°. Similarly, when the liquid is an oil, the surface is considered oleophobic when the contact angle between the refrigerant droplet and the substrate is greater than 90°.
[0004] On a relatively smooth surface, the relationship between the contact angle and the relevant surface and interfacial energies may be given by Young's equation (Equation 1). However, on a rough surface, the apparent contact angle of the droplet may differ from that measured on a smooth surface. In some cases, the droplet may sit on top of surface features so that a composite (solid-liquid-vapor) interface is formed, as shown in FIG. 1 c (right, labeled Cassie-Baxter). Tuteja et al. (Science, 318, 1618, 2007) describe formation of composite interfaces on re-entrant curved surfaces with the drop sitting partially on air; contact angle measurements are given for octane on a silane coated smooth surface (advancing contact angle approx. 55°, receding approx.) 50° and a rough “microhoodo” surface (advancing contact angle approx. 163°, receding approx. 145°). Re-entrant curvature may be characterized by a surface topography which cannot be described by a simple univalued function z=h(x,y) and for which a vector projected normal to the x-y plane intersects the texture more than once (Tuteja et al, 2008, Proc. Nat. Acad. Sci, 105(47), 18200-18205).
[0005] Condensation of a liquid phase from a vapor phase occurs in condenser heat transfer devices used in power generation and refrigeration systems. When the latent heat of vaporization is released during condensation on a surface, heat is transferred to the surface. During the condensation process, the condensing liquid may form a film over the entire surface in a process termed filmwise condensation. Alternately the condensed liquid may form as drops on the surface in a process termed dropwise condensation. Higher heat transfer coefficients have been reported for dropwise condensation of steam than filmwise condensation at atmospheric pressure (Rose 2002, Dropwise condensation theory and experiment: a review, Proc Instn Mech Engrs, 216(Part 4): 115-128).
BRIEF SUMMARY
[0006] Provided herein are methods and devices related to heat transfer, such as by dropwise condensation of a refrigerant vapor on a surface. In an aspect, the surface and various aspects of the system are configured to ensure the surface is refrigerant repelling. In an embodiment, the refrigerant repelling surface is configured so that a refrigerant that may normally wet a surface is instead repelled The surface and various aspects of the system may also be configured to enhance droplet mobility, condensation rate and/or the heat transfer coefficient.
[0007] In an embodiment, the systems and devices of the invention are configured so as to increase the contact angle between a condensed droplet and a surface. For example, the contact angle may be increased as compared to the contact angle on a droplet of the same liquid on a flat smooth surface of the same material. Relevant aspects that facilitate an increase in contact angle include surface characteristics, fluid characteristics, and physical process characteristics. Surface characteristics include surface composition and/or surface geometry, such as position and geometry of relief or recessed features. Relevant fluid characteristics include molecular weight, surface tension, liquid-vapor interfacial energy, liquid-solid interfacial energy, solid-vapor interfacial energy, vapor pressure, saturation temperature, saturation pressure, critical temperature, and critical pressure. Accordingly, any of the methods and devices provided herein can relate to selection of any one or more of these aspects so as to ensure a maximal or acceptable increase in contact angle. Whether or not a surface is considered a repelling surface may be influenced by contact angle between a condensed droplet and the contact surface. In an embodiment, a refrigerant-repelling surface may be textured to provide a nonwetting surface even for surface-refrigerant systems that may normally be considered as wetting systems.
[0008] Examples of relevant physical process characteristics affecting the refrigerant-repellency of a surface include pressure, temperature and composition of the atmosphere. Another process characteristic that may affect the refrigerant-repellency of the surface is the condensation rate within the heat transfer device. Provided herein are methods and devices for accurately operating at atmospheric pressure or at non-atmospheric pressures, including below atmospheric pressure, above atmospheric pressure and substantially above atmospheric pressure. In addition, many conventional systems suffer from the limitation of having air present in the atmosphere of the heat transfer system. Provided herein are methods and devices wherein the atmosphere composition is substantially vapor of the refrigerant, including an atmosphere which contains either no air or negligible amounts of air. It has been observed that the vapor pressure of refrigerant in the atmosphere can affect the contact angle of a droplet on a surface; in some cases the characteristic or apparent contact angle may be lower in a vapor saturated atmosphere as compared to an air atmosphere (see Example 2 and FIG. 17 ). In these cases, increasing the contact angle of a liquid droplet on a surface when the atmosphere is substantially vapor of the refrigerant may be more difficult than for a droplet exposed to an atmosphere which is essentially air. In this manner, precise control over operating parameters are achieved, providing the ability tailor the process and device to particular refrigerant/substrate systems to achieve maximum possible increase in contact angle, thereby increasing the repellency of the surface to condensed droplets of refrigerant vapor.
[0009] In one aspect, the invention provides methods for condensation heat transfer which lead to dropwise condensation of refrigerant or working fluid. In an embodiment, the dropwise condensation heat transfer methods of the invention can lead to heat transfer exceeding 1 kW/cm 2 . In different embodiments, the condensation heat transfer processes of the invention take place under saturation conditions, under near saturation conditions, under conditions where the vapor is superheated, under conditions where the surface is undercooled or combinations thereof. In an embodiment, the condensation heat transfer processes of the invention take place under saturation conditions.
[0010] In an embodiment, the invention provides a method for condensation heat transfer comprising condensing a refrigerant vapor on a textured portion of an interior surface of a chamber to form a plurality of refrigerant droplets at a user selected pressure, thereby transferring heat from the refrigerant vapor to the interior surface wherein the user selected pressure is not atmospheric pressure, the textured portion of the interior surface comprises surface features, the surface features comprising a surface material and the apparent contact angle of the refrigerant droplets on the surface features is non-zero and greater than the characteristic contact angle of the refrigerant droplets on the surface material of the surface features.
[0011] In the methods of the invention, the apparent contact angle may be greater than the characteristic contact angle by at least 20 degrees or by at least 45 degrees. The methods of the invention may comprise condensing a refrigerant vapor on a textured surface to form a plurality of refrigerant droplets having an apparent contact angle greater than 90°. In different embodiments, the apparent contact angle of the droplets may be greater than 90° to less than or equal to 180°, 160°, 150°, 140°, 130°, 120°, or 110°. The refrigerant may comprise a halocarbon or hydrocarbon refrigerant and a lubricant such as a polyol ester or polyalkylene glycol lubricant. The composition of the refrigerant vapor may vary with position in the heat exchanger. In different embodiments, the refrigerant vapor may contain up to 5%, 10%, 15%, 20%, 25%, 30%, 40%, 45% or 50% by mass lubricant. The textured surface may comprise elevated or relief surface features. The surface features may form a “waffle” pattern as schematically illustrated in FIGS. 3A and 3B , Other surface features may have a reentrant geometry and may take the general form of “micromushrooms” schematically illustrated in cross-section in FIG. 19 . In addition, the textured surface comprises a surface material. The surface material may be a material with relatively low surface energy such as a fluorosilane or a polymer formed as a coating on the interior of the chamber. Other suitable type of surface coating materials is a mixture comprising a polymer such as polydimethylsiloxane (PDMS) and a filler material, such as zinc oxide or silica. In an embodiment, nonwetting refrigerant droplets can be achieved on the textured surface even though droplets of the refrigerant wet nontextured surface material. In different embodiments of the present invention, the characteristic contact angle of the refrigerant on the surface materials is less than 75°, less than 60°, less than 50°, less than 40°, less than 30°, less than 20°, less than 10° or less than 5°. In other embodiments, a plurality of refrigerant droplets on the textured surface have an apparent contact angle of 90° or less than 90°, but the apparent contact angle is greater than the characteristic contact angle of the refrigerant on the surface material. The temperature of the interior surface of the chamber where condensation occurs may be in a preselected temperature range and the surface tension of the refrigerant in the preselected temperature range may be from 5 mN/m to 25 mN/m, 5 mN/m to 20 mN/m, 5 mN/m to 15 mN/m or 5 mN/m to 10 mN/m.
[0012] The textured surface may be located inside a chamber such as a pressure vessel or vacuum chamber. The condensation process can take place under saturation conditions or near saturation conditions. The vapor may also be superheated and/or the surface may be supercooled in at least a portion of the chamber. In an embodiment, the pressure in the vessel may be from 5 kPa to 5 MPa, including specific subranges thereof such as above atmospheric pressure, below atmospheric pressure, or a pressure that is not atmospheric, including substantially not atmospheric. In an embodiment, standard atmospheric pressure may be taken as approximately 101.3 kPa. In an embodiment, the pressure in the vessel may be greater than atmospheric pressure and less than 5 MPa. “Substantially not atmospheric” refers to a pressure range that is at least 20% different from atmospheric. The temperature of the interior surface of the chamber where condensation occurs may be in a preselected range; the preselected range may be the saturation temperature of the refrigerant vapor+/−20%, 15%, 10% or 5%.
[0013] The methods of the invention may also comprise condensing a refrigerant vapor on a textured surface comprising a surface material to form a plurality of refrigerant droplets, wherein the mobility of the droplets is higher on the textured surface than the mobility of droplets formed on an “untextured” or “smooth” surface of the surface material, the condensation rate is higher on the textured surface than the condensation rate of an “untextured” or “smooth” surface of the surface material, and/or the heat transfer coefficient is higher for the textured surface than the heat transfer coefficient on an “untextured” or “smooth” surface of the surface material.
[0014] In another aspect, the invention provides a heat exchanger system which is a closed system containing both liquid and vapor phases. In an embodiment, at least a portion of the heat exchanger system comprises a textured portion, the textured portion of the system facilitating dropwise condensation of refrigerant vapor. The surface features of the texture may vary within the heat exchanger system in accordance with variations in vapor composition, pressure and temperature within the system. The portion of the heat exchanger system comprising the textured portion may be located in a condenser, and the system heat exchanger system may further comprises an evaporator configured to produce a vapor from a source liquid, the evaporator being in fluid communication with the condenser. FIG. 35 schematically illustrates a heat exchanger system comprising a condenser (100), evaporator (200) and compressor (300).
[0015] In an aspect, the invention provides a heat exchanger system for condensation heat transfer through condensation of a refrigerant vapor into droplets of the refrigerant, the heat exchanger system comprising: a chamber comprising an interior hollow portion and an interior surface, the interior surface comprising a textured portion, the textured portion of the surface comprising surface features, the surface features comprising a surface material wherein the apparent contact angle of the refrigerant droplets on the surface features is greater than the characteristic contact angle of the refrigerant droplets on the surface material of the surface features.
[0016] In another aspect, the invention provides a heat exchanger system for condensation heat transfer, the heat exchanger system comprising:
a) a chamber comprising an interior hollow portion and an interior surface, the interior surface comprising a textured portion, the textured portion of the surface comprising surface features, the surface features comprising a surface material; and b) a refrigerant positioned in the hollow portion of the chamber, the refrigerant being selected from the group consisting of halocarbon, hydrofluorocarbon (HFC), hydrofluoroolefin (HFO) and hydrocarbon (HC)
wherein the characteristic contact angle of a refrigerant droplet on the surface material in an atmosphere substantially comprising refrigerant vapor is less than 50° under saturation conditions.
[0019] In another aspect, the invention provides a heat exchanger system for condensation heat transfer, the heat exchanger system comprising:
a) a chamber comprising an interior hollow portion and an interior surface, the interior surface comprising a textured portion, the textured portion of the surface comprising surface features, the surface features a surface material; and b) a refrigerant positioned in the hollow portion of the chamber, the refrigerant being selected from the group consisting of halocarbon, hydrofluorocarbon (HFC), hydrofluoroolefin (HFO) and hydrocarbon (HC)
wherein as measured under saturation conditions or near saturation conditions the mobility of the droplets is higher on the textured surface than the mobility of droplets formed on an smooth surface of the surface material, the condensation rate is higher on the textured surface than the condensation rate of a smooth surface of the surface material, and/or the heat transfer coefficient is higher for the textured surface than the heat transfer coefficient on a smooth surface of the surface material.
[0022] In the methods and devices of the invention, the refrigerant may be any suitable refrigerant known to the art. In an embodiment, the refrigerant may comprise a component selected from the group consisting of halocarbon, hydrofluorocarbon (HFC), hydrofluoroolefin (HFO), hydrocarbon (HC) and water or may be selected from the group consisting of halocarbon, hydrofluorocarbon (HFC), hydrofluoroolefin (HFO) and hydrocarbon (HC).
[0023] In an aspect of the invention, the surface characteristics are selected to contribute to refrigerant repellency, increased droplet mobility, increased condensation rate and/or higher heat transfer coefficient. In an embodiment, the surface features on the interior surface of the pressure vessel comprise nanoparticles. In an embodiment, the average diameter of the nanoparticles is 2-300 nm and the average spacing between nanoparticles is 10-1000 nm. In an embodiment, the elevated features form a network of “walls” surrounding features of lower elevation (relative depressions) to form a “waffle” pattern. The elevated “wall” features may have an average width between 5 nm and 10 microns and an average spacing or pitch between 50 nm and 250 micron or from 5 micron to 100 micron, 10 to 50 microns or from 15 microns to 30 microns. The depth of the depressions may be from 50 nm to 250 microns, from 5 micron to 100 micron, 5 to 50 microns or from 15 microns to 30 microns. The pitch may be greater than the depth of the depressions.
[0024] In another embodiment the surface features comprise elevated features shaped like “micromushrooms” with a “cap” typically wider than the “stem”. FIG. 19 illustrates several parameters which can be used to characterize such “micromushroom” structures. Suitable ranges of these parameters for the refrigerants described herein include, but are not limited to: D=40-70, W=20-100, R=25-40 and H=65-110, D=40-60, W=80-100, R=25-40 and H=90-110 and D=45-55, W=90-100, R=30-40 and H=100-110 and intermediate ranges.
[0025] A refrigerant repelling surface may have any surface texture capable of contributing to refrigerant repellency and may be such that the surface features of the textured surface provide a re-entrant geometry or such that surface features form a “waffle” or grid pattern. The surface material composing the refrigerant repelling material may have a relatively low surface energy and may comprise a polymer or a surface treatment material such as a silane coating. In some embodiments, the surface material comprises a fluoropolymer or a fluorosilane. Other materials proposed for use as relatively low surface energy coatings include diamond-like carbon and fluorinated diamond-like coatings.
[0026] In an embodiment, the atmosphere in the pressure vessel substantially comprises refrigerant vapor. For example, the amount of air present in the atmosphere of the pressure vessel may be less than 50%, less than 25%, less than 10%, less than 5%, or about zero.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIGS. 1 a - 1 c : Standard conceptual models for a liquid droplet on a flat surface ( 1 a ), on a wetted rough surface ( 1 b ), and on a partially wetted surface ( 1 c ). The wetting state in the middle ( 1 b ) is the Wenzel mode, and the wetting state on the right ( 1 c ) is the Cassie-Baxter mode.
[0028] FIG. 2 : Graphical Representation of T C γLV
[0029] FIGS. 3A-B : Schematic top view of a hexagonal waffle structure ( FIG. 3A ) and a grid-like waffle structure ( FIG. 3B ).
[0030] FIGS. 4A-4C : Schematic top view of different configurations of pillar elements: hexagonal arrangement ( FIG. 4A ), square arrangement ( FIG. 4B ), and honeycomb arrangement ( FIG. 4C ).
[0031] FIG. 5 : Experimental apparatus
[0032] FIG. 6 : Contact angles plotted at the saturation pressure of water for a given temperature between 25 and 250° C.
[0033] FIG. 7 : Image of a droplet of distilled water on a waffle patterned Si wafer coated in PTFE inside of pressure vessel. Image taken at 35.8° C. and 62.0 kPa. Vapor is water.
[0034] FIG. 8 : Image sequence of a droplet of water evaporating on a flat Si wafer coated in PTFE inside of the pressure vessel. Images taken at labeled temperatures and corresponding saturation pressures.
[0035] FIG. 9 : Plot of temperature dependent contact angle for a textured surface (pillars, d=50 μm h=50 μm p=100 μm) compared to a flat surface and the mathematical model. Vapor is water.
[0036] FIGS. 10 a - 10 b : Image sequence of water droplet on waffle patterned Si wafer coated in PTFE. Droplet heated from 31.7° C. to 54.1° C. Droplet triple line expands outward due to expansion of trapped pockets of water vapor between droplet and surface until reaching a maximum at 46.4° C. Vapor is water. FIG. 10 a shows 31.7° C. to 43.2° C. FIG. 10 b shows 46.4° C. to 54.1° C.
[0037] FIG. 10 c : magnified image of vapor expansion inside of water droplet. (from FIG. 10 b ) Vapor is water.
[0038] FIG. 11 : Image sequence of water droplet on waffle textured (25 μm squares 50 μm pitch) Si wafer coated with PTFE inside pressure vessel. As triple line expands, Er decreases from ˜90° to ˜32° after the trapped water vapor completes expansion inside droplet. Vapor is water.
[0039] FIG. 12 : Droplet of water on a glass slide with micro textured surfaces coated in silane inside of pressure vessel. Image taken at 22° C. and 100. 3 kPa. Vapor is water. Apparent contact angle 113°.
[0040] FIG. 13 : droplet of water on a glass slide with micro textured surfaces without silane coating inside of pressure vessel. Image taken at 22° C. and 100. 3 kPa. Vapor is water. Apparent contact angle 60°.
[0041] FIG. 14 : Scanning Electron Microscope (SEM) image of microtextures on glass slide.
[0042] FIG. 15 : Water droplet on zinc-oxide nano particle coated glass slide. Image taken at 22° C. and 100. 3 kPa. Apparent contact angle 170 degrees. Vapor is water.
[0043] FIGS. 16 a and b : SEM images of a PDMS:ZnO coating at two different magnfications
[0044] FIG. 17 : Water droplets on a flat PTFE coated surface and various micro textured surfaces as indicated. All images taken at 22° C.
[0045] FIG. 18 a : Apparent contact angle of water droplets on flat and square pillar textured surfaces in saturated water vapor. Model predictions also shown.
[0046] FIG. 18 b Apparent contact angle of water droplets on flat and square waffle textured surfaces in saturated water vapor. Model predictions also shown.
[0047] FIG. 19 : Schematic cross-sectional view of “micromushroom” features. Partial micromushroom shown at right and left edges.
[0048] FIGS. 20 a - f : SEM images of micro mushrooms of various configurations.
[0049] FIGS. 21 a - d show sessile drops on a micromushroom texture with D=53 μm W=66 μm R=35 μm and H=85 μm. FIG. 21 a : water on uncoated surface. FIG. 21 b : oleic acid on uncoated surface. FIG. 21 c : water on surface coated with Teflon® AF. FIG. 21 d : oleic acid on surface coated with Teflon® AF.
[0050] FIGS. 22 a - d show sessile drops on a micromushroom texture with D=68 μm W=58 μm R=30 μm H=90 μm. FIG. 22 a : water on uncoated surface.
[0051] FIG. 22 b : oleic acid on uncoated surface. FIG. 22 c : water on surface coated with Teflon® AF. FIG. 22 d : oleic acid on surface coated with Teflon® AF.
[0052] FIGS. 23 a - d show sessile drops on a micromushroom texture with D=44 μm W=92 μm R=28 μm H=107 μm. FIG. 23 a : water on uncoated surface.
[0053] FIG. 23 b : oleic acid on uncoated surface. FIG. 23 c : water on surface coated with Teflon® AF. FIG. 23 d : oleic acid on surface coated with Teflon® AF.
[0054] FIGS. 24 a - d show sessile drops on a micromushroom texture D=55 μm W=19 μm R═NA μm H=94 μm. FIG. 24 a : water on uncoated surface.
[0055] FIG. 24 b : oleic acid on uncoated surface. FIG. 24 c : water on surface coated with Teflon® AF. FIG. 24 d : oleic acid on surface coated with Teflon® AF.
[0056] FIGS. 25 a - d show sessile drops on a micromushroom texture D=48 μm W=96 μm R=35.7 μm H=107 μm. FIG. 25 a : water on uncoated surface.
[0057] FIG. 25 b : oleic acid on uncoated surface. FIG. 25 c : water on surface coated with Teflon® AF. FIG. 25 d : oleic acid on surface coated with Teflon® AF.
[0058] FIGS. 26 a - d show sessile drops on a micromushroom texture D=60 μm W=31.5 μm R=30 μm H=67 μm. FIG. 26 a : water on uncoated surface.
[0059] FIG. 26 b : oleic acid on uncoated surface. FIG. 26 c : water on surface coated with Teflon® AF. FIG. 26 d : oleic acid on surface coated with Teflon® AF.
[0060] FIG. 27 : Images of halocarbon 200 oil on ZnO particle coated slide. Image taken at 22° C. and 100. 3 kPa.
[0061] FIG. 28 a : Image of RL 68H oil droplet on ZnO particle coated surface (5% ZnO, 2:1fPDMS). The apparent contact angle was measured as 25.4°.
[0062] FIG. 28 b : Image of contact angle obtained for a PDMS:ZnO 2:1 coating at standard temperature and pressure (STP). The apparent contact angle obtained was 138.6°.
[0063] FIG. 28 c : Image of RL 68H oil droplet on micropillar textured surface (d=10, p=22, h=20) coated with PTFE. The apparent contact angle was measured as 122.0°.
[0064] FIGS. 29 a - f : Image of various R-134:RL 68H compositions at saturation on a micromushroom textured surface (D=68 μm W=58 μm R=30 μm H=90 μm) coated with Teflon® AF. FIG. 29 a : 0% R-134a; FIG. 29 b : 25% R-134a. FIG. 29 c : 33% R-134a. FIG. 29 d : 50% R-134a. FIG. 29 e : 60% R-134a. FIG. 29 f : 80% R-134a.
[0065] FIGS. 30 a - f : Image of various R-134:RL 68H compositions at saturation on a micromushroom textured surface (D=55 μm W=19 μm R═NA μm H=94 μm) coated with Teflon® AF. FIG. 30 a : 0% R-134a; FIG. 30 b : 25% R-134a. FIG. 30 c : 33% R-134a. FIG. 30 d : 50% R-134a. FIG. 30 e : 60% R-134a. FIG. 30 f : 80% R-134a.
[0066] FIGS. 31 a - f : Image of various R-134:RL 68H compositions at saturation on a micromushroom textured surface (D=48 μm W=96 μm R=35.7 μm H=107 μm) coated with Teflo® n AF. FIG. 31 a : 0% R-134a; FIG. 31 b : 25% R-134a. FIG. 31 c : 33% R-134a. FIG. 31 d : 50% R-134a. FIG. 31 e : 60% R-134a. FIG. 31 f : 80% R-134a.
[0067] FIGS. 32 a - f : Image of various R-134:RL 68H compositions at saturation on a square waffle textured surface (p=12 μm) coated with Teflon® AF. FIG. 32 a : 0% R-134a; FIG. 32 b : 25% R-134a. FIG. 32 c : 33% R-134a. FIG. 32 d : 50% R-134a. FIG. 32 e : 60% R-134a. FIG. 32 f : 80% R-134a.
[0068] FIGS. 33 a - f : Image of various R-134:RL 68H compositions at saturation on a square waffle textured surface (p=22 μm) coated with Teflon® AF. FIG. 33 a : 0% R-134a; FIG. 33 b : 25% R-134a. FIG. 33 c : 33% R-134a. FIG. 33 d : 50% R-134a. FIG. 33 e : 60% R-134a. FIG. 33 f : 80% R-134a.
[0069] FIG. 34 : Image of R-134a droplet with a relatively high apparent contact angle on PTFE coated waffle pattern Si wafer in pressure vessel. Image taken at 24° C. and 645.8 kPa. Vapor is R134a.
[0070] FIG. 35 : Schematic of heat exchanger system including a condenser, evaporator and compressor.
DETAILED DESCRIPTION
[0071] As used herein, a refrigerant is a substance used in a heat cycle that undergoes a phase change between gas and liquid. Accordingly, a refrigerant vapor is the gas phase of a refrigerant. If the refrigerant is a mixture of components, the composition of the vapor phase may differ from that of the liquid. For example if the refrigerant is a mixture of a halocarbon refrigerant and a lubricant, the vapor of the mixture may be mostly halocarbon refrigerant vapor.
[0072] Refrigerants include inorganic refrigerants, halocarbon refrigerants, and hydrocarbon refrigerants. Refrigerants also include mixtures of inorganic refrigerants, halocarbon refrigerants and hydrocarbon refrigerants with additional components in the system such as lubricants. The methods and devices provided herein are compatible with a wide range of refrigerants, so long as the vapor is capable of condensing into liquid droplets on a surface, including onto a surface that is refrigerant repelling. Examples of certain refrigerants of interest in the context of the methods and devices provided herein include: R-11 Trichlorofluoromethane, R-12 Dichlorodifluoromethane, R-13 B1 Bromotrifluoromethane, R-22 Chlorodifluoromethane, R-32 Difluoromethane R-113, Trichlorotrifluoroethane, R-114 Dichlorotetrafluoroethane, R-123 Dichlorotrifluoroethane, R-124 Chlorotetrafluoroethane, R-125 Pentafluoroethane, R-134a Tetrafluoroethane, R-143a Trifluoroethane, R-152a Difluoroethane and R-245a Pentafluoropropane, 2,3,3,3-tetrafluoroprop-1-ene (HFO 1234yf) and rans-1,3,3-tetrafluoroprop-1-ene (HFO 1234zeE), R290 propane, R600 n-butane, R600a isobutene (2-methyl propane), R1150 ethylene and R1270 propylene, R-401A (53% R-22, 34% R-124, 13% R-152a), R-401B (61% R-22, 28% R-124, 11% R-152a), R-402A (38% R-22, 60% R-125, 2% R-290), R-404A (44% R-125, 52% R-143a, R-134a), R-407A (20% R-32, 40% R-125, 40% R-134a), R-407C (23% R-32, 25% R-125, 52% R-134a), R-502 (48.8% R-22, 51.2% R-115) 0.283 4.1 and R-507 (45% R-125, 55% R-143).
[0073] Inorganic refrigerants known to the art include air, ammonia, carbon dioxide sulfur dioxide and water. In an embodiment, water may be used as a refrigerant in the methods of the invention under selected process conditions (e.g. under saturation or near saturation conditions and the pressure is less than atmospheric pressure). The surface tension of water is 72.8 mN/m @ 20° C.
[0074] As used herein, the term halocarbon refers to a chemical compound including carbon and one or more of the halogens (bromine, chlorine, fluorine, iodine). In an embodiment, the halocarbon may also include hydrogen. Exemplary halocarbon refrigerants include R-11 Trichlorofluoromethane, R-12 Dichlorodifluoromethane, R-13 B1 Bromotrifluoromethane, R-22 Chlorodifluoromethane, R-32 Difluoromethane R-113, Trichlorotrifluoroethane, R-114 Dichlorotetrafluoroethane, R-123 Dichlorotrifluoroethane, R-124 Chlorotetrafluoroethane, R-125 Pentafluoroethane, R-134a Tetrafluoroethane, R-143a Trifluoroethane, R-152a Difluoroethane and R-245a Pentafluoropropane.
[0075] In an embodiment, the halocarbon refrigerant is a hydrofluorocarbon (HFC) or hydrofluoroolefin (HFO). Exemplary HFC refrigerants include, but are not limited to, R-125 Pentafluoroethane, R-134a Tetrafluoroethane, R-143a Trifluoroethane, R-152a Difluoroethane and R-245a Pentafluoropropane. Exemplary hydrofluorolefin refrigerants include but are not limited to 2,3,3,3-tetrafluoroprop-1-ene (HFO 1234yf) and rans-1,3,3-tetrafluoroprop-1-ene (HFO 1234zeE). Surface tension of R-134a is 14.6 mN/m @-20° C.; surface tension of HFO-1234yf is 2.0 @ 55° C., 9.5 @ 0° C.
[0076] As used herein, the term hydrocarbon refers to a chemical compound consisting of carbon and hydrogen. Hydrocarbon refrigerants include, but are not limited to R290 propane, R600 n-butane, R600a isobutene (2-methyl propane), R1150 ethylene and R1270 propylene.
[0077] Refrigerant mixtures are also possible. The mixture may be an azeotropic: mixture whose vapor and liquid phases retain identical compositions over a wide range of temperatures. The mixture may also be a zeotropic mixture whose composition in liquid phase differs from that in vapor phase. Zeotropic refrigerants therefore do not boil at constant temperatures unlike azeotropic refrigerants. Exemplary refrigerant mixtures are R-401A (53% R-22, 34% R-124, 13% R-152a), R-401B (61% R-22, 28% R-124, 11°/o R-152a), R-402A (38% R-22, 60% R-125, 2% R-290), R-404A (44% R-125, 52% R-143a, R-134a), R-407A (20% R-32, 40% R-125, 40% R-134a), R-407C (23% R-32, 25% R-125, 52% R-134a), R-502 (48.8% R-22, 51.2% R-115) 0.283 4.1R-507 (45% R-125, 55% R-143).
[0078] A variety of lubricants suitable for use in heat exchanger systems are known to the art. In different embodiments, the lubricant may be a polyol ester (POE) or a polyalkylene glycol (PAG). Polyol esters include, but are not limited to neopentyl glycols, trimethylolpropanes, pentaerythritols and dipentaerytrhitols. Specific polyol esters include, but are not limited to RL68H. In an embodiment, the viscosity of the lubricant may be described by an ISO viscosity grade number such as ISO 68, ISO 46 or ISO 100.
[0079] In the methods of the invention, the temperature and pressure of the vapor is generally less than the critical temperature and pressure of the refrigerant. The temperature and pressure of the vapor may vary within the heat exchanger apparatus. For example, the vapor may be superheated after exiting a compressor and be at a lower temperature, such as at or near its saturation temperature, adjacent to a surface of surface of the condenser. Under saturation conditions, the refrigerant can exist in both liquid and vapor form. The saturation temperature is the temperature where a substance changes between its liquid and its vapor phase (at a given pressure). Similarly, the saturation vapor pressure is the vapor pressure where a substance changes between its liquid and its vapor phase (at a given temperature). The relationship between the pressure and the temperature is fixed under saturation conditions. Near saturation conditions, where the pressure and temperature are close to but not at the steady state values, can also support evaporation and condensation. In different embodiments, near saturation conditions capable of supporting evaporation and condensation may involve pressures and temperatures which are within 20%, 15%, 10% or 5% of their saturation values. In an embodiment, the condensation heat transfer processes of the invention take place in an enclosure such as a pressure vessel under saturation or near saturation conditions.
[0080] As used herein, “characteristic contact angle” refers to the static contact angle of a droplet of refrigerant on an essentially flat or smooth solid surface of a given material, including under standard conditions. The characteristic contact angle may be taken as the mean or median of several measurements of contact angle. The characteristic contact angle is also referred to as θ. In different embodiments of the present invention, the characteristic contact angle of the refrigerant on a surface material is less than 50°, less than 40°, less than 30°, less than 20°, less than 10° or less than 5°. The characteristic contact angle may be a static contact angle, an advancing contact angle or a receding contact angle.
[0081] As used herein, “apparent contact angle” refers to the contact angle of a droplet of refrigerant on a textured surface and may also be referred to as θ*. In an embodiment, the size of the droplet is greater than or equal to the size of the features creating the surface texture. For example, if the surface texture is created by particles on the surface, the droplet size may be greater than the particle size. In an embodiment, the apparent contact angle of a droplet of refrigerant on a textured surface of a given material is greater than the characteristic contact angle of the refrigerant on the same material (without texture) when the droplet size is greater than the size of the features creating the surface texture, the surrounding atmosphere, temperature and pressure being the same in both cases. In different embodiment, the apparent contact angle may be greater than the characteristic contact angle by greater than 45°. In an embodiment, the apparent contact angle of at least some of the droplets is greater than 90°. In an embodiment, the apparent contact angle on a given surface texture is assessed in the temperature or pressure range of interest under saturation conditions. The contact angle of a droplet may also depend on whether the measurement is a static measurement or a dynamic measurement.
[0082] In an aspect, the contact angle of a droplet with a surface may change during droplet formation. Accordingly, any of the methods and devices provided herein may measure contact angle at a user-defined times or stages, thereby providing the ability to better characterize and compare different systems. For example, the time point may be at specified time after droplet condensation begins, or may be at a specific stage of the process, such as immediately prior to exit of the moving droplet from the system or any stage between formation to exit, such as at a half-way point. Other relevant parameters may include rates or speed at which maximum contact angle is achieved as certain fluids may initially condense with a rather flat contact angle and then increased in contact angle as the droplet further forms. With this in mind, any of the devices and methods provided herein may be characterized in terms of a surface repellency ratio defined as θ*/θ for a given system, such as a surface repellency ratio that is greater than or equal 2, including selected from a range that is greater than or equal to 2 and less than or equal 150, greater than or equal to 5 and less than or equal 100 ratio, or greater than or equal to 5 and less than or equal 15, or about 10 or more, with θ*>90° and θ< 90 °.
[0083] Surface composition (e.g. use of low energy surfaces or low energy surface coatings) can influence the wettability of the surface by the liquid. In some embodiments, the surface may comprise a fluoropolymer or fluorosilane. Suitable fluoropolymers include, but are not limited to, Polytetrafluoroethylene (PTFE) and amorphous PTFE (e.g. Teflon® AF). Commercially available fluorosilanes such as Dow Corning 2604, 2624, and 2634; DK Optool DSX™; Shintesu OPTRON™; heptadecafluoro silane (manufactured, for example, by Gelest); FLUOROSYL™ (manufactured, for example, by Cytonix).
[0084] In one aspect, textured surfaces useful for the invention have surface textures which facilitate droplet mobility along the surface. In this manner, as droplets form on a surface, the droplets move along the surface thereby avoiding film formation. In an embodiment, the refrigerant repelling surfaces of the invention facilitate droplet movement along the surface. One way to measure the ease of roll-off is to determine the angle of tilt from the horizontal needed before a drop will roll off a surface. The lower the tilt angle, the more easily the drop rolls off the surface.
[0085] As used herein, “surface texture” can refer to three-dimensional features on a surface that intrudes into an interior volume that contains the refrigerant. In an aspect, surface texture may comprise relief and recess features. In this manner, an elevated surface feature is considered a relief feature, and the corresponding non-elevated portion may be considered, relative to the relief feature, a recess feature. For example, the “micromushroom” features shown in FIG. 19 may be considered to be relief features. Refrigerant behavior on textured surfaces may be compared to that on smooth surfaces. In an embodiment, a “smooth” surface has a surface roughness significantly less than (e.g. less than ½ of, less than ¼ of or less than 1/10 of) the characteristic depth or height of features on the textured surface. In an embodiment, the surface texture of the interior of the pressure vessel includes topographically complex, three-dimensional microstructures or nanostructures with reentrant geometries. Surfaces having a reentrant geometry typically include a protruding portion configured to protrude toward a liquid and a reentrant portion opposite the protruding portion. Such reentrant structures can be formed by particles or fibers, whose curvature provides the reentrant feature. The reentrant structures can also be made with etching techniques. Nonwoven or woven fabrics, including fabrics woven of metal fibers, can also provide reentrant geometry.
[0086] In another embodiment, the surface features on the interior surface of the pressure vessel comprise nanoparticles. In an embodiment, the average diameter of the nanoparticles is 2-300 nm and the average spacing between nanoparticles 10-1000 nm. In an embodiment, the nanoparticles may be selected from the group consisting of ZnO and other metal oxides as well as silica and silicon dioxide. The surface of the nanoparticle may also be treated to adjust the wettability of the nanoparticle. For example, the nanoparticles can be halogenated, perhalogenated, perfluorinated, or fluorinated nanoparticles, for example, perfluorinated or fluorinated silsesquioxanes. Particle coatings are also described in Steele et al., 2009, Nano Letters, 9, 501-505, hereby incorporated by reference.
[0087] In another embodiment the features of the textured surface form a periodically repeating array. FIG. 3A schematically illustrates a top view of features forming a “waffle” pattern of interconnected elevated “wall” or “ridge” features (indicated by double lines in the figure) surrounding hexagonal depressions. FIG. 3B schematically illustrates a top view of features forming a “waffle” pattern interconnected elevated grid-like “wall” or “ridge” features (indicated by double lines in the figure) surrounding square depressions. Such features may be characterized by the dimension of the depression (e.g. w or w), the pitch or microstructure period (dimension of depression+dimension of wall, e.g. p or p) and the depth of the depression (e.g. d or d) or height of the wall (e.g. h or h). In an embodiment, the elevated wall features in the “waffle” have an average width between 5 nm and 10 microns and an average spacing between 50 nm and 250 microns. The depth of the depressions/height of the elevated features may be on the order of the width of the depressions (spacing between the elevated features. In different embodiments, the depth of the depressions may be from 5 nm to 250 microns or 50 nm to 250 microns. The dimensions of the surface features are selected in accordance with operating conditions and refrigerant composition so as to ensure increase in the contact angle of a condensed droplet on the textured surface. In an embodiment, the surface texture is selected so that the surface is considered refrigerant repelling, even though refrigerant may wet a flat surface of the surface material.
[0088] In another embodiment, the features of the textured surface resemble mushrooms, with a top cap portion that is wider than its stem. As illustrated by FIG. 19 , this type of structure can be characterized by its cap width (2W), the height between the bottom of the cap and the surface (H), the cap radius (R) and the spacing between neighboring caps (2D). Suitable ranges of these parameters for the refrigerants described herein include: D=40-70, W=20-100, R=25-40 and H=65-110.
[0089] All references cited herein are hereby incorporated by reference to the extent not inconsistent with the disclosure herewith. All references throughout this application, patent application publications; and non-patent literature documents or other source material; are hereby incorporated by reference herein in their entireties, as though individually incorporated by reference, to the extent each reference is at least partially not inconsistent with the disclosure in this application (for example, a reference that is partially inconsistent is incorporated by reference except for the partially inconsistent portion of the reference).
[0090] All patents and publications mentioned in the specification are indicative of the levels of skill of those skilled in the art to which the invention pertains. References cited herein are incorporated by reference herein in their entirety to indicate the state of the art, in some cases as of their filing date, and it is intended that this information can be employed herein, if needed, to exclude (for example, to disclaim) specific embodiments that are in the prior art. For example, when a compound is claimed, it should be understood that compounds known in the prior art, including certain compounds disclosed in the references disclosed herein (particularly in referenced patent documents), are not intended to be included in the claim.
[0091] Every formulation or combination of components described or exemplified can be used to practice the invention, unless otherwise stated. Specific names of compounds are intended to be exemplary, as it is known that one of ordinary skill in the art can name the same compounds differently. When a compound is described herein such that a particular isomer or enantiomer of the compound is not specified, for example, in a formula or in a chemical name, that description is intended to include each isomers and enantiomer of the compound described individual or in any combination. One of ordinary skill in the art will appreciate that methods, device elements, starting materials, and synthetic methods other than those specifically exemplified can be employed in the practice of the invention without resort to undue experimentation. All art-known functional equivalents, of any such methods, device elements, starting materials and synthetic methods, and are intended to be included in this invention. Whenever a range is given in the specification, for example, a temperature range, a time range, or a composition range, all intermediate ranges and subranges, as well as all individual values included in the ranges given are intended to be included in the disclosure.
[0092] As used herein, “comprising” is synonymous with “including,” “containing,” or “characterized by,” and is inclusive or open-ended and does not exclude additional, unrecited elements or method steps. As used herein, “consisting of” excludes any element, step, or ingredient not specified in the claim element. As used herein, “consisting essentially of” does not exclude materials or steps that do not materially affect the basic and novel characteristics of the claim. Any recitation herein of the term “comprising”, particularly in a description of components of a composition or in a description of elements of a device, is understood to encompass those compositions and methods consisting essentially of and consisting of the recited components or elements. The invention illustratively described herein suitably may be practiced in the absence of any element or elements, limitation or limitations which is not specifically disclosed herein.
[0093] The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims.
[0094] In general the terms and phrases used herein have their art-recognized meaning, which can be found by reference to standard texts, journal references and contexts known to those skilled in the art. The following definitions are provided to clarify their specific use in the context of the invention.
[0095] Although the description herein contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of the invention. For example, thus the scope of the invention should be determined by the appended claims and their equivalents, rather than by the examples given.
[0096] The invention may be further understood by the following non-limiting examples.
Example 1
Surface Tension and Contact Angle Calculations
[0097] Equations 1 and 2 give relationships between the flat surface contact angle and the relevant surface free energies and the variation in the surface free energy with temperature.
[0000]
Cos
(
θ
C
)
=
γ
SG
-
γ
SL
γ
LV
(
Equation
1
)
γ
(
T
)
=
γ
(
T
0
)
+
Tc
γ
*
(
Δ
T
)
(
Equation
2
)
[0098] Where θ c : Flat surface contact angle, γ LV : Surface tension of water, γ SG : Surface free energy (SFE) of surface (e.g. PTFR), γ SL : SFE between surface and water, γ(T 0 ): Value of γ at temperature T 0 ., T C γ : Temperature coefficient of the substance., ΔT: (T 0 −T).
[0099] FIG. 1 a illustrates the contact angle on a flat surface; in FIG. 1 a θ is equivalent to θ c in equation 1.
[0100] FIG. 2 shows water surface tension as a function of temperature.
[0000]
Cos
(
θ
int
)
=
γ
SG
(
T
int
)
-
γ
SL
(
T
int
)
γ
LG
(
T
int
)
(
Equation
3
)
Cos
(
θ
crit
)
=
γ
SG
(
T
crit
)
-
γ
SL
(
T
crit
)
γ
LG
(
T
crit
)
(
Equation
4
)
Tc
γ
SL
=
γ
SL
(
T
crit
)
-
γ
LV
(
T
int
)
T
crit
-
T
int
(
Equation
5
)
[0101] Where γ SLcrit : Critical surface tension. Defined as Cos(θ c )=1 @ γ LV (T crit )=γ crit , T crit : Temperature where γ LV (T)=γ crit , θ int :θ c at T int . Use Equation 2 to solve Equations 3-5 simultaneously. This determines T C γSL , γ SL @ 25 °, and T C γSL . Once these values are known, Equation 1 can be solved at any temperature. Tables 1 and 2 show initial conditions and unknowns related to interfacial energy related parameters and contact angle parameters respectively.
[0000]
TABLE 1
γ
γ @ 25° C. (mN/m)
T Cγ (mN/m*K)
γ LV
72.04
−0.1514
γ SG
19.71
−0.0580
γ SL
??
??
γ SLcrit
18.00
N/A
[0000]
TABLE 2
θ
Angle (°)
T
(° C.)
θint
95
T int
25
θcrit
0
T crit
??
[0102] FIG. 1 b illustrates a liquid droplet on a rough surface in the Wenzel state. This state may be described by cos θ w =r cos θ (Equation 6), where r is the Wenzel roughness factor. FIG. 1 c illustrates a liquid droplet on a rough surface in the Cassie-Baxter state, where the droplet sits on top of the surface roughness. This state may be described by cos θ CB =f (cos θ+1)−1=f cos θ−(1−f) (Equation 7) where f is the Cassie roughness factor. For a surface with pitch p, A elements per area p 2 , surface area of element top s, element height h and perimeter of element top L, the Wenzel roughness factor may be described by r=1+(A/p 2 ) hL (Equation 8). Similarly the Cassie roughness factor may be described by f=(A/p 2 ) S (Equation 9).
Example 2
Measurements for Water and Oleic Acid
[0103] FIGS. 3A-B and 4A-C schematically illustrate some of the waffle and pillar surface textures fabricated for testing. FIG. 3 is a schematic top view of a hexagonal waffle structure ( FIG. 3A ) and a grid-like waffle structure ( FIG. 3B ). FIG. 4 is a schematic top view of different configurations of pillar elements: hexagonal arrangement ( FIG. 4A ), square arrangement ( FIG. 4B ), and honeycomb arrangement ( FIG. 4C ).
[0104] Tables 3 and 4 respectively provide additional information about waffle and pillar surface textures. In Table 2, h is element height, p is pitch and w is width of square or hexagonal depression. In Table 4, A is elements per area p 2 , d is diameter of the pillar, p is pitch, and h is element height.
[0000]
TABLE 3
Square Waffles
h (μm)
p(μm)
w (μm)
3
22
20
Hexagonal Waffles
h (μm)
p(μm)
w (μm)
3
12
10
[0000]
TABLE 4
Square Pillars
A
d (μm)
h (μm)
p (μm)
1
50
50
100
Hexagonal Pillars
A
d (μm)
h (μm)
p (μm)
1.57
50
300
100
[0105] FIG. 5 shows an experimental setup used for contact angle measurements. The apparatus includes a pressure chamber 10 , a pump 20 , which may be an infusion pump, a camera 30 , a light source 40 and data acquisition unit 50 .
[0106] Table 5 shows the contact angle (CA) measured for water and oleic acid oil on smooth and microtextured surfaces. The surfaces are either smooth, textured with a waffle pattern of FIG. 3 as either hexagons or squares, or textured with a standard lotus leaf type pattern consisting of dense pillar structures ( FIG. 4 ). w is feature width, d is diameter, p is microstructure period, and h is feature height (or depth of waffles).
[0000]
TABLE 5
w or d
p
h
Water
Oleic Acid
Pattern
μm
μm
μm
CA°
CA°
Smooth
—
—
—
118
66
Hexagon Waffles
20
22
0.3
144
135
Hexagon Waffles
20
22
1.0
142
137
Square Waffles
20
22
151
151
139
Square Waffles
20
22
146
146
140
Square Pillars
10
20
148
149
68
[0107] FIG. 6 shows a graph for θ values between 25 and 250° C. Contact angles plotted at the saturation pressure of water for a given temperature for different surface textures (values from model).
[0108] FIG. 7 shows an image of a droplet of distilled water on a waffle patterned Si wafer coated in PTFE inside of pressure vessel. Image taken at 35.8° C. and 62.0 kPa. Vapor is water.
[0109] FIG. 8 shows an image sequence of a droplet of water evaporating on a flat Si wafer coated in PTFE inside of the pressure vessel. Images taken at labeled temperatures and corresponding saturation pressures.
[0110] FIG. 9 shows a plot of temperature dependent contact angle for a textured surface (pillars, d=50 μm h=50 μm p=100 μm) compared to a flat surface and the mathematical model. Vapor is water.
[0111] FIGS. 10 a - 10 b show an image sequence of water droplet on waffle patterned Si wafer coated in PTFE. Droplet heated from 31.7° C. to 54.1° C. Droplet triple line expands outward due to expansion of trapped pockets of water vapor between droplet and surface until reaching a maximum at 46.4° C. Vapor is water. FIG. 10 c shows a magnified image of vapor expansion inside of water droplet. (see FIG. 10 b ) Vapor is water. Waffle pattern 10 micrometer squares, 20 micrometer pitch.
[0112] FIG. 11 shows an image sequence of water droplet on waffle textured (25 μm squares 50 μm pitch). Si wafer coated with PTFE inside pressure vessel. As triple line expands, θ* decreases from ˜90° to ˜32° after the trapped water vapor completes expansion inside droplet. Vapor is water.
[0113] FIG. 12 shows a droplet of water on a glass slide with micro textured surfaces coated in silane inside of pressure vessel. Image taken at 22° C. and 100. 3 kPa. Vapor is water. Apparent contact angle 113°.
[0114] FIG. 13 shows a droplet of water on a glass slide with micro textured surfaces without silane coating inside of pressure vessel. Image taken at 22° C. and 100. 3 kPa. Vapor is water. Apparent contact angle 60°.
[0115] FIG. 14 shows an SEM image of microtextures on glass slide (see FIGS. 12 and 13 ).
[0116] FIG. 15 shows a water droplet on zinc-oxide nano particle coated glass slide. Image taken at 22° C. and 100. 3 kPa. Vapor is water
[0117] FIGS. 16 a - b show SEM images of a 2PDMS:1ZnO coating at two different magnfications.
[0118] FIG. 17 shows water droplets on flat and microtextured PTFE coated surfaces, when the surrounding environment is air, low pressure air, or water vapor. The apparent contact angle of the droplets decreased for both the square pillar and square waffle textured surfaces when the vapor phase was changed from air to water vapor. These measurements demonstrate that the vapor environment around the water droplet influences how the water droplet wets the surface (All images taken at 22° C.). FIG. 18 a shows apparent contact angles for flat and square pillar textured surfaces while FIG. 18 b shows apparent contact angles for flat and square waffle surfaces in saturated water vapor at various temperatures.
[0119] FIG. 19 illustrates relevant dimensions for surface features having a “mushroom” or “micro mushroom” geometry. W is width from the center of the stem to the edge of the cap. R is the radius of the cap. H is the distance between the lower portion of the surface and the bottom of the cap. 2D is the spacing between the edges of the caps. Θ is the characteristic contact angle, ψ is the local geometry angle, h1 is a sagging height and h2 is a pore depth (Tuteja et al., 2008, PNAS, 107(47), 18200-19205). Table 6 lists relevant dimensions for several micromushroom surface textures.
[0000]
TABLE 6
D
W
R
H
Sample No.
(μm)
(μm)
(μm)
(μm)
1
53
66
35
85
2
67.5
58
30
90
3
44
92
28
107
4
55
19
N/A
94
5
48
96
35.7
107
6
60
31.5
30
67
[0120] FIG. 20 a shows a SEM image of micromushroom sample texture 1 (see Table 6), FIG. 20 b shows an SEM image of micromushroom sample texture 2, FIG. 20 c shows a SEM image of micromushroom sample texture 3, FIG. 20 d shows an SEM image of micromushroom sample texture 4, FIG. 20 e shows a SEM image of micromushroom sample texture 5, and FIG. 20 f shows a SEM image of micromushroom sample texture 6 (samples 1-6 as given in Table 6)
[0121] Table 7 lists apparent contact angles measured and calculated for water and oleic acid for the coated and uncoated micromushroom geometries of Table 6.
[0000]
TABLE 7
GEOMETRY
COATING
LIQUID
θ Calc
θ Measured
Flat
None
Water
N/A
68.5
Flat
Teflon AF
Water
N/A
127.1
Flat
None
Oleic Acid
N/A
28.6
Flat
Teflon AF
Oleic Acid
N/A
45.0
μMushroom - 1
None
Water
153.5
30.7
μMushroom - 1
Teflon AF
Water
172.3
147.5
μMushroom - 1
None
Oleic Acid
150.5
N/A
μMushroom - 1
Teflon AF
Oleic Acid
147.8
132.0
μMushroom - 2
None
Water
158.2
142.3
μMushroom - 2
Teflon AF
Water
170.2
146.5
μMushroom - 2
None
Oleic Acid
155.5
N/A
μMushroom - 2
Teflon AF
Oleic Acid
153.3
147.3
μMushroom - 3
None
Water
147.6
131.1
μMushroom - 3
Teflon AF
Water
171.1
137.8
μMushroom - 3
None
Oleic Acid
143.9
N/A
μMushroom - 3
Teflon AF
Oleic Acid
140.5
147.9
μMushroom - 4
None
Water
167.8
148.2
μMushroom - 4
Teflon AF
Water
172.2
157.7
μMushroom - 4
None
Oleic Acid
166.5
N/A
μMushroom - 4
Teflon AF
Oleic Acid
165.2
147.9
μMushroom - 5
None
Water
148.0
146.7
μMushroom - 5
Teflon AF
Water
173.4
145.7
μMushroom - 5
None
Oleic Acid
144.3
N/A
μMushroom - 5
Teflon AF
Oleic Acid
142.0
139.0
μMushroom - 6
None
Water
163.7
152.9
μMushroom - 6
Teflon AF
Water
171.9
165.9
μMushroom - 6
None
Oleic Acid
161.8
N/A
μMushroom - 6
Teflon AF
Oleic Acid
160.1
126.8
[0122] FIGS. 21 a - d show sessile drops on micromushroom texture 1. FIGS. 21 a - b respectively show a drop of water and a drop of oleic acid on the uncoated texture while FIGS. 21 c - d respectively show a drop of water and a drop of oleic acid on the texture as coated with Teflon® AF.
[0123] FIGS. 22 a - d show sessile drops on micromushroom texture 2. FIGS. 22 a - b respectively show a drop of water and a drop of oleic acid on the uncoated texture while FIGS. 22 c - d respectively show a drop of water and a drop of oleic acid on the texture as coated with Teflon® AF.
[0124] FIGS. 23 a - d show sessile drops on micromushroom texture 3. FIGS. 23 a - b respectively show a drop of water and a drop of oleic acid on the uncoated texture while FIGS. 23 c - d respectively show a drop of water and a drop of oleic acid on the texture as coated with Teflon® AF.
[0125] FIGS. 24 a - d show sessile drops on micromushroom texture 4. FIGS. 24 a - b respectively show a drop of water and a drop of oleic acid on the uncoated texture while FIGS. 24 c - d respectively show a drop of water and a drop of oleic acid on the texture as coated with Teflon® AF.
[0126] FIGS. 25 a - d show sessile drops on micromushroom texture 5. FIGS. 25 a - b respectively show a drop of water and a drop of oleic acid on the uncoated texture while FIGS. 25 c - d respectively show a drop of water and a drop of oleic acid on the texture as coated with Teflon® AF.
[0127] FIGS. 26 a - d show sessile drops on micromushroom texture 6. FIGS. 26 a - b respectively show a drop of water and a drop of oleic acid on the uncoated texture while FIGS. 26 c - d respectively show a drop of water and a drop of oleic acid on the texture as coated with Teflon® AF.
[0128] Advancing and receding contact angles were measured using the sliding angle method. A droplet was deposited on a tilted surface. A camera captures the droplet movement as it slides down the inclined surface.
[0000]
TABLE 7
Saturated Water Advancing Contact Angles
T sat = 20° C.,
T sat = 40° C.,
T sat = 60° C.,
T sat = 80° C.,
T sat = 100° C.,
Sample
P sat = 2.3 kPa
P sat = 2.3 kPa
P sat = 2.3 kPa
P sat = 2.3 kPa
P sat = 2.3 kPa
Flat
87
78
86
89
88
Pillar (h = 3 μm)
140
149
110
89
84
Pillar (h = 10 μm)
150
135
127
128
130
Pillar h = 20 μm)
154
150
152
138
128
Waffle (p = 12 μm)
120
123
127
110
19
Waffle (p = 12 μm)
133
134
136
110
91
[0000]
TABLE 8
Saturated Water Receding Contact Angles
T sat = 20° C.,
T sat = 40° C.,
T sat = 60° C.,
T sat = 80° C.,
T sat = 100° C.,
Sample
P sat = 2.3 kPa
P sat = 2.3 kPa
P sat = 2.3 kPa
P sat = 2.3 kPa
P sat = 2.3 kPa
Flat
73
65
70
73
78
Pillar (h = 3 μm)
102
105
68
66
75
Pillar (h = 10 μm)
111
106
105
112
106
Pillar (h = 20 μm)
118
110
116
113
110
Waffle (p = 12 μm)
104
102
100
90
90
Waffle (p = 12 μm)
106
108
104
102
71
Example 3
Measurements for HC-200
[0129] The contact angle of halocarbon oil HC-200 was measured on smooth and square waffle patterns. The experimental methods were the same as above, with only the liquid type being different. HC-200 is a liquid polymer oil with the chemical name chlorotrifluoroethylene. HC-200 has a surface tension about 0.025 N/m, which is lower than the surface tension for oleic acid. Table 9 shows the results, where the square waffle patterns are oleophobic, while a smooth surface of the same material is oleophillic. In Table 9, w is feature width, p is microstructure period, and d is feature depth.
[0000]
TABLE 9
w
p
d
Oil
Pattern
Liquid
μm
μm
μm
CA°
Smooth
HC 200
—
—
—
40
Square Waffles
HC 200
20
22
0.3
122
[0130] FIG. 27 shows images of halocarbon 200 oil on ZnO particle coated slides; these images illustrate the change in contact angle over 20 seconds. Image taken at 22° C. and 100. 3 kPa.
Example 4
Measurements for RL 68H and Mixtures of R134a and RL 68H
[0131] The contact angle of polyol ester oil RL 68H was measured on various textured surfaces. RL 68H is a commonly used oil in pumps for refrigeration systems.
[0132] Sessile drop measurements were obtained for some coatings including zinc oxide nanoparticles. FIG. 28 a shows the contact angle obtained for a 5% ZnO, 2:1fPDMS coating. The apparent contact angle was 25.4°. FIG. 28 b shows the contact angle obtained for a PDMS:ZnO 2:1 coating at STP. The apparent contact angle obtained was 138.6°. The coating of zinc oxide (ZnO) nanoparticles and PDMS in FIG. 28 b was formed by mixing the ZnO particles into suspension of Polydimethylsiloxane (PDMS) and spraying the mixture onto a silicon wafer. The particle coated substrate was then coated with polytetrafluoroethylene (PTFE) before measuring contact angles.
[0133] FIG. 28 c shows the contact angle of 122.0° obtained on a PTFE coated textured surface (pillars, d=10 μm h=20 μm p=22 μm). FIGS. 29 a , 30 a , and 31 a illustrate drops obtained on micromushroom structures and FIGS. 32 a and 33 a illustrate drops obtained on waffle structures.
[0134] The mixing process for R-134a and RL 68H was as follows. A quantity of RL 68H was measured to +/−0.5 g. The RL 68H was then added to the pressure vessel. The pressure vessel was then evacuated to 0.15 psi at 22 c to remove air and water vapor. The pressure vessel was then cooled to 10 C. A quantity of R-134a was then measured to within +/−0.5 g and added to the pressure vessel. The mixture was then recovered into a sampling vessel.
[0135] The contact angle of mixtures of R134a and RL 68H was measured for several Teflon coated textured surfaces. Table 10 lists contact angle measurements for several mixtures. For comparison, the contact angle measured on flat surfaces ranged from zero to 70 degrees depending on the mixture.
[0000]
TABLE 10
Psat =
Psat =
Psat =
Psat =
Psat =
270 kpa,
363 kpa,
384 kpa,
430 kpa,
441 kpa,
Tsat =
Tsat =
Tsat =
Tsat =
Tsat =
10.1° C.
11.5° C.
11.0° C.
12.3° C.
14.2° C.
Sample
θ
θ
θ
θ
θ
25% R-134a,
33% R-134a,
50% R-134a
60% R-134a,
80% R-134a,
75% RL 68H
66% RL 68H
50% RL 68H
20% RL 68H
20% RL 68H
μμMushroom
120
59
51
44
12
D = 68 μm W =
58 μm R = 30 μm
H = 90 μm
μMushroom
100
58
47
31
25
D = 55 μm W =
19 μm R = N/A
H = 94 μm
μMushroom
139
125
111
87
51
D = 48 μm W =
96 μm R = 35.7
μm H = 107 μm
Waffle (p = 12
113
94.5
81
75
19
μm)
Waffle (p = 22
119
116
112
70
40
μm)
[0136] FIGS. 29 a - f illustrate sessile drops of mixtures of R134a and RL68H on a micro mushroom patterned surface (D=67.5 micron, W=58 micron, R=30 micron, H=90 micron, see micromushroom texture 2). FIG. 29 a : 0% R-134a, Psat=101 kPa, Tsat=10.3° C. FIG. 29 b : 25% R-134a, Psat=270 kPa, Tsat=10.1° C. FIG. 29 c : 33% R-134a, Psat=363 kPa, Tsat=11.5° C. FIG. 29 d : 50% R-134a, Psat=384 kPa, Tsat=11.0° C. FIG. 29 e : 60% R-134a, Psat=430 kPa, Tsat=12.3° C. FIG. 29 f : 80% R-134a, Psat=441 kPa, Tsat=14.2° C.
[0137] FIGS. 30 a - f illustrate sessile drops of mixtures of R134a and RL68H on a micro mushroom patterned surface (D=55 micron, W=19 micron, R═N/A micron, H=94 micron, see micromushroom texture 4). FIG. 30 a : 0% R-134a, Psat=101 kPa, Tsat=10.3° C. FIG. 30 b : 25% R-134a, Psat=270 kPa, Tsat=10.1° C. FIG. 30 c : 33% R-134a, Psat=363 kPa, Tsat=11.5° C. FIG. 30 d : 50% R-134a, Psat=384 kPa, Tsat=11.0° C. FIG. 30 e : 60% R-134a, Psat=430 kPa, Tsat=12.3° C. FIG. 30 f : 80% R-134a, Psat=441 kPa, Tsat=14.2° C.
[0138] FIGS. 31 a - f illustrate sessile drops of mixtures of R134a and RL68H on a micro mushroom patterned surface (D=48 micron, W=96 micron, R=35.7 micron, H=107 micron, see micromushroom texture 5). FIG. 31 a: 0% R-134a, Psat=101 kpa, Tsat=10.3° C. FIG. 31 b : 25% R-134a, Psat=270 kpa, Tsat=10.1° C. FIG. 31 c : 33% R-134a, Psat=363 kpa, Tsat=11.5° C. FIG. 31 d : 50% R-134a, Psat=384 kpa, Tsat=11.0° C. FIG. 31 e : 60% R-134a, Psat=430 kpa, Tsat=12.3° C. FIG. 31 f : 80% R-134a, Psat=441 kpa, Tsat=14.2° C.
[0139] FIGS. 32 a - f illustrate sessile drops of mixtures of R134a and RL68H on a waffle pattern with a pitch of 12 micrometers (h=10 micrometers, w=10 micrometers). FIG. 32 a : 0% R-134a, Psat=101 kpa, Tsat=10.3° C. FIG. 32 b : 25% R-134a, Psat=270 kpa, Tsat=10.1° C. FIG. 32 c : 33% R-134a, Psat=363 kpa, Tsat=11.5° C. FIG. 32 d : 50% R-134a, Psat=384 kpa, Tsat=11.0° C. FIG. 32 e : 60% R-134a, Psat=430 kpa, Tsat=12.3° C. FIG. 32 f : 80% R-134a, Psat=441 kpa, Tsat=14.2° C.
[0140] FIGS. 33 a - f illustrate sessile drops of mixtures of R134a and RL68H on a waffle pattern with a pitch of 22 micrometers (h=10 micrometers, w=20 micrometers). FIG. 33 a : 0% R-134a, Psat=101 kpa, Tsat=10.3° C. FIG. 33 b : 25% R-134a, Psat=270 kpa, Tsat=10.1° C. FIG. 33 c : 33% R-134a, Psat=363 kpa, Tsat=11.5° C. FIG. 33 d : 50% R-134a, Psat=384 kpa, Tsat=11.0° C. FIG. 33 e : 60% R-134a, Psat=430 kPa, Tsat=12.3° C. FIG. 33 f : 80% R-134a, Psat=441 kPa, Tsat=14.2° C.
Example 5
Measurement for R134a
[0141] FIG. 34 . shows an image of R-134a droplet with a relatively high apparent contact angle on PTFE coated textured Si wafer in pressure vessel. Image taken at 24° C. and 645.8 kPa. Vapor is R134a. The surface texture was a waffle pattern, 25 μm squares, 50 μm pitch. The contact angle for R-134a on a flat surface coated with PTFE was less than 10 degrees Surface tension of R-134a is 14.6 mN/m @−20° C. | Methods and devices for dropwise condensation of a refrigerant vapor on a surface are provided. The surface and various aspects of the system are configured to ensure the surface is refrigerant repelling, enhances droplet mobility, increases condensation rate and/or increases heat transfer rate. The refrigerant repelling surface may be configured so that a refrigerant that may normally wet a flat non-textured surface is instead repelled | 5 |
DOMESTIC PRIORITY
[0001] This application is a continuation of U.S. patent application Ser. No. 14/940,568, filed Nov. 13, 2015, the disclosure of which is incorporated by reference herein in its entirety.
BACKGROUND
[0002] The present invention relates to virtual machines, and more specifically, to scheduling control blocks of virtual machines operating in a processing system.
[0003] Virtual machines emulate computer systems. Any number of virtual machines may be operated on a real computing system or network. The virtual machines may naively execute operating systems and software by emulating the underlying hardware of a real machine. Other virtual machines may perform particular processes in a virtual execution environment.
[0004] In some instances, virtual machines are controlled by a hypervisor or a virtual machine monitor that typically operates on a host machine and provides a virtual operating platform to virtual machines (guest machines). Such hypervisors may in turn, operate on a guest machine and host additional guest machines (nested hypervisors/virtual machines), such that there may be a hierarchy of hypervisors operating on a real host machine.
SUMMARY
[0005] According to an embodiment of the present invention, a method for operating a processing system comprising in a hypervisor, negotiating with a host platform to determine compatibility between a virtual machine and the host platform, responsive to determining that the virtual machine is compatible with the host platform, receiving a control block from the virtual machine, tagging the control block with information that associates the control block with a control group, determining whether the hypervisor is a base hypervisor, and scheduling the control block for processing responsive to determining that the hypervisor is the base hypervisor.
[0006] According to another embodiment of the present invention, a method for operating a processing system comprises in a first virtual machine, negotiating with a host platform to determine compatibility between the first virtual machine and the host platform, responsive to determining that the first virtual machine is compatible with the host platform, tagging a control block with information that associates the control block with a control group associated with the first virtual machine, and sending the tagged control block to a scheduler.
[0007] According to yet another embodiment of the present invention, a computer program product comprising a computer readable storage medium having program instructions embodied therewith, the program instructions executable by a processor to cause the processor to perform a method that comprises in a hypervisor, negotiating with a host platform to determine compatibility between a virtual machine and the host platform, responsive to determining that the virtual machine is compatible with the host platform, receiving a control block from the virtual machine, tagging the control block with information that associates the control block with a control group, determining whether the hypervisor is a base hypervisor, and scheduling the control block for processing responsive to determining that the hypervisor is the base hypervisor.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 illustrates an exemplary embodiment of a processing system.
[0009] FIG. 2A illustrates an example of a virtual machine system.
[0010] FIG. 2B illustrates the operation of the virtual machine system of FIG. 2A .
[0011] FIGS. 3A and 3B illustrates a diagram of an example of the operation of an exemplary embodiment of the system of FIG. 1 that coordinates the processing of control blocks amongst virtual machines.
[0012] FIG. 4 illustrates a flow diagram of an exemplary operation of a virtual machine or a hypervisor of a virtual machine system.
[0013] FIG. 5 illustrates an alternate exemplary method of operation that may be performed by a virtual machine.
DETAILED DESCRIPTION
[0014] Hypervisors, or more generally, operating systems, schedule processes or compute tasks by encapsulating each process or task in a uniform memory backed data structure. These data structures can be referred to as control blocks. Hypervisors typically receive control blocks from guest machines, the control blocks are portions of processing tasks that are sent to the real machine hardware for execution. In this regard, if multiple virtual machines are operating on a particular real machine, hypervisors will receive multiple control blocks from each of the virtual machines. The hypervisors may associate control blocks from each virtual machine with corresponding control groups. The hypervisor may then apply scheduling rules that promote fairness in the order in which the control blocks are processed amongst the control groups.
[0015] This scheme does indeed promote fairness across control groups if none of the guest machines are in turn hosting other guest machines. In such an alternative scheme, imposing fairness in control block processing becomes more complex. Further, if virtual machines host nested hypervisors or virtual machines of a similar nature, each level of scheduling is operating on the same structures, but the levels of scheduling are isolated from each other. The embodiments described below allow control blocks to be normalized and scheduled from a single context. This reduces scheduling inefficiencies and global scheduling across the system can be optimized.
[0016] FIG. 1 illustrates an exemplary embodiment of a processing system 100 . The system 100 includes a processor portion 102 , a memory portion 104 communicatively connected to the processor portion 102 , a display 106 communicatively connected to the processor portion 102 , and an input device 108 communicatively connected to the processor portion 102 . A network 110 may also be communicatively connected to the processing portion 102 such that the processing portion may communicate with other processors and/or share processing tasks with other processors.
[0017] FIG. 2A illustrates an example of a virtual machine system that operates on the processor portion 102 (of FIG. 1 ). The virtual machine system includes a hypervisor I 202 that operates and schedules control block processing on the host system. The hypervisor I 202 hosts a first guest machine or virtual machine (VM 1 ) 204 . The VM 1 204 runs a hypervisor II 210 that in turn, hosts a second guest machine or virtual machine (VM 2 ) 212 . The hypervisor I 202 may host any number of additional guest machines. In the example, a third virtual machine (VM 3 ) 206 is hosted by the hypervisor I 202 . Each virtual machine generates and outputs control blocks, for example, VM 1 204 includes control blocks 206 ( a - d ), VM 2 212 includes control blocks 214 ( a - c ), and VM 3 206 includes control blocks 208 ( a - e ).
[0018] FIG. 2B illustrates the operation of the virtual machine system. In operation, the hypervisor II 210 receives control blocks 214 and schedules the control blocks 214 for processing by the VM 1 204 , which outputs both the control blocks 214 from VM 2 212 and the control blocks 206 from VM 1 204 to the hypervisor I 202 . The hypervisor I 202 receives the control blocks 214 and control blocks 206 as well as the control blocks 208 from the VM 3 206 . Since the control blocks 206 and 214 were both output by the VM 1 204 , the hypervisor I 202 groups the control blocks 206 and 214 into a first control group 216 that is associated with the VM 1 204 . The hypervisor I 202 groups the control blocks 208 in a second control group 218 that is associated with the VM 3 206 . If the fairness rules associated with allocating real system resources to processing the control blocks are applied with respect to the control groups 216 and 218 one can see that the VM 1 204 and VM 2 212 will be allocated system resources at a slower rate than the VM 3 206 .
[0019] FIGS. 3A and 3B illustrates a diagram of an example of the operation of an exemplary embodiment of a system that coordinates the processing of control blocks amongst virtual machines. In this regard, FIG. 3A is similar to the arrangement of the system described above in FIG. 2A . However, in operation, the hypervisor I 202 and the hypervisor II 210 are operative to negotiate with the guest or virtual machines to ensure that the control blocks generated and output by the virtual machines are compatible with the system such that the control blocks 214 may pass through the hypervisor II 210 and the VM 1 204 and be scheduled for processing by the hypervisor I 202 without being scheduled by other hypervisors in the hierarchy.
[0020] FIG. 3B illustrates an example of the operation of the exemplary embodiment such that the control blocks 206 of VM 1 204 are associated with a control group 302 that is substantially exclusively associated with the VM 1 204 . Likewise, the control blocks 214 of VM 2 212 are associated with a second control group 304 that is substantially exclusively associated with the VM 2 212 , and the control blocks 208 of VM 3 206 are associated with a third control group 306 that is substantially exclusively associated with the VM 3 206 . Thus, when the hypervisor I 202 operates under a fairness rule to more evenly, fairly, or efficiently schedule the processing of the control blocks by control group, the VM 1 206 , VM 2 212 , and VM 3 206 are treated substantially equally with respect to the scheduling of the processing of their control blocks.
[0021] FIG. 4 illustrates a flow diagram of an exemplary operation of a virtual machine or a hypervisor of a virtual machine system. In this regard, in some embodiments the methods of FIG. 4 (and FIG. 5 described in further detail below) may be performed by either a hypervisor, a virtual machine or both a hypervisor and virtual machine. For clarity, the embodiments described below will be performed by a hypervisor, however alternate embodiments may be performed by a virtual machine or a real machine. Referring to FIG. 4 , in block 402 the host platform and the virtual machine negotiate to receive and exchange compatibility information. For example, compatibly information may include memory layout and structure of the control blocks operated on by the hypervisor and guest operating systems. When non-identical guest and host operating systems are used, a lookup table or similar construct may be used to hash control block layout and structure. A look up table or similar construct may be used to map and manipulate structures to make them compatible. Such mapping may include, for example, moving fields or renaming fields of the control blocks. In block 404 if the guest is compatible, the virtual machine will receive a control block from a guest machine in block 406 . The virtual machine may apply a tag to the control block that associates the control block with a control group associated with the guest machine, may include information indicative of address space adjustments if needed.
[0022] In block 410 , if the present hypervisor is the base scheduler (e.g., hypervisor I 202 of FIG. 3A ) the hypervisor, will schedule the control block for processing in block 412 . If in block 410 , the present hypervisor is not the base scheduler; the present hypervisor sends the control block to the next scheduler in the hierarchy in block 414 , which performs a similar process starting with block 402 .
[0023] FIG. 5 illustrates an alternate exemplary method that may be performed by a virtual machine. In this regard, in block 502 , the host platform and the virtual machine negotiate to receive and exchange compatibility information. If the host platform and the virtual machine are compatible in block 504 , a control block from the virtual machine (guest machine) is sent to the hypervisor. Prior to sending the control block, the virtual machine may tag, annotate, or associate the control block with information that associates the control block with a control group associated with the guest machine, and may include information indicative of address space adjustments if needed.
[0024] In block 508 , the virtual machine sends the control block to the hypervisor or scheduler for scheduling. Thus, in the embodiment described in FIG. 5 , the virtual machine may tag control blocks that are generated or received by the virtual machine with information that identifies the control block group that the control block belongs to, and in some embodiments, include address space information or adjustments that allow the control blocks to be processed fairly, and reduces the processing burdens of the virtual machines or hypervisors in the hierarchy by addressing control blocks to ideally, real address spaces on the host processor.
[0025] Such exemplary methods of operation described above improve the efficiency of the processing of the control blocks of virtual machines and improves the performance of the system.
[0026] The present invention may be a system, a method, and/or a computer program product. The computer program product may include a computer readable storage medium (or media) having computer readable program instructions thereon for causing a processor to carry out aspects of the present invention.
[0027] The computer readable storage medium can be a tangible device that can retain and store instructions for use by an instruction execution device. The computer readable storage medium may be, for example, but is not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of the computer readable storage medium includes the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanically encoded device such as punch-cards or raised structures in a groove having instructions recorded thereon, and any suitable combination of the foregoing. A computer readable storage medium, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire.
[0028] Computer readable program instructions described herein can be downloaded to respective computing/processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network, a wide area network and/or a wireless network. The network may comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and/or edge servers. A network adapter card or network interface in each computing/processing device receives computer readable program instructions from the network and forwards the computer readable program instructions for storage in a computer readable storage medium within the respective computing/processing device.
[0029] Computer readable program instructions for carrying out operations of the present invention may be assembler instructions, instruction-set-architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code or object code written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like, and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The computer readable program instructions may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider). In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGA), or programmable logic arrays (PLA) may execute the computer readable program instructions by utilizing state information of the computer readable program instructions to personalize the electronic circuitry, in order to perform aspects of the present invention.
[0030] Aspects of the present invention are described herein with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer readable program instructions.
[0031] These computer readable program instructions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. These computer readable program instructions may also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and/or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture including instructions which implement aspects of the function/act specified in the flowchart and/or block diagram block or blocks.
[0032] The computer readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions/acts specified in the flowchart and/or block diagram block or blocks.
[0033] The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.
[0034] The descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein. | A method for operating a processing system comprising in a hypervisor, negotiating with a host platform to determine compatibility between a virtual machine and the host platform, responsive to determining that the virtual machine is compatible with the host platform, receiving a control block from the virtual machine, tagging the control block with information that associates the control block with a control group, determining whether the hypervisor is a base hypervisor, and scheduling the control block for processing responsive to determining that the hypervisor is the base hypervisor. | 6 |
BACKGROUND OF THE INVENTION
[0001] Intraocular lenses were first implanted following cataract surgery by Harold Ridley in England in 1949. Since then there have been enormous advances in both the lens design and the surgical procedure for removal of cataracts. The modem surgical procedure is done under topical anesthesia, the cataract is removed by phacoemulsification and a foldable replacement lens is inserted into the eye through a 3.5 mm incision. The surgical procedure takes approximately 10-15 minutes and the patient goes home in less than an hour.
[0002] An appropriate intraocular lens of the correct power has to be selected for each individual eye undergoing surgery. In the early days of lens implantation this was based upon the patient's refraction. Later ultrasound biometry was developed to further refine the true accuracy of lens power selection. In the majority of cases this is performed by placing a transducer on the surface of the cornea and recording by means of a printer the peaks of the sound wave as it strikes the posterior inner surface of the eye, the posterior and anterior surfaces of the human lens and the anterior and posterior surfaces of the cornea. From these tracings the axial length of the eye, the length of the vitreous cavity, the lens thickness and the depth of the anterior chamber can be measured. One or a combination of these measurements are fed into a computer along with measurements of the average of the radii of curvature of the cornea at both its steepest and flattest meridians, the “K” Readings.” The biometrist then enters into the computer a constant for the particular lens design (the “A” constant) and selects one of several available formulas to calculate the lens power. The computer printer then produces a list of lenses for selection with the anticipated postoperative refraction for each lens power. The surgeon then selects from the computer printout the appropriate lens to implant.
[0003] This technique of biometry is by far the most common currently performed method of biometry and requires a skilled and experienced technician. The technician has to place the transducer onto the cornea with the least amount of corneal distortion or flattening and do this consistently from eye to eye. The most critical measurement entered into the formula is the axial length of the eye. A 1 mm indentation of the cornea shortens the axial length, and can result in a postoperative refractive error of 3 diopters leaving the patient severely myopic. Accurate biometry is therefore vital to get good uncorrected visions postoperatively. Many surgeons have not, until recently, evaluated the uncorrected outcomes of their surgery.
[0004] In the late 90's a multifocal intraocular lens was introduced into the market, the Array™ by Allergan. This lens focuses the light on the retina of the eye both for distance and near simultaneously. The brain has to select the appropriate image it wishes to recognize. This lens allows the patient to see at distance and near; however because the light in focus is divided between a distance and near target, contrast is lost and there is significant glare. The development of this lens, however, has made the eye surgeon conscious of the importance of the accuracy of the preoperative biometry. Since the objective of implanting the lens is to enable the patient to live without glasses. As explained above, this examination entails utilizing sound waves to measure the length of the eye, this measurement plus the radii of curvature of the cornea at its steepest and flattest meridians is applied to one of several formulas to determine what lens power should be implanted into the eye to give a predetermined preoperative refraction. In most cases this selection of the lens power for an eye would result in the patient being able to see well as distance without glasses, i.e. emmetropia.
[0005] The introduction of the Array™ intraocular lens should enable patients to see at distance and near without glasses. In order to achieve this goal the surgeon has to have excellent uncorrected vision and the importance of accurate biometry has become very apparent to the surgeons implanting this multifocal lens.
[0006] Accurate biometry can be achieved by two methods, one utilizing the standard biometry equipment modified to allow the measurement to be made through a fluid or water bath (immersion biometry). The second method is by means of the IOL Master™ from Zeiss which utilizes partial coherent laser interferometry to define the various intraocular measurements. Immersion biometry has not been popular with surgeons and their technicians because a chamber has to be placed onto the eye and filled with fluid before the biometry measurement can be made. The techniques for doing this have been cumbersome and in many cases required the patients to lie flat on their backs and the technician to be skilled. The great advantage of this technique however is that there is not corneal distortion and therefore very accurate lens power estimations care obtained. The IOL Master™ from Zeiss is also accurate because it is user friendly and does not involve contact with the cornea. This instrument does, however, have two disadvantages. First, it cannot be used on patients with dense cataracts and secondly is expensive. The immersion technique, if it could be simplified, is therefore the preferable technique. The basis of this patent is a simplification of the technique of immersion biometry.
BRIEF SUMMARY OF THE INVENTION
[0007] The invention provides a device to facilitate immersion biometry allowing the biometrist to perform the study without having to hold a device onto the patient's eye and without the need for a local topical anesthetic. The device renders the examination much more acceptable and more comfortable to the patient than other immersion biometry techniques.
[0008] The device consists of a mask or goggles that fit over the patient's eyes. The mask/goggles can have a single fluid chamber covering both eyes or two fluid chambers, one to cover each eye. The mask, designed to be watertight, is held in place by an adjustable strap that goes around the head. The mask is connected by flexible tubes to a container or bag of fluid, usually water or saline.
[0009] The container is connected by one tube if there is one chamber in the goggle or two tubes if there are two chambers. The fluid container is located beneath the goggle. The chamber(s) of the goggle is (are) filled with saline by raising the bag above the level of the goggle. When the goggle chambers are full of saline, a clamp is closed across the tube connecting the container to the goggle and the bag lowered to a level beneath the goggle. There is then a “waterbath” between the eye and the front of the goggle through which sound waves can pass without there being any contact between the goggle fitted with a transducer and the eye.
[0010] Two transducers are mounted in the goggle, one opposite each eye. The transducers are mounted in a housing that allows each one to be manipulated so that it is axially aligned with the eye under examination. Each eye is examined separately by re-routing the cables connecting each transducer to the ultrasound scanner.
[0011] Upon completion of the scans, the clamp preventing the drainage of saline from the goggle is opened and the saline is drained back into the bag.
[0012] The parallel-sided transducer is mounted in the goggle such that its alignment can be moved to align with the optical axis of the eye. This is essential in order to take a reading. The adjustable alignment can be achieved by a ball-and-socket arrangement or XY movements. The transducer has to be movable in and out to a distance range in which measurements can be taken. The housing or opening for the transducer has to be watertight, which can be achieved by the use of a circular flexible membrane with a hole in its center or with O rings. The transducer can then slide into or out of the mask or goggles and rotate onto the optical axis by asking the patient to look at a fixation light on the end of the transducer. During the manipulation, the examiner would watch the biometer screen; a measurement would only be recorded when the transducer distance and alignment with the eye is correct. The cables from each transducer would be activated alternately by a cable switch such that one eye could be examined after the other.
[0013] The mask or goggle design has a hole(s) in its roof to allow the air to escape from the mask as it fills with saline or water. The floor of the mask tapers or funnels into the outflow tube so that when the clamp or lock is opened the saline will pool in the funnel during its drainage from the mask, leaving little or no residue.
[0014] The mask is constructed such that it has windows through which the biometrist can observe the tip of the transducer to correctly position it relative to the eye. Alternatively the mask may utilize a goggle, similar to a swimming goggle, with a transducer mount
[0015] The mask will fit all faces and have an adjustable headband to fit around or around and over the head.
[0016] A system can be designed such that there are two bags: the input bag and the drain bag. The goggles are filled by lifting the input bag above the level of the goggles after opening a clamp or a stopcock. After the goggles are full, the clamp is closed and the bag with a reservoir of remaining solution is lowered to rest on the patient's lap. Solution remaining in the bag can be used for future examinations. After completing the biometry, a second clamp or stopcock is opened and the fluid drained from the goggle.
[0017] Utilizing the system with cleaning the goggles between patients, multiple examinations can be performed using the same input bag of fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] 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:
[0019] [0019]FIG. 1 is a perspective frontal view of one embodiment of the biometry goggles;
[0020] [0020]FIG. 2 is a perspective top view of the biometry goggles of FIG. 1;
[0021] [0021]FIG. 3 a is a perspective frontal view of one embodiment of the biometry with viewing windows;
[0022] [0022]FIG. 3 b is a perspective frontal view of an alternative embodiment of the biometry goggles with viewing windows;
[0023] [0023]FIG. 4 is sectional side view of one embodiment of a fluid chamber with a ball-and-socket system;
[0024] [0024]FIG. 5 is a sectional side view of the fluid chamber of FIG. 4 further illustrating the ball-and-socket system;
[0025] [0025]FIG. 6 is a top view of the fluid chamber of FIG. 5;
[0026] [0026]FIG. 7 is schematic top view illustrating an alternative embodiment of the invention with an X-Y system;
[0027] [0027]FIG. 8 is a schematic illustrating an embodiment of the invention utilizing a single fluid container; and
[0028] [0028]FIG. 9 is a schematic illustrating an embodiment of the invention utilizing a first fluid container and a second fluid container.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Referring to FIG. 1, a pair of biometry goggles 10 is shown worn about a patient's head. In the displayed embodiment, a pair of fluid chambers or goggles 11 , 12 are shown placed over the patient's eyes. The fluid chambers 11 , 12 are interconnected to one another through a fluid chamber connector 16 . This fluid chamber connector may be a flexible strap, rigid piece of material connecting the fluid chambers 11 , 12 , such as plastic, or the fluid chamber connector may be made of any material allowing for adjustable positioning of the fluid chambers 11 , 12 over the patient's eyes. Furthermore, the fluid chamber connector may be integrally molded with the fluid chambers 11 , 12 . The fluid chambers 11 , 12 are secured to the patient's head preferably with a strap 15 that is flexible and adjustable. In other embodiments, other materials and other configurations may utilized to secure the fluid chambers 11 , 12 over the patient's eyes. Although the biometry goggles 10 are shown in FIG. 1 with two fluid chambers 11 , 12 , an alternate embodiment of the invention includes a single fluid chamber. This single fluid chamber may be a chamber that covers one or both eyes of a patient.
[0030] The fluid chambers 11 , 12 have a fluid chamber base 18 , 19 . The fluid chamber base 18 , 19 interfaces with the surface of the patient's head. The fluid chamber base 11 , 19 may be configured concavely to follow the curvature of a person's head. The fluid chamber base 18 , 19 provides a water tight seal around the patient's eye. The fluid chamber base may include a rubber seal, a sponge foam, or other material to form a seal between the fluid chamber base and the patient's head, for example material that is ordinarily used in swimming goggles to form a seal around the eyes.
[0031] In one embodiment the fluid chambers 11 , 12 of the biometry goggles 10 have a viewing panel/transducer support frame 14 and one or more viewing panels 13 . The viewing panel 13 are fitted within the support frame 14 and the fluid chamber base 18 , 19 . The viewing panels allow the device operator to see the patient's eye and to view the positioning of the transducer 16 . Alternatively, the fluid chamber may be made with a single viewing panel or goggle with the viewing panel or goggle having a central transducer mount. The viewing panels or goggle are preferably made from a polycarbonate material. However, other material may be used that allowing viewing through the material, for example, certain plastics and glass.
[0032] Referring now to FIG. 2, a perspective top view of the biometry goggles of FIG. 1 is shown. The fluid chambers 11 , 12 have transducers 16 , 17 that are mounted in the fluid chambers. The fluid chambers 11 , 12 have a transducer mount 20 , 21 . The transducer mount 20 , 21 houses the transducer 16 , 17 . The transducer mount 20 , 21 allows for movement of the transducer 16 , 17 for biometry analysis of the eye.
[0033] [0033]FIGS. 3 a and 3 b illustrate other embodiments of the biometry goggles 10 showing different configurations of viewing panels.
[0034] [0034]FIG. 4 is a sectional side view of one embodiment of a fluid chamber 21 . In this embodiment, the transducer mount 20 utilizes a ball 22 for rotatable movement of the transducer 16 . A transducer lead 23 is connected to the transducer 16 . The transducer 16 is held within the rotatable ball 22 . The fluid chamber 21 when placed over the patient's eye forms a “liquid-tight” fluid reservoir 24 . The transducer 16 when taking biometry readings is immersed in the fluid reservoir.
[0035] Referring now to FIG. 5, a sectional side view of the fluid chamber of FIG. 4 further illustrates the ball-and-socket system. The ball 22 of the ball and socket system holds the transducer 16 in place. The transducer 16 , in addition to being rotatably positionable, may be moved anteriorly away from the surface of the eye 31 and posteriorly towards the surface of the eye 31 . The ball 22 may be configured in separate sections such that the ball is removable from the transducer mount 20 . In this configuration, the ball includes an anterior portion 24 and posterior portion 25 which are held to a main body 26 of the ball 22 by set screws or other fixation means. Seals 32 , 31 may be used to provide a water-tight seal for the transducer. The seals 31 may be replaced by removing the anterior or posterior portions 24 , 26 and exchanging the seal for a new seal.
[0036] [0036]FIG. 6 is a top view of the fluid chamber of FIG. 5. The transducer 16 is placed in a central hole of the ball 22 . In this embodiment, a rubber seal 16 is utilized to retain the transducer 16 in the ball 22 and allow the transducer to move anteriorly and posteriorly from the eye while providing a water-tight seal.
[0037] In FIG. 7 an alternate embodiment of the transducer mount 20 is shown. In this embodiment the transducer mount 20 , includes an X-Y visual axis alignment mechanism instead of the rotating ball system. The X-Y mechanism allows the operator to examine the eye in the straight-ahead position adjusting the transducer up or down and side to sided to correspond to the visual axis of the eye.
[0038] Referring now to FIG. 8, a schematic illustration depicts an embodiment of the biometry goggles 10 utilizing a single fluid reservoir 43 for providing a fluid 44 to the fluid chambers 11 , 12 . A patient wearing the biometry goggles generally lies in the supine position. The fluid reservoir 43 is raised to a level above the biometry goggles 10 . A fluid flow regulator 41 , such as a clamp or stopcock, controls the release of the fluid 44 from the fluid container 43 . A fluid transport carrier 40 , such as tubing, attaches to the biometry goggles to fluid valves 46 and 47 . The fluid flow regulator 41 when opened releases the fluid 44 from the fluid reservoir 43 which is then dispensed into the fluid chambers 11 , 12 . When fluid chambers 11 , 12 are full of fluid, the fluid flow regulator 41 is closed and the fluid reservoir 43 lowered to a level beneath the goggles 10 . The fluid in the fluid chambers 11 , 12 provides a “waterbath” between the eye and the transducers 16 , 17 . Sound waves can pass through the fluid without any contact between the eye and the transducers 16 , 17 . After biometric readings have been taken, the fluid in the fluid chambers 11 , 12 may be released back to the fluid reservoir 43 .
[0039] The biometry goggles 10 may include air inlet/outlet valves 18 , 19 to release air in the fluid chambers 11 , 12 when filing the chambers with the fluid 44 and to intake air when releasing the fluid back into the fluid reservoir 43 .
[0040] Transducer lead lines 23 , 27 may be connected to a control switch 42 allowing for selective biometric reading for an individual transducer, or both, allowing the operator to take independent readings of the right eye or the left eye, or both concurrently. The lead lines 23 , 27 continue through the control switch 42 to a plug 45 for the biometric reading machine.
[0041] Referring to FIG. 9, a schematic illustration of an embodiment of the invention is shown where the biometry goggles 10 utilize a first fluid reservoir 44 and a second fluid reservoir 51 . In this embodiment, a first fluid reservoir 55 containing a fluid 44 is release by way of a first flow control regulator 52 into to the biometry goggles 10 . This operation is similar to the operation of the embodiment of FIG. 8. Instead of the fluid being released back into the same reservoir, when biometric readings are completed, the fluid is released into a second fluid reservoir 51 . The release into the second fluid reservoir is controlled by a second flow control regulator 53 . In this embodiment, each fluid chamber includes two fluid valves 56 , 57 , and 58 , 59 . A first set of fluid valves 56 , 58 are used to fill the fluid chambers 11 , 12 from a first fluid transport carrier 55 , and a second set of fluid valves 57 , 58 are used to release the fluid into a second fluid transport carrier 60 .
[0042] 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. | A biometry device to facilitate immersion biometry allowing the biometrist to perform the study without having to hold a device onto the patient's eye and without the need for a local topical anesthetic. The device consists of a mask or goggles that fit over the patient's eyes. The mask/goggles can have a single fluid chamber covering both eyes or two fluid chambers, one to cover each eye. Transducers are mounted in the goggle, one opposite each eye. The transducers are mounted in a housing that allows each one to be manipulated so that it is axially aligned with the eye under examination. | 0 |
OBJECT OF THE INVENTION
[0001] The determination of thymic function in adults has attracted increasing interest in the context of immunological system diseases, and in particular in those diseases that cause lymphopenias. The present invention is advantageous over methods known in the prior art in terms of reducing experimental errors and the time and savings involved.
[0002] A first object of the present invention is a set of primers for determining the functionality of the human thymus by calculating the quotient between the delta and beta-type TREC content (T-cell rearrangement excision circle).
[0003] A second object of the present invention is a method based on multiplex nested PCR which uses said primers and can be used to determine the TREC quotient measured in samples of human blood or tissues, particularly in the thymus and in peripheral blood, a parameter which is an indicator of the functionality of the thymus due to its direct correlation with the percentage of double positive thymocytes.
[0004] The last object of the present invention is set of tools to implement said method based on multiplex nested PCR.
STATE OF THE ART
[0005] During T-lymphocyte generation (TL), the alpha and beta chains that for the TL clonotypical receptor (T-Cell Receptor, or TCR), are generated by the random recombination of gene segments, type V, D and J.
[0006] During this recombination, the DNA that separates it is eliminated from the chromosome in the shape of a circle, forming said TREC (T-cell rearrangement excision circle). These TREC are DNA fragments that exist independently from the chromosome, which means they lack replication origins. When the cell carrying it proliferates, the TREC does not replicate and is conserved by only one of the cells generated. Since the only way of generating TREC is by using the gene reordering that occurs in the thymus, they have been considered as molecular markers of thymic function.
[0007] There are hundreds of different TREC, as many as there are possibilities of compatible recombination between the gene segments V, D and J of the TCR chains. From all of them, one is particularly well known which, due to its formation characteristics, is extremely frequent between the TL that abandon the thymus, which is the δRec-ψJ{acute over (α)} TREC, or more commonly signal-joint TREC or delta TREC (Douek et al. “Changes in thymic function with age and during the treatment of HIV infection”; Nature 1998, Vol. 396, 690-695). Traditionally, delta TREC have been used as markers of thymic function, finding numerous publications that use them, most of them in the context of HIV infection or in bone marrow transplant in immunodepressed patients.
[0008] However, many of these publications indicate a limitation of the technique for measuring thymic function, in particular in the case of the HIV infection [Hazemberg et al. “Increased cell division but not thymic dysfunction rapidly affects the T-cell receptor excision circle content of the naive T cell population in HIV-1 infection” 2000 Nature Medicine Vol. 6 (8) 1036-1042]. Although the absolute number of TREC cannot increase independently from the thymus, the frequency of carrier cells in peripheral blood can change due to proliferation and/or apoptosis of the mature TL. These parameters are increased in HIV infection, and may decrease with the antiretroviral treatment. These changes may increase the frequency of carrier cells of TREC without thymic function having increased, simply due to reduction in activated TL, lacking TREC (diluting cells).
[0009] Recently, a variation has been published in the technique which overcomes this difficulty: it determines the quotient between two types of TREC: the traditionally measured delta and beta TREC (Dion et al. HIV Infection Rapidly Induces and Maintains a Substantial Suppression of Thymocyte Proliferation; 2004 Immunity, Vol. 21, 757-768), based on the following model: the generation in the thymus of a TL implies the step ordered by different phases of differentiation characterized by the sequential expression of surface markers that define the triple negative (TN 1 CD3″ CD4″ CD8″), double positive (DP, CD4 + CD8 + ) and single positive (SP, CD3 + CD4 + or CD3 + CD8 + ) populations as well as by the following sequence: reordering of the beta chain, cell proliferation phase and reordering of the alpha chain. After the productive reordering of the beta chain during the TN phase all cells have beta TREC as by-product of said reordering, and then a phase of proliferation and transformation in DP cells commences.
[0010] This expansion makes it possible to increase the number of cells with productive reordering of the beta TCR, but they have as consequence the dilution in the number of beta TREC in said population of thymocytes. Next, and during the alpha chain reordering process, the delta TREC is generated, fixing at this point the delta/beta TREC quotient, a quotient which will characterize the cohort of TL which will later exit the thymus.
[0011] The hypothesis of Dion's article establishes that the degree of proliferation between the TN and DP stages is variable and that it can be estimated by analysing the quotient in the TL exported from the thymus. We can suppose that there is a direct relation between the degree of intrathymic proliferation and the total cells exported by the thymus (Almeida et al. T Cell Homeostasis: Thymus Regeneration and Peripheral T Cell Restoration in Mice with a Reduced Fraction of Competent Precursors. 2001. Journal of Experimental Medicine, Vol 194, 591-599) and that this quotient is not altered by peripheral expansion of the TL. This relation has been proven, establishing a direct correlation between the percentage of DP thymocytes as indicative of its functionality, and the TREC quotient measured in the thymus and/or in the peripheral blood.
[0012] The problem of this new approach is that, unlike the delta TREC, which is unique, there are up to thirteen different possibilities for recombination to generate beta TREC, which requires individually determining each possible TREC separately and adding the partial values. The technique proposed by Dion measures ten of the thirteen beta TREC, each one using an independent quantitative PCR. Next, they are all added together to obtain the total beta TREC of the sample. According to the originally described technique, to determine the quotient between the delta TREC and the sum of beta TREC 11 conventional PCRs and 55 real time PCR per samples were used (performing the measurements in triplicate). With the present approach by multiplex PCR, six of the thirteen beta TREC are co-amplified simultaneously and re-amplified together with the multiplex reaction in the same PCR tube. In this way, to determine the quotient of a sample (also in triplicate), only six conventional and three real time PCRs are needed.
EXPLANATION OF THE INVENTION
[0013] A first object of the present invention is a set of primers for determining the functionality of the human thymus by calculating the quotient between the delta and beta TREC content; said set includes at least three primers each one of which have a sequence of nucleotides which is complementary with a region between nucleotides 187957 to 190719 of the sequence deposited in the Genbank database with access number 066061, as well as a sequence of nucleotides at their 5′ end which is substantially non-complementary with any known region of the human genome. Preferably, the primers that form the set have at their 3′ end a same common sequence to all of them which is either identical, or complementary, to one of sequences SEQ. ID. 01 to SEQ. ID. 99 (see tables 1 and 2) and more preferably the sequence common to all the primers at its 3′ end is SEQ. ID. 07. Additionally, the set of primers includes at least one primer which contains one of sequences SEQ. ID. 100 to SEQ. ID. 112, and preferably simultaneously:
[0000] a) at least one primer which contains one of sequences SEQ. ID. 100 to SEQ. ID. 105.
b) at least one primer which contains one of sequences SEQ. ID. 106 to SEQ. ID. 107.
c) a primer which contains sequence SEQ. ID. 108.
d) at least one primer which contains one of sequences SEQ. ID. 109 to SEQ. ID. 112.
[0014] In a preferred embodiment of the invention, said set of primers is formed by:
[0000] a) six primers which contain sequences SEQ. ID. 100 to SEQ. ID. 105.
b) two primers which contain sequences SEQ. ID. 106 and SEQ. ID. 107.
c) a primer which contains sequence SEQ. ID. 108.
d) four primers which contain sequences SEQ. ID. 109, SEQ. ID. 110, SEQ. ID. 111 and SEQ. ID. 112.
[0015] A second object of the present invention is a method for determining the functionality of the human thymus which includes simultaneous amplification stages of more than one beta or delta-type TREC by polymerase chain reaction (multiplex PCR). Said method comprises:
a) performing an amplification reaction from a cellular DNA preparation using a specific primer of a sequence common to the set of TREC of the beta family to be amplified, and a set of specific primers for each individual TREC of the beta family to be amplified, which have at its 5′ end an identical sequence for all of them and which is substantially non-complementary with any known region of the human genome; b) performing in parallel, but independently, an amplification reaction from a cellular DNA preparation using a pair of specific primers of the sequence of specific bases of a delta-type TREC; c) performing a single amplification reaction from a mixture of aliquots of said previous amplification reactions, wherein at least one primer is used which comprises the sequence present at the 5′ end of the set of primers used in the stage a). The aliquots of the amplification products of the first amplification reactions are used directly or diluted at least in the proportion 1:2, preferably 1:20.
[0019] The detection of the products of the polymerase chain reaction of the set of delta and beta TREC are performed in real time using a hybridization probe common for all beta TREC and a hybridization probe specific for delta TREC, the signals of both probes being distinguishable. Preferably, said hybridization probes for the detection of the PCR products of the set of delta and beta TREC, are fluorescence probes.
[0020] In a preferred embodiment, the primers used correspond to sequences SEQ. ID. 100 to SEQ. ID. 112 and the method is carried out according to the following stages:
a) a first amplification round of six β-TREC in a single multiplex PCR reaction using six sense primers (SEQ. ID. 100 to SEQ. ID. 105) specific for each β-TREC and a single antisense primer (SEQ. ID. 106) specific for a constant region of six β-TREC and, in parallel, a first amplification round of δ-TREC using PCR using the primers which contain sequences SEQ. ID. 109 and SEQ. ID. 110, all from cellular DNA samples, particularly of blood or thymus cells; b) a second amplification round set of aliquot dilutions of at least 1:2, preferably 1:20, of each one of the amplifications performed in the previous step using a single multiplex PCR which uses the primers which contain sequences SEQ. ID. 107 and SEQ. ID. 108 for the β-TREC amplified in the previous step and the primers which contain sequences SEQ. ID. 111 and SEQ. ID. 112 for the δ-TREC amplified in the previous step; c) calculation of the quotient between the quantity of δ-TREC and the total quantity of β-TREC.
[0024] In parallel to the test samples a serialized dilution is amplified of a straight-line pattern which contains known concentrations of the products of the first δ-TREC or β-TREC amplification reaction, so that it can be compared with the values obtained with the test samples in the threshold amplification cycle of the second real time PCR, obtaining the concentrations from the interpolation of the threshold cycles of each test sample with the logarithmic-linear adjustment of the threshold cycle of the straight-line pattern. The absolute number of copies of δ-TREC or β-TREC per microlitre of cellular DNA preparation is normalized from the number of copies of the beta-globin gene, with two copies of said gene per cell, expressing the frequency of said TREC as number of circles per million total cells.
[0025] A third object of the present invention is a set of tools for determining the functionality of the human thymus using the method of the invention, which includes:
a) set of primers which contain sequences SEQ. ID. 100 to SEQ. ID. 112. b) hybridization probes which make it possible to differentiate between the β-TREC and the δ-TREC, preferably fluorescence probes. c) cloning vectors with known concentrations of β-TREC and δTREC which allow construction of a straight line pattern.
BRIEF DESCRIPTION OF THE FIGURES
[0029] FIG. 1 : Design of the multiplex PCR for the delta/beta TREC quotient. Schematic diagram of the PCR for the simultaneous amplification of delta and beta TREC. The pre-amplification PCR of step 1 ( FIG. 1A ) and 2 ( FIG. 1B ) are done separately, using a mixture of a single antisense primer and six sense primers, each one specific for a TCR-β reordering of Dβ1-Jβ1.1 to Dβ1-Jβ1.6, for step 1, and two external primers for delta TREC (step 2). Later, 1:20 dilutions of each first round of PCR (in triplicate) are re-amplified using real time PCR ( FIG. 10 ).
[0030] FIG. 2 : Simultaneous detection of the delta TREC signal (square, F2 channel for Red640 readings) and the integrated signal of six possible beta TREC (circles, F3 channel for Red705 readings). The amplifications of a representative sample are shown in triplicate.
[0031] FIG. 3 : Absence of saturation in the 20-cycle pre-amplification reaction compared to 16-cycle pre-amplification. FIG. 3A shows the accumulated threshold cycle of both PCRs for the amplification of the cloned sequences of beta TREC after 20 (circles) or 16 cycles (square). The same for FIG. 3B (amplification of delta TREC sequences).
[0032] FIG. 4 : Interassay variability of the technique. The threshold cycle measured in the F2 and F3 fluorescence channels (hybridization probes of delta and beta TREC, respectively) for a same reaction tube is represented for each point of the straight-line measured in independent experiments. The dispersion is small for the most concentrated straight-line points.
[0033] FIG. 5 : Comparison of the delta TREC determination in thymic samples using the previously described technique of direct real time PCR, compared with the multiplex nested PCR for determining the delta/beta quotient. The paired values show identical measures with both techniques.
[0034] FIG. 6 : A) Correlation between the percentage of DP cells and the concentration of delta TREC per million thymic tissue cells. B) Correlation between the percentage of DP cells and the concentration of beta TREC per million thymic tissue cells. C) The δ/β TREC quotient measured in thymic samples stops working due to the presence of immature cells The quotients obtained in mature thymic tissue were grouped in three blocks in accordance with the percentage of double positive cells (DP) and they were compared with paediatric thymic tissue or with peripheral blood mononuclear cells (PBMC) obtained from the umbilical cord. The homogenous population of mature T-lymphocytes present in the umbilical cord have an average quotient of 1000, whilst the quotient in total thymic tissue is less, in particular in the most active thymuses.
[0035] FIG. 7 : Correlation between thymic function measured as percentage of double positive thymocytes (DP, CD4 + CD8 + ) and delta/beta TREC quotient in peripheral blood mononuclear cells (PBMC) of adult individuals. A) Correlation between delta TREC content in PBMC and percentage of DP cells in the thymus; B) Representation of beta TREC content in PBMC compared with the percentage of double positive cells showing the absence of correlation; C) Correlation between the delta and beta TREC quotient in PBMC and percentage of DP cells in the thymus.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The general objective of the present invention is to develop a simplified method for determining, in biological samples, the quotient between the delta-type TREC (δ)Rec-φJα) and a set of beta-type TREC (specifically six possible recombinations between segment Dβ1 and segments Jβ1 to Jβ6). In the state of the art (Dion et al., previously cited) for each individual TREC that participates in calculation of the quotient, a first multiplex PCR reaction is needed which pre-amplifies said TREC and a fragment of the CD3 gene as reference, followed by two real time PCR reactions, which finally calculate the concentration of said TREC and the fragment of the CD3 gene, separately. After normalization of the measurements using CD3, the individual values obtained for each beta TREC of the chosen set are added together. Depending on the number of beta-type TREC that one wants to include in the calculation (between six and ten) thus between seven and eleven conventional PCR and between fourteen and twenty-two real time PCR are needed.
[0037] The simplification obtained in the present invention fundamentally relates to a reduction in the number of PCR reactions and primers necessary to effectively measure said parameters. For this, the multiplex PCR approach is used differently, which makes it possible to reduce the number of PCR to be performed on two conventional and one real time PCR, if it uses, for example, a set of six beta-type TREC, resulting in a large sample economy. In its general design a multiplex PCR pre-amplification is performed of a set of beta TREC, in parallel with another pre-amplification of the single delta TREC, followed by final multiplex amplification of the set of beta TREC and delta TREC, in a single reaction tube. Using specific sequence fluorescent tubes, the amplification of delta TREC and the set of beta TREC amplified are detected in real time, which makes it possible to calculate the quotient in a single tube, without the need to normalize by the quantity of genomic DNA present in the preparation of DNA.
[0038] For the embodiment of the multiplex PCR pre-amplification of the chosen set of beta TREC, a minimum set of primers was designed with the following characteristics: a single antisense primer was used specific for segment Db1, and therefore, common to the set of beta TREC, and a group of sense primers, each one of them specific for one of six segments Jb1.1 to Jb1.6 ( FIG. 1A ). The set of sense primers specific for segments Jβ1.1 to Jβ1.6 was designed with the condition that their 3′ end is an identical sequence of at least three nucleotides, ideally more. Said identical sequence for the whole set of primers must naturally be present in all Jβ1 segments, since in the present invention a single consensus sequence is not used, but, at least three, preferably six sequences, each one specific for a JβI segment. In a preferred embodiment of the present invention, a set of primers was selected with the CACAG sequence (SEQ. ID. 07) at its 3′ end. Additionally, each one of the sense primers specific for segments Jβ1.1 to Jβ1.6 was synthesized with a tail added at their 5′ end which had the following characteristics: being an arbitrary sequence designed to be compatible with the other primers used in the different multiplex PCR. Additionally, it was verified that they were not complementary of any known sequence in the human genome. The presence of said extension at 5′ provides the following benefits to the state of the art:
1) The sequence of this extension at 5′ is incorporated in the amplified DNA fragments, for which reason the primers are already completely complementary to the amplified sequences in the successive phases of denaturing/alignment, which produces two desired effects: in first place they generate a sequence at 5′ common to six amplification products of beta TREC, which makes it possible to design a second PCR which uses said sequence, together with another antisense primer, more internal than that used in the first reaction. In this way, with only two primers six beta TREC can be amplified, in an approach we can consider as “semi-nesting”, as only one of the second primers are internal to the amplification product ( FIG. 1C ). 2) Any amplification product derived from the pairing by error of two sense primers equipped with said extension (either dimers of primers or amplification products by non-specific pairings in different regions of the genome) will have complementary ends, which has been described to generate secondary structures which reduce the efficacy of its subsequent amplification (Brownie J, Shawcross S, Theaker J, Whitcombe D, Ferrie R, Newton C 1 Little S. The elimination of primer-dimer accumulation in PCR. Nucleic Acids Res. 1997 Aug. 15; 25(16):3235-41).
[0041] To define said primers the sequence of segments Db1 and Jb1.1 to Jb1.6 deposited in the Genbank with reference number 066061 has been used as reference. For the design of the specific primers for the delta TREC the sequence contained in the locus of the TCR delta deposited in the Genbank with reference number AE000661 has been used as reference.
[0042] The number of PCR performed in the first beta and delta PCR must be included in the log-linear region which characterizes any PCR, before the appearance of the plateau phase and which cancels the quantitative property of the PCR. Ideally from 16 to 20 cycles are performed.
[0043] The amplification products of both first PCR cycles are subjected to a second multiplex PCR reaction wherein the sequences which are simultaneously amplified correspond to the TREC and at least one of the beta TREC sequences of the chosen set. The sample of nucleic acids to be amplified in the second reaction corresponds to a mixture of the products of the 1 st beta multiplex and the 1 st delta multiplex in equal parts. Said sample may be additionally diluted in a variable factor, ideally 1/20. The primers used in the second multiplex reaction meet the following condition: one of them corresponds to the sequence included as extension at 5′ of the set of primers of segments Jb1.1 to Jb1.6, in isolated manner.
[0044] The antisense primer is designed on the Db1 region, being more internal than the one previously used.
[0045] The accumulation of the amplification products is measured during the second PCR reaction in each cycle, by real time PCR technology. The FRET technology enables the detection of characteristic sequences of delta TREC or of a sequence common to all possible beta TREC. Through the use of thermocyclers in real time, such as the LightCycler, it is possible to distinguish, using readings at different wavelengths, the quantity produced of a determined DNA sequence throughout each cycle. The fluorescence in one channel collects the amplification in the reaction capillary of the sequence amplified for the delta TREC. The fluorescence in another channel simultaneously measures the fluorescence emitted associated to the common sequence of all beta TREC. This fluorescence intensity is proportional to the sum of all possible amplified beta TREC, without possibility of distinguishing between the different amplified beta TREC. The objective of the present invention is to determine the value of the sum of all beta TREC, without determining each value individually. In each PCR reaction and in parallel to the test samples a serialized dilution of a straight-line pattern is amplified which contains known concentrations of different cloning vectors each one of them containing the product of the first amplification reaction of delta TREC or beta TREC individually amplified. The concentration in number of delta TREC or sum of beta TREC per microlitre of DNA preparation is obtained by comparison of the threshold amplification cycle in the second real time PCR of the test sample with a serialized dilution of a standard sample with known concentrations of the sequences amplified by the plasmids. Therefore, the volume of sample to be loaded in each reaction tube must be identical between the test samples and the standard samples. The concentrations will be obtained from the interpolation of the threshold cycles of each test sample with the log-linear adjustment of the threshold cycle of each point of the standard straight line. The determination of the threshold cycle, characteristic of each PCR reaction, is performed using a mathematical analysis algorithm of the amplification curves of each individual PCR reaction. Preferably, that known as “second derivative method”, included in the analysis software packet of the LightCycler (Roche), will be used. It is, however, possible that this volume is different for the delta PCR and the beta multiplex of the first round, due to the lower frequency of beta TREC present in the test sample typically analysed. In a preferred embodiment, this load volume per reaction tube is 5 μL for the delta TREC PCR and 10 μl for the beta TREC multiplex PCR.
[0046] To calculate the quotient between delta and beta TREC it suffices to know the relative concentration of delta and beta-type TREC in a cellular preparation, without the need to know the genomic DNA concentration present in said preparation. With the present invention it is only necessary to know the relative concentration of delta and beta type TREC, and it is not necessary to determine the concentration using absorbance methods at 260 nm or preferably by quantitative PCR of a reference gene such as CD3, the beta chain of haemoglobin or any other sequence whose number of copies per cellular genome is known at present.
[0047] As complement to the method described here, to calculate the different TREC per million cells, the absolute number of copies of delta or beta-type TREC per microlitre of DNA preparation shall be normalized by the genomic DNA concentration. This is determined by measuring the number of beta-globin gene copies, considering the existence of two copies of said gene per cell, and expressing the frequency of TREC as number of circles per million total cells.
EMBODIMENT OF THE INVENTION
Example 1
Amplification Conditions of the Multiplex PCR for Determining the Delta/Beta TREC Quotient
[0048] In the present invention, the quantitative PCR technique is used to calculate the concentrations and the corresponding quotient between a delta-type TREC and a subset of six beta-type TREC, in appropriate biological samples. A preferred embodiment involves the following general steps, schematized in FIG. 1 :
1) Pre-amplification from a cellular DNA preparation of the set of six beta-type TREC derived from the recombinations between the Dβ1 gene segment and the Jβ1.1 to Jβ1.6 gene segment, using a single multiplex PCR reaction, performed in a conventional thermocycler ( FIG. 1A ) 2) Pre-amplification from a cellular DNA preparation of delta-type TREC derived from recombination of the δRec and ψJα gene segments, also performed in a conventional thermocycler ( FIG. 1B ) 3) Re-amplification of aliquots of the PCR reactions of steps 1) and 2) in a single multiplex PCR reaction in a thermocycler with real time monitoring of the progression of the amplified derivatives of delta TREC and of the set of six beta TREC, using FRET hybridization probe technology ( FIG. 1 C).
[0052] The different steps are described in detail below:
[0053] For the pre-amplification of delta and beta-type TREC, one starts from a human cellular DNA preparation obtained using a commercial kit according to the manufacturer's indications, appropriate for the extraction of thymic tissue (NucleoSpin® Tissue Kit) or mononuclear blood cells (NucleoSpin® Blood Kit), both from Macherey-Nagel, Germany. The DNA preparation thus obtained usually has a concentration between 10 and 150 ng/μL and it is used directly for PCR reactions. The determination of the TREC concentrations in each test sample is determined in triplicate, using for each PCR reaction three 10 μL aliquots of DNA for the case of beta TREC and three 5 μL aliquots for delta TREC. Both reactions are performed independently, with identical final reaction volume conditions (50 μL), the reaction mixture being formed by 2 U of catalyzing enzyme (EuroClone thermostable DNA polymerase), reaction buffer supplied by the manufacturer at a concentration of 1×, dNTPs, and final CfeMg concentration of 3 mM, varying the set of primers used in each case. Thus, for the pre-amplification of the set of six beta TREC performed in step 1 six “sense” primers are used of sequences SEQ ID. 100 to SEQ ID. 105 (one for each possible Jβ1 segment present in the beta TREC), at a final concentration of 80 nM each, and an “antisense” primer (SEQ. ID. 106, specific for the Dβ1 segment, present in six beta TREC) at a final concentration of 280 nM. For the pre-amplification of delta TREC performed in step 2, the primers are used with sequences SEQ ID 109 and SEQ ID 110, at a concentration of 100 nM each.
[0054] Both amplification reactions of steps 1 and 2 are performed independently in a “Biometra Tgradient” thermocycler, with the following amplification conditions: initial denaturing for 5 minutes at 95° C., followed by cyclical denaturing phases during 20 seconds at 95° C., hybridization for 45 seconds at 57° C. and extension for 30 seconds at 72° C., followed by a final extension phase for 5 minutes at 72° C. The number of amplification cycles varies depending on the nature of the sample, 16 cycles for DNA preparations obtained from paediatric thymic tissue or 20 cycles for samples of mononuclear blood cells.
[0055] For the second amplification round (step 2) a common 1:20 dilution is made of the amplification products of the first PCR, adding 10 μL of the pre-amplification of beta TREC and 10 μL of the pre-amplification of delta TREC at a volume of 180 μL of water for PCR. The triplicates of the independent amplification reactions are combined by pairs so that the second amplification is per-also performed in triplicate from three independent 1:20 dilutions. The reaction conditions of step 3 consist of the amplification of an aliquot of 3 μL of said 1:20 solution in a final reaction volume of 20 μL. The reaction mixture uses the FastStart DNA MasterPLUS kit (Roche Molecular Biochemicals, Mannheim, Germany), including the primers SEQ ID 107, SEQ ID 108 at a concentration of 200 nM, the primers SEQ ID 111, SEQ ID 112 at a concentration of 100 nM, and the aforementioned hybridization probes SEQ ID 113, SEQ ID 114 (Franco et al. “T-cell repopulation and thymic volume in HIV-1-infected adult patients after highly active antiretroviral therapy”; Blood 2002 Vol. 99 3702-3706) and SEQ ID 115, SEQ ID 116 (Dion et al. “HIV infection rapidly induces and maintains a substantial suppression of thymocyte proliferation”; Immunity 2004 Vol. 21 757-768), at a final concentration of 100 nM and the acceptor fluorophores, type FRET Red640 and Red705, respectively (see Table 3). For the real time PCR a LightCycler® thermocycler was used, with an initial denaturing step of 10 minutes at 95° C. followed by 45 denaturing cycles (10 seconds at 95° C.), alignment (20 seconds at 57° C.) and extension (15 seconds at 72° C.). The fluorescence measurements are made at the end of the alignment phase.
[0056] FIG. 2 shows the fluorescence measurements obtained for each amplification cycle corresponding to amplification of delta TREC (square, fluorescence emitted by Red605) and of beta TREC (circles, fluorescence emitted by Red740) in a representative sample.
Example 2
Characterization of the Multiplex PCR for Determining the Delta/Beta TREC Quotient
[0057] To characterize the test properties, the DNA sequences characteristically amplified in the two pre-amplification reactions were cloned in pGEM-T Easy cloning vectors (Promega, Madison, USA) following the manufacturer's instructions. Clones were obtained corresponding to delta TREC and beta TREC Dβ1:Jβ1.1, Dβ1:Jβ1.2, Dβ1: β1.3 and Dβ1:Jβ1.4.
[0058] Once preparations of known concentration are obtained of each individual plasmid, a mixture base dilution was performed of said plasmids characterized in that they contain 4747 copies/μL of the cloning vector which contains the amplified sequence of delta TREC and 189 copies/μL of a mixture in equal parts of the cloning vectors containing beta TREC Jβ1.1 to Jβ1.4. Said concentrations correspond to a characteristic delta TREC/Σ betas quotient for the straight-line pattern of 25, irrespective of the dilution used.
[0059] Various assay parameters were analysed using said straight-line pattern, in 30 independent reactions. For each assay, a 1:10 serialized dilution was made of the aforementioned standard curve, and 10 and 5 μL aliquots were amplified according to the conditions described in steps 1 and 2 of example 1, respectively. The different dilutions of the straight-line provided, therefore, an average of 23735 to 23.7 delta-type amplifiable sequences and 1890 to 1.9 beta-type amplifiable sequences per tube, respectively.
[0060] The sensitivity analysis of the assay described in example 1 were capable of amplifying all the dilutions containing delta-type sequences, as well as 97% of the reactions containing an average of 19 beta-type amplifiable sequences per tube, and 75% of the reactions containing 1.9 sequences per tube. These frequencies are in accordance with the expected tube distribution that lack amplifiable sequences following a normal distribution of an average of 1.9, which shows that the assay has sufficient sensitivity to amplify from only one copy of DNA mould specific per reaction tube.
[0061] To evaluate if the pre-amplification reactions may have missed the linear amplification phase and entered in the plateau phase, the mean of the values calculated in the real time PCR was calculated for each point of the standard curve, after 16 or 20 pre-amplification cycles. The number of previously performed cycles are added to the threshold cycle calculated in the second PCR. The result of said sum (mean±standard deviation) is shown in FIG. 3A for the case of amplification of beta-type TREC sequences, and in FIG. 3B for the case of amplification of delta-type TREC sequences, after 16 (square) or 20 (circles) pre-amplification cycles, showing the linearity of the technique until 20 cycles of the first PCR.
[0062] To analyse the reproducibility of the assay between experiments, the pairs of threshold cycles calculated in the second round of PCR for the fluorescence signal of channel F2 (delta TREC) and channel F3 (beta TREC) were represented in FIG. 4 . The symbols represent the points of the straight-line pattern without diluting (inverted triangles) or serially diluted in a factor of 10 (triangles, circles and squares respectively).
Example 3
Maintenance of the Reordering of Delta TCR in the Thymus of Advanced Age Despite the Lack of Double Positive Cells (DP)
[0063] The mechanisms which lead to age-associated thymic involution are not known. The thymus lacks a population of cells which are capable of self-renewing themselves, for which reason they need haematopoietic precursors of the bone marrow to maintain thymopoiesis. Thus, it is generally accepted that involution of the thymus is due to a reduction in the quantity of progenitors that colonize the thymus. However, a reduction has recently been shown of age-related intrathymic proliferation as cause of thymus involution. To evaluate if the delta/beta TREC quotient really measures thymic function, the relation was analysed between the percentage of double positive thymocytes and the delta/beta TREC quotient of this thymic tissue samples. Some paediatric thymuses were analysed as controls.
[0064] The ages of the 50 patients analysed were included between 36 and 81 years of age (median 60 years of age, interquartile ranges 59-73 years of age). 60% were men. As expected, the degree of residual thymopoiesis was variable, ranging from 0 to 71% of double positive (median 32%, interquartile range 15-50%). A direct and significant correlation was found between the percentage of double positive cells and the delta TREC values per total million thymic tissue cells (p<0.001, r=0.759, n=50, FIG. 6A ). Furthermore, the beta TREC content per million tissue cells also correlates with the percentage of DP (p<0.001, r=0.668, n=50, FIG. 6B ).
[0065] FIG. 6C shows the delta/beta TREC quotient in adult thymus samples grouped as percentage of double positives as very reduced (0-15%), moderate (15-50%) or almost normal (>50%). These quotients were compared with samples of paediatric thymus and cord mononuclear blood cells. Mann-Whitney's U-test showed significant differences between all groups with paediatric thymus, except for the almost normal double positives group. As the single positive cells are the subpopulation of the inthrathymic proliferation evaluated directly by the delta/beta TREC quotient, greater quotients were expected in the paediatric thymuses and in the samples with more than 50% DP. However, FIG. 6C shows unexpectedly low quotients for these groups compared with the samples with a percentage of DP between 15 and 50% or with the cord blood cells (p<0.001). It is probably due to the presence in the thymus of immature positive cells for beta TREC and negative for delta TREC, altering the quotient of the entire thymopoietic series. Thus, to adequately measure the quotient in thymocytes with a fixed measurement it is necessary to previously isolate the single positive CD4 and CD8 cells.
[0066] Finally, 9 thymuses were detected of the 50 analysed without double positive thymocytes. The cells isolated from these thymuses had cytometry profiles compatible with lymphoid cells, including CD3+CD45RA cells-single positive, suggesting a certain recirculation of mature lymphocytes. Two samples were negative both for beta TREC and for delta TREC, however, the seven remaining ones were positive for beta TREC but negative for delta TREC or with a delta/beta TREC quotient close to one. This suggests that even in the total absence of DP a certain number of stem cells still colonize the thymus and start the reordering of the TCR-β. The lack of delta TREC and DP points to a drastic reduction in intrathymic proliferation associated to an effective reordering of the TCR beta chain, the assay described here being capable of detecting these residual reorderings.
Example 4
Comparison of the Measurement of Delta TREC Using Multiplex Nested PCR with a Direct Delta TREC Assay
[0067] In order to compare the measurement of the delta TREC obtained according to the assay described in example 1 with the measurements obtained by a real time PCR assay for direct quantification of the aforementioned delta TREC (Franco et al. “T-cell repopulation and Thymic volume in HIV-1-infected adult patients after highly active antiretroviral therapy”; Blood 2002 Vol. 15 3702-3706), the thymic tissue samples of example 3 were measured by both assayed.
[0068] Briefly, a direct amplification of delta TREC was additionally performed using the primers SEQ ID 117 and SEQ ID 118 (see Table 3), using LightCyder® FastStart DNA MasterPLUS, with an initial denaturing step at 95° C. for 10 minutes followed by 40 denaturing cycles (10 seconds at 95° C.), alignment (15 seconds at 50° C.) and extension (20 seconds at 72° C.). The fluorescence measurements are performed at the end of the alignment phase using the hybridization probes SEQ ID 113 and SEQ ID 114 (see Table 3).
[0069] To express the TREC content as number of cycles per million cells, primers SEQ ID 119 and SEQ ID 120 were used (see Table 3) to quantify the human beta-globin gene according to the aforementioned protocol (Franco et al.
[0070] “T-cell repopulation and Thymic volume in HIV-1-infected adult patients after highly active antiretroviral therapy”; Blood 2002 Vol. 15 3702-3706). It was considered that each cell carries two copies of said sequence. The PCR reaction was performed in duplicate using LightCycler® FastStart DNA MasterPLUS SYBR Gren I. After an initial denaturing cycle at 95° C. for 10 minutes 40 denaturing cycles were performed (10 seconds at 95° C.), alignment (10 seconds at 66° C.) and extension (15 seconds at 72° C.). The fluorescence of the SYBR Green I is measured at the end of the extension phase.
[0071] FIG. 5 shows the correlation between the measurements obtained with both techniques. The linear regression adjusted to the logarithmically expressed measurements showed a gradient of 1.005 (p<0.001, r=0.916, n=47), indicating that the delta TREC is measured in similar fashion with both assays.
Example 5
The Delta/Beta TREC Quotient in Peripheral Blood Directly Correlates to Residual Thymic Function
[0072] The relation was analysed between the thymic function measured directly from thymic tissue and the TREC in peripheral blood mononuclear cells (PBMCs).
[0073] FIG. 7A shows a direct correlation between the delta TREC values in the blood and the percentage of double positive cells in the thymus (p<0.001, r=0.564, n=50). The quantity of beta TREC per million PBMCs ( FIG. 7B ) does not correlate with the percentage of DP (p=0.288). The beta TREC content in adult PBMCs is similar to that of cord blood (145±56 and 45±6 beta TREC per million PBMCs, respectively). Eight samples were negative for the beta TREC PCR, for which reason it was not possible to calculate the delta/beta TREC quotient. The delta/beta TREC quotient ( FIG. 7C ) in other peripheral blood samples showed a direct correlation with the percentage of DP cells in thymic tissue samples (p<0.001, r=0.605, n=42), showing their use in the measurement of the thymic function. These results agree with those obtained from mathematical models (Van den Dool et al. “The effects of age, thymectomy, and HIV infection on alpha and beta TCR excision circles in naive T cells”; J Immunol 2006 Vol. 177 4391-4401). The fraction of recent thymic emigrants (RTEs) which have beta TREC strongly depend on intrathymic proliferation that the cord blood cells must have lower beta TREC levels than individuals of age. In a thymic involution model that affects intrathymic proliferation, the total beta TREC values exported to the periphery must exclusively depend on how many haematopoietic stem cells started to reorganize their TCR-β locus. The quantity of intrathymic proliferation has an effect on the proportion of RTEs that conserve a beta TREC, but the absolute number of beta TREC exported must be constant. Thus, the frequency of beta TREC in PBMCs must be maintained constant irrespective of the quantity of intrathymic proliferation, as suggested in the aforementioned mathematical model.
[0074] Intrathymic proliferation is a parameter fixed during T-cell differentiation and is not later altered by the additional proliferation of the mature cells. For this reason, it is not necessary to isolate the subpopulations of T-cells to eliminate the memory or activated T-cells. However, intrathymic proliferation can be considered an “instantaneous” parameter: it is a property of a cohort of RTEs that have just abandoned the thymus. If the thymus was capable of modulating its activity in stimulating drugs or other stimulants in a short period of time, the delta/beta TREC quotient could be indicative of these changes.
[0075] It would be more interesting to isolate the different subpopulations of the peripheral blood mononuclear cells before determining the delta/beta TREC quotient. The population of T-cells most rich in RTEs should be isolated, isolating the CD27+ virgin T-cells or the CD45RA+CD31+ subpopulation, which will provide more exact details. Thus, the multiplex PCR will need a much greater quantity of DNA.
[0076] The quotient in PBMCs also shows a direct correlation with the percentage of CD45RA+CD27+ virgin cells both in the CD4+ (p<0.001, r=0.531) and in the CD8+ (p<0.001, 1=0.511) subpopulation (data not shown). No correlation was found with age (p=0.770, n=42). Significant differences were showed by sex, with women showing greater ratios (66.5±12 vs. 37.3±7, p=0.015, Mann-Witney's U test).
[0000]
TABLE 1
Sequences of 5 nucleotides common
to all primers at their 3′ end
SEQ. ID. 1
ACCAG
SEQ. ID. 23
GCAGA
SEQ. ID. 2
AGACT
SEQ. ID. 24
GCTCA
SEQ. ID. 3
AGAGT
SEQ. ID. 25
GGCAG
SEQ. ID. 4
AGGGA
SEQ. ID. 26
GGGAG
SEQ. ID. 5
AGTGG
SEQ. ID. 27
GGGGT
SEQ. ID. 6
ATTTT
SEQ. ID. 28
GGGTA
SEQ. ID. 7
CACAG
SEQ. ID. 29
GGGTC
SEQ. ID. 8
CACTG
SEQ. ID. 30
GGTGG
SEQ. ID. 9
CAGAA
SEQ. ID. 31
GTAAG
SEQ. ID. 10
CAGCT
SEQ. ID. 32
GTCTT
SEQ. ID. 11
CAGGG
SEQ. ID. 33
GTTCT
SEQ. ID. 12
CCAGA
SEQ. ID. 34
TCAGG
SEQ. ID. 13
CCAGG
SEQ. ID. 35
TCCCT
SEQ. ID. 14
CCTCT
SEQ. ID. 36
TCCTC
SEQ. ID. 15
CTCCT
SEQ. ID. 37
TCTCT
SEQ. ID. 16
CTCTC
SEQ. ID. 38
TCTTT
SEQ. ID. 17
CTCTG
SEQ. ID. 39
TGGGG
SEQ. ID. 18
CTGTC
SEQ. ID. 40
TGGGT
SEQ. ID. 19
CTGTG
SEQ. ID. 41
TTCTT
SEQ. ID. 20
GAAGG
SEQ. ID. 42
TTTGG
SEQ. ID. 21
GACTC
SEQ. ID. 43
TTTTG
SEQ. ID. 22
GAGAA
SEQ. ID. 44
TTTTT
[0000]
TABLE 2
Sequences of 4 nucleotides common
to all primers at their 3′ end
SEQ. ID. 45
AAAG
SEQ. ID. 73
GGAC
SEQ. ID. 46
AAGA
SEQ. ID. 74
GGCA
SEQ. ID. 47
AAGG
SEQ. ID. 75
GGGA
SEQ. ID. 48
ACAG
SEQ. ID. 76
GGGT
SEQ. ID. 49
ACTC
SEQ. ID. 77
GGTA
SEQ. ID. 50
ACTG
SEQ. ID. 78
GGTC
SEQ. ID. 51
AGAC
SEQ. ID. 79
GGTT
SEQ. ID. 52
AGAG
SEQ. ID. 80
GTAA
SEQ. ID. 53
AGCT
SEQ. ID. 81
GTCA
SEQ. ID. 54
AGGG
SEQ. ID. 82
GTGG
SEQ. ID. 55
AGGT
SEQ. ID. 81
GTGT
SEQ. ID. 56
ATGT
SEQ. ID. 84
GTTC
SEQ. ID. 57
CACA
SEQ. ID. 85
TAAG
SEQ. ID. 58
CACT
SEQ. ID. 86
TATG
SEQ. ID. 59
CAGA
SEQ. ID. 87
TCAG
SEQ. ID. 60
CAGG
SEQ. ID. 88
TCCA
SEQ. ID. 61
CCAG
SEQ. ID. 89
TCTT
SEQ. ID. 62
CCCT
SEQ. ID. 90
TGAA
SEQ. ID. 63
CCTT
SEQ. ID. 91
TGGA
SEQ. ID. 64
CTCA
SEQ. ID. 92
TGGC
SEQ. ID. 65
CTGA
SEQ. ID. 93
TGGG
SEQ. ID. 66
CTTT
SEQ. ID. 94
TGTC
SEQ. ID. 67
GAAA
SEQ. ID. 95
TGTG
SEQ. ID. 68
GAAG
SEQ. ID. 96
TTCT
SEQ. ID. 69
GACT
SEQ. ID. 97
TTGG
SEQ. ID. 70
GAGT
SEQ. ID. 98
TTTG
SEQ. ID. 71
GCAG
SEQ. ID. 99
TTTT
SEQ. ID. 72
GCTT
[0000]
TABLE 3
Sequences from the prior art used
in the embodiment of the invention
SEQ ID 113
AGG GAT GTG GCA TCA CCT TTG TTG ACA
SEQ ID 114
GGC ACC CCT CTG TTC CCC ACA GGA
SEQ ID 115
CTG GGA GTT GGG ACC GCC AGA GAG GT
SEQ ID 116
TTT GTA AAG GTT TCC CGT AGA GTT GAA
TCA TTG TG
SEQ ID 117
AGG CTG ATC TTG TCT GAC ATT TGC TCC
G
SEQ ID 118
AAA GAG GGC AGC CCT CTC CAA GGC
SEQ ID 119
CAA CTT CAT CCA CGT TCA CC
SEQ ID 120
GAA GAG CCA AGG ACA GGT AC | Determining thymic function in adults has attracted increasing interest in the context of diseases that affect the immunological system and, in particular, diseases that produce lymphopenias. The invention relates to a set of primers for determining the functionality of the human thymus by calculating the quotient between two types of TREC content, as well as to a method based on multiplex nested PCR which uses the aforementioned primers and can be used to determine the TREC quotient measured in samples of human blood or tissue. The invention is advantageous over methods known in the prior art in terms of reducing experimental errors and the time and costs involved. | 2 |
This is a continuation of U.S. patent application Ser. No. 12/012,666, filed on Feb. 5, 2008, which is herein incorporated by reference in its entirety, and assigned to a common assignee.
RELATED PATENT APPLICATIONS
This application is related to Ser. No. 11,710,722, filed on Feb. 26, 2007, and Ser. No. 11,710,723, filed on Feb. 26, 2007, which are herein incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to a system and a method for building a point of sale (POS) system to manage business operations. The business operations range from a single branch to a large chain of stores or branches.
More particularly this invention relates to an online, web-based point of sale builder method, which can assist non-expert business operators in assembling a point of sale system to manage their businesses.
Description of Related Art
Current practice in the field of assembling point of sale systems includes manually coding front-of-screen information. Typically, this front-of-screen information contains menu selections, page selections, and general answers to business questions. This front-of-screen menu is typically manually coded by a business expert with the help of a programmer or data expert. Also, currently the entry of this front-of-screen information requires intimate knowledge of a complex interface to a front-of-screen programming language. In summary, current practice includes the manual building of a point of sale (POS) screen. This manual process requires defining the position and operation of touch screen keys and their database correspondence. Currently, only specially trained people can build or change POS screens. This manual POS building and editing is prone to mistakes and is time-consuming. Since POS screen changes are difficult and prone to error, store owners tend to retain older, inaccurate, out-of-date POS screens in order to avoid the POS screen editing process. Also, current POS screen editing occurs off-line with the testing of the screens occurring at a later date, at a remote store location. The following references represent prior art in the field of screen configuration building.
U.S. Pat. No. 5,818,428 (Eisenbrandt et al.) describes a control system with a user configurable interface, particularly suitable for use in connection with appliances. Users can configure display screens either at a point of sale location or at home with a personal computer.
U.S. Pat. No. 6,629,080 B1 (Kolls) describes a universal advertising and payment system and method for networking, monitoring and advancing electronic commerce and controlling vending equipment.
U.S. Pat. No. 7,051,091 B1 (Cohen et al.) discloses a configuration builder useful in configuring software containing hardware units which are serviced by a center which services a multiplicity of similar units having a plurality of different configurations.
U.S. Pat. No. 5,987,426 (Goodwin) describes a system and method of transferring information between a first software application and a second software application which employ an isolation layer. The system includes a client computer system provided by a first seller of computer systems, including a client software application, and a server computer system provided by a second seller of computer system.
BRIEF SUMMARY OF THE INVENTION
It is the objective of this invention to provide a system and a method for building a point of sale (POS) system to manage business operations. The business operations range from a single branch to a large chain of stores or branches.
It is further an object of this invention to provide an online, web-based point of sale builder system and method, which can assist non-expert or expert business operators in assembling a point of sale system to manage their businesses. This point of sale building operation can be done in real time from anywhere in the world.
The objects of this invention are achieved by a web-based point of sale (POS) builder comprising one or more point of sale terminals, which display POS, screens, an Internet connection to a web server, one or more local or remote PC workstations, and point of sale builder software which runs on said web server. Local or remote workstations can be utilized to build or edit said POS terminals in real time, from anywhere in the world and over the world-wide web.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a typical point of sale touch screen for a pretzel store, as an example only.
FIG. 2 shows a typical touch screen for the drinks panel of a pizza restaurant, as an example only.
FIG. 3 is a system diagram for web-based back office which supports point of sale terminals.
FIG. 4 a is a sample screen builder panel before the screen building process begins.
FIG. 4 b is a sample screen builder panel after the screen building process is under way.
FIG. 5 is a high level flowchart which illustrates the main embodiment of the screen building process.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a typical point of sale (POS) touch screen for, as an example only, a pretzel store. There are touch keys for pretzels 11 and for drinks 12 . Selecting these keys would typically bring up secondary screens displaying specific product keys for ordering different types of pretzels and drinks respectively. In addition, the screen in FIG. 1 has some specific pretzel product keys 13 and specific pretzel topping keys 14 . Currently in the prior art, a touch screen as shown in FIG. 1 is manually configured by a programmer who knows the specific proprietary point of sale system used by a store or business. The FIG. 1 screen design involves the specific key layout and size of keys. In addition, the FIG. 1 screen keys must have corresponding hooks or references to product data such as item name, price, cost, group, taxable, and inventory as shown in FIG. 4 . In this invention, this product data and the touch key structure is stored in relational databases in the back office which is stored on the web servers 36 shown in FIG. 3 .
As an example only, FIG. 2 shows a touch screen for the drinks page of a pizza restaurant. Again in the prior art, a specialized programmer had to design the layout and data for these POS touch keys. Typically, the programmer is located remotely from the store or business. He or she must learn about the store's POS requirements via phone calls, emails, and meetings with store operators. In addition, the programmer would need to iterate several passes of the touch screen design and allow the store operator to test the screens. With this invention, the store operator will be able to build his POS screens online over the Internet. With input from the store operator, the POS builder can specify and display the number, shape and arrangement of selection keys or buttons on said POS screens. The store operator, who does not have to be technically trained, will be able to edit and test his screens until he is satisfied with the end results. The testing of said POS screens can be done iteratively by the store operator in real time while said POS terminals are simultaneously in use during store and business operation hours or after store hours. Alternatively, the testing of said POS screens can be done iteratively by a remotely located person such as a store manager or director in real time while said POS terminals are simultaneously in use during store hours or after store hours. All backoffice changes which include screen changes, price changes, employee validation changes are submitted to a batch bucket or queue. These changes have to be submitted for final posting at a scheduled time. For example, the phasing in of new screens and/or new data such as prices and employee validation can be scheduled. The time schedule for uploading or posting these screen changes and/or new data can be specified as follows. Only as examples, the changes can take place after the present transactions are completed. Alternatively, the changes can take place at the end of the business day, during the night, at the start of the next day or at the next application restart for example. Typically, screen changes will take place at the next application start at the beginning of a business day.
This automatic online POS builder will reduce the development time for POS screens by weeks. In addition, the store operator will be able to edit the POS screens and its relational databases any time as often as desired. In addition, the store operator will be able to edit, change and test the screens within minutes in real time. The store operator can iterate these changes instantly until he gets the desired screen appearance. This real-time testing and iteration of screen designs is an important feature of this invention. This feature motivates the store operator to keep his screens up to date and accurate. Previously, the store operator would avoid updating screens, since it involved the time and expense of working with programmers off line.
FIG. 3 shows a high level diagram of this invention. There are N POS terminals (POS 1 , POS 2 . . . POS N) in “Store” 31 and in “Store N” 32 . POS 31 is in Store 1 and POS 2 ( 32 ) is in Store 2 . Each POS includes personal computer hardware and software. Additional POS terminals beyond those shown, as well as additional stores beyond the two shown, are within the scope of the invention. Each POS normally operates with a hardware/software connection 35 to the Internet or Web. However, if the web goes down, the POS terminal continues to operate. There is a “loose coupling” of the POS to the back office (BO): the POS to BO connection is not required for the basic business functions of the POS. All transaction data is stored in a relational database on the hard drive in the POS.
A relational database stores all of its data inside tables. All operations on data are done on the tables themselves. Some operation produce other tables as the result. A table is a set of rows and columns. Each row is a set of columns with only one value for each. All rows from the same table have the same set of columns, although some columns may have NULL values. A NULL value is an “unknown” value. The rows from a relational table are analogous to a record, and the columns are analogous to a field. Below is an example of a relational table.
There are two basic operations one can perform on a relational table. The first one is retrieving a subset of its columns. The second is retrieving a subset of its rows. The field names such as company describe the content of the columns of the relational table. The rows delineate the individual records stored in the relational tables.
As transactions are created at a POS a log entry for the newest transaction is also created, this log entry is used to flag if the transaction has been uploaded to the web server. Part of the POS application, the BO interface is continuously running in the background. This component reads the log of transactions. If a transaction needs to be sent, it tries to send it. If the send fails (for example, if the connection to, or the Internet itself, is down), it goes to sleep and tries again later. Additionally, the BO interface requests update from the BO such as new items, price changes, employees, etc. The POS terminals communicate via HTTP protocol (hypertext transfer protocol) 35 with Back-office BO software, which is implemented on web servers 36 , which can be located anywhere in the world. In addition, the BO software and data can be viewed from any store employee at any PC 33 who has Internet access 37 and a password.
The POS such as 31 send transaction data to the BO in the form of an HTTP post or communication. The packet 35 sent from the POS to the BO consists of transactions, employee clock, customer add/update, item add/update, promotions and more. Promotions are configured in the back office and associated with items or customers or departments. For example, a promotion may be associated with a customer to implement customer loyalty points or a promotion may be associated with a certain item for a % discount. A client who is the store manager or owner selects a promotion type, associates it with an item, department, etc, then sets the parameters that control how that promotion works. These transaction transmissions between the POS and the BO can be encrypted to insure privacy and security. A typical encryption method is 128 bit SSL (secure sockets layer). A further element of security is that each BO client (individual POS, store or multi-store owner) gets their own instance of a database. When they log into the BO they are attached to their own relational database associated and validated via their user login and password.
FIGS. 4 a and 4 b show a typical web-based POS builder interface. FIG. 4 a shows a grid of boxes labeled with screen numbers 1 - 4 . Typically, screens will have screen names such as in 21 , “Subs”. Under each screen box column are boxes labeled “Add Item”. These boxes allow the addition of different products such as small pizza, large pizza, etc. as shown in FIG. 4 b . FIG. 4 b shows the data interface which would appear when selecting the large pizza box. The store operator would be able to enter and/or modify item name, price, cost, group, taxable and inventory. The above illustrates the ease of building POS screens by store operators via the Web.
FIG. 5 shows a flowchart of the point of sale builder methodology. The flow in FIG. 5 also refers to FIGS. 4 a and 4 b . The Begin POS Build block 51 is entered when the Builder Program is initiated 50 from a Web page action.
When creating a new POS, Block 51 brings up a screen such as that shown in FIG. 4 a . The screens in FIG. 4 a need to be defined. Block 53 allows the store operator to select which screen number to define. FIG. 4 b shows what appears on the Web screen after the store operator selects screen # 1 ( 53 ) to work on. In FIG. 5 , Block 54 allows the store operator to enter/edit the screen name being worked on, such as pizza, as an example only, in FIG. 4 b . In FIG. 5 , block 54 allows the store operator to enter the number of touch keys planned for the pizza screen, as an example only.
FIG. 4 b shows the screen after a few touch screen buttons have been defined. Screen 1 has been labeled Pizza. The pizza screen in FIG. 4 b currently has 1 touch screen button item defined on the screen, Large pizza 22 . The Large Pizza item button was entered by hitting ADD Item 20 in FIG. 4 a . After hitting add item, FIG. 4 b appears with the template 23 to be filled in. This step is shown in block 56 of FIG. 5 . The template includes Item Name, Price, Cost, Group, Taxable, Inventory. Item Name is Large Pizza. Price is easily changeable, Cost is the cost of making materials. Group is the Pizza Group, Taxable is as yes or no selection. Inventory can be used to monitor the number of Large Pizza's makeable with the dough, cheese and sauce on hand. Other Template items can be added to the template 23 in FIG. 4 b.
In FIG. 5 , block 57 asks whether the screen being worked on i.e.) Pizza Screen is done. If the store operator answers yes 59 , the flowchart flows to Node 52 in FIG. 5 . This allows the store operator to select another screen # as shown in FIG. 4 a . If the store operator answers no 58 , the flowchart flows to Node 55 in FIG. 5 . This allows the store operator to select, add, or edit another item on the pizza screen.
The key advantages of the Web-based POS builder are that it is completely built on the foundation of the Web. The POS builder is accessible anywhere in the world. It can be used by a person of any skill level. The POS builder builds, edits, and tests new POS terminals in real time. In addition, all screen designs and changes are reflected real-time into the back office (BO) server's screen database. For example, all screen designs inputted from any PC in the world appear instantly in the BO screen database, which is instantly viewable anywhere in the world via web browsers. Another big advantage is that all screen design software is located and executed in the BO server. Since all screen designs and changes are immediately visible from any manager's PC at their home or at headquarters, there is always management oversight of these changes. Therefore, this screen builder allows for local in-store flexibility by the individual store operator or manager, but also provides for corporate visibility of screens instantly for control and standardization. Also, this screen builder does not require the need for any server to be located in the store. Another advantage of this system is the use of standard PC and web architecture which offers both full-scalability without degrading system performance. This results in improved performance and lower cost of implementing these business systems. There is a lower cost associated with projects developed with the technology of this invention due to the flexibility of easy design changes and well-understood software. There is less training required for programmers and system testers. Projects can draw on the huge talent pool in the open source development community. The invention allows configurable software modules for different types of businesses and sales promotions. The invention allows remote monitoring of screen designs from anywhere via the web. There is minimal time required for the implementation and installation of the POS builder system, since the POS builder setup is as basic as a home PC setup. Another advantage is that the POS builder system can be provided as a service or deployed within a corporation. For example, Software as a Service (SAAS) is a software distribution model in which applications are hosted by a vendor or service provider and made available to customers over a network, typically the Internet. Another advantage of this invention is that the POS builder system is maintained in customer centric databases, making it impossible for customers to see other's data. Each POS builder system client gets their own instance of a database. When they log into the BO they are attached to their own relational database associated and validated via their user login and password.
While this invention has been particularly shown and described with Reference to the preferred embodiments thereof, it will be understood by those Skilled in the art that various changes in form and details may be made without Departing from the spirit and scope of this invention. | This invention provides a system and a method for online, web-based point of sale (POS) building and configuration, which can assist non-expert business operators in building, editing and testing a point of sale system to manage their businesses. The business operations range from a single branch to a large chain of stores or branches. The key advantages of the Web-based POS builder are that it is completely built on the foundation of the Web. The POS builder is accessible anywhere in the world. It can be used by a person of any skill level. The POS builder builds, edits, and tests new POS terminals in real time. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a liquid permeable fluid management nonwoven composite fabric for use in filtration, fluid transfer and absorption, for example, in disposable absorbent articles such as diapers, adult incontinence products, sanitary napkins and the like. The invention further relates to methods of producing such liquid permeable composite fabrics.
[0002] It is known, for example, in European Patent No. 963 747, that it is desirable to provide a fluid management member in a disposable absorbent article which is able to collect and retain low viscosity, high solid materials such as fecal matter, while still permitting passage of liquids such as urine. In order to manage low viscosity fecal matter the patent document proposes a structure where a fluid permeable support has a plurality of fibers woven into the support, which fibers project outwardly from the support. The support is described variously as nonwoven webs, breathable films, microporous films, apertured nonwoven webs and the like. The fibers woven into the supporting member extend generally greater than 1 mm above the support member, preferably higher. The individual fibers are preferably from 15 to 30 denier and are woven in regular intervals into arc-like forms. The woven fibers provide the laminate composite structure with a compression resistance of at least 30% under an applied pressure of about 1,000 newtons per cm 2 , most preferably, at least 50% under this applied pressure. Also the materials are able to resume its shape after being subjected to this type of pressure after about 30 seconds to recover by at least 50 to 85%. The fluid management member is provided to minimize the amount of low viscosity fecal material on the skin of the wearer, preventing movement of the fecal material and also separating the fecal material into its solid and liquid components allowing the liquid components to be transported to the underlying absorbent structure.
[0003] A similar-like structure is described in U.S. Pat. No. 5,705,249. In this patent, the composite material described includes a nonwoven onto which filaments having a diameter of 0.05 to 5 mm are deposited. The filaments can be preformed or directly extruded onto the nonwoven. Following this, the filaments are intermittently bonded to the nonwoven resulting in bulges, which are created by elastic deformation of the large diameter filaments where they are not bonded. These filaments separate the nonwoven fabric from the wearer's skin. However no discussion of fecal management is described relative to this material. This material is designed solely to increase the comfort of the wearer by separating a liquid absorbent layer or fluid transport nonwoven from the wearer's skin.
[0004] U.S. Pat. No. 5,976,665 describes another approach to address the problems faced by the above U.S. Pat. No. 5,705,249 patent. A nonwoven fluid transport layer or absorbent is separated from a wearer's skin by attaching a corrugated perforated film or nonwoven. The corrugated material is formed into a series of wave-crests and wave-troughs. The wave-crests contact the wearer's skin and reduce the perceived wetness of the article. However in this patent the wave-like structure is also stated as useful in handling the solid discharges in a diaper or menstrual discharges in a sanitary appliance by trapping the solids in the wave-troughs. The corrugated layer is corrugated between the annealing surfaces of two mutually engaging corrugating cylinders and for example, thermally bonded to the underlying layer.
[0005] It is also known in the filtration area to provide netting or like material prior to a porous filter for dewatering high solid content materials. Such an approach is described in U.S. Pat. No. 5,776,567, where a multilayer laminate of flexible filter material is separate by polymeric netting that serves as a dewatering layer for high solids content material. The filter and nesting materials are simply laid up against one another and placed in a framing device.
[0006] European Patent No. 976 375 describes a fecal management member where the material structure is similar to that described in the U.S. Pat. No. 5,976,665 patent above. A sheet of fibers, preferably a nonwoven web, is corrugated and attached to an additional liquid permeable web. For example, a nonwoven sheet of fibers is fed between the enmeshed engaging portions of the mating corrugating members and joined to a second nonwoven web by thermally bonding the corrugated nonwoven. Additional fibers are deposit on top of the corrugated web. Although these various designs for fecal and fluid management members are advantageous, there remains a need for methods and materials that can do at least one, or more, of directly producing a fluid management member which is flexible, allows for good bonding between the separation member and the fluid transport member, creates a low outer surface contact area and/or can function effectively to separate high solids materials from liquids.
DISCLOSURE OF THE INVENTION
[0007] The present invention provides improved fluid management composites and their method of manufacture comprising a multiplicity of corrugated strands of resilient material and one or more sheets of porous material intermittently bonded to the corrugated strands. The corrugated strands have arcuate portions projecting from the porous material between portions of the strands that are bonded to the porous material. These corrugated strands are resistant to compression. These fluid management composites provides advantages when used in disposable garments such as diapers, training pants, adult incontinence briefs or sanitary napkin products or for dewatering high solid content fluids.
[0008] The present invention also provides novel methods for making the fluid management composites. The fluid management composites are well constructed for their intended end uses and yet simple and inexpensive to manufacture. The method is also flexible affording versatility in selecting characteristics of the fluid management composites to be produced without major modifications of the equipment.
[0009] According to the present invention there is provided a method for forming a fluid management composite which comprises (1) providing at least a sheet of porous material (e.g., a perforated polymeric film, or a sheet of woven natural or polymeric fibers, or a coherent nonwoven web of natural or polymeric fibers); (2) extruding spaced generally parallel elongate strands of molten thermoplastic material that are resilient when cooled (e.g., polyolefins); (3) forming the extruded stands to have arcuate portions projecting in the same direction from spaced anchor portions of the extruded strands; and (4) attaching the anchor portions of the extruded strands to form a porous laminate material with the arcuate portions of the extruded strands projecting outward from the porous material.
[0010] By this method there is provided a novel fluid management composite comprising a multiplicity of corrugated strands of resilient thermoplastic material extending in a generally parallel spaced relationship. The corrugated strands have anchor portions bonded at first strand bonding locations to longitudinally spaced sections of the porous material. The strands have arcuate portions projecting between the strand bonding locations.
[0011] Extruding the strands between opposing corrugating members generally causes the strands to flatten and form into corrugations having arcuate portions. The spaced apart anchor portions when joined to the porous material at the bonding locations are flattened further or indented along the parts of the strand's surfaces that are closely adjacent the anchor portions. The solidified strands generally have uniform morphology along their lengths, however the bonding locations can see a different thermal history and have a slightly different morphology. The strands can be pressed against the surfaces of the porous material at the bonding locations of the anchor portion so that the strands have a greater width between the opposite elongate side surface portions of the strands along the bonding locations than between the bonding locations to provide very firm attachment between the porous material and the strands.
[0012] In the method described above for forming a fluid management composite the forming step can comprise the steps (which can be performed in any order and may omit some steps) of (1) providing first and second generally cylindrical corrugating members each having an axis and including a multiplicity of spaced ridges defining the periphery of the corrugating member, the ridges having outer surfaces and defining spaces between the ridges adapted to receive portions of the ridges of the other corrugating member in meshing relationship with the multiple strand material therebetween; (2) mounting the corrugating members in axially parallel relationship with portions of the ridges in meshing relationship; (3) rotating at least one of the corrugating members; (4) extruding the multiple strand material onto at least one corrugating member so that the strands are fed between the meshed portions of the ridges to generally conform the strand material to the periphery of a first corrugating member to form the arcuate portions of the strand material in the spaces between the ridges of the first corrugating member and the anchor portions of the strand material along the outer surfaces of the ridges of the first corrugating member; and (5) retaining the formed strand material along the periphery of one of the first corrugating members for a predetermined distance after movement past the meshing portions of the ridges. The extruding step includes providing an extruder that, through a die with spaced openings, extrudes the spaced strands of molten thermoplastic material along the periphery of a first corrugating member within the predetermined distance. This method allows the diameter of the strands to be easily varied by either changing the pressure in the extruder by which the strands are extruded (e.g., by changing the extruder screw speed or type) and/or by changing the speed at which the first corrugating member, is moved (i.e., for a given rate of output from the extruder, increasing the speed the corrugating member is moved will decrease the diameter of the strands, whereas decreasing the speed at which the corrugating member is moved will increase the diameter of the strands). Also, the die through which the extruder extrudes the thermoplastic material can have an easily changeable die plate in which are formed a row of spaced openings through which the strands of molten thermoplastic material are extruded. Such die plates with openings of different diameters and different spacings can relatively easily be formed by electrical discharge machining or other known methods to afford different spacings and diameters for the strands. Varied spacing and/or diameters for the openings along the length of the row of openings in one die plate can be used, for example, to produce a fluid management composite which will have greater or less compression resistance as may be required for a given end use. Different effects can be achieved by shaping and or modifying the die to form hollow strands, strands with shapes other than round (e.g., square or cross-shaped) or bi- or multi-component strands.
[0013] As indicated above, the fluid management composite according to the present invention can further include a second set of strand material having anchor portions thermally bonded at second sheet bonding locations to longitudinally spaced portion of the porous material along corresponding second elongate surface portions thereof, and having arcuate portions projecting from the second elongate surface portions of the elastic strands between the second sheet bonding locations.
[0014] Using the method described above, such a second set of strand material can be provided in the fluid management composite in at least two different ways. One way is to form the second set of strand material to have arcuate portions projecting in the same direction from spaced anchor portions of the second set of strand material; and positioning the spaced anchor portions of the second set of strand material in closely spaced opposition to the spaced anchor portions of the first set of strand material with the arcuate portions of the first and second set of strand material projecting in opposite directions so that the porous material is fed between the anchor portions of both the first and second sets of strand material to bond simultaneously to the anchor portions of both the first and second sets of strand material. Another way is to provide a second set of strand material after the first set of strand material is bonded to the porous material and bond the second set of strand material to at least some of the spaced apart bond portion of the porous material.
[0015] The porous material in the fluid management composite can be any porous material that would allow the passage of fluid into the porous material and optional into and through the porous material. The porous material could be a (1) polymeric perforated film (e.g., polypropylene, polyethylene or polyester); (2) conventional woven, knitted, stitch bonded or like fibrous material; (3) nonwoven fibrous materials or laminates of a porous material to a second needle punched porous material or nonporous material. The nonwoven fibrous material can be stabilized by bonding or entangling the fibers each to the other such by hydroentangling, spunbonding, thermal bonding or bonding by various types of chemical bonding such as latex bonding, powder bonding, etc. Alternatively the fibers could be bonded externally to a second sheet material that has at least some mechanical stability. The fibers can be formed of any suitable polymer or other fiber forming materials such as of polypropylene, polyethylene, polyester, nylon, cellulose, superabsorbent fibers or polyamides Also bi- or multi-component fibers can be used, for example, a core of polyester and a sheath of polypropylene can be used which provides relatively high strength due to its core material and is easily bonded due to its sheath material. The fibers can also be mixed or blended with particles or other fibers of different materials or material combinations.
[0016] The fluid management composite can be conveniently included in a disposable garment (e.g., a disposable diaper or training pants, adult incontinence brief or sanitary napkin product) at a location where there is encountered fluid discharge. The fluid management composite can be adhered to an external surface or placed in a structure between a fluid transport cover layer and a further layer such as an absorbent layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The present invention will be further described with reference to the accompanying drawing wherein like reference numerals refer to like parts in the several views, and wherein:
[0018] [0018]FIG. 1 is a schematic view illustrating a first embodiment of a method and equipment according to the present invention for making a first embodiment of a fluid management composite according to the present invention;
[0019] [0019]FIG. 2 is a perspective view of an embodiment of the fluid management composite according to the present invention made by the method and equipment illustrated in FIG. 1 and 5 ;
[0020] [0020]FIG. 3 is a fragmentary enlarged sectional view taken approximately along line 3 A- 3 A of FIG. 2;
[0021] [0021]FIG. 4 is a fragmentary enlarged top view of FIG. 2;
[0022] [0022]FIG. 5 is a schematic view illustrating a second embodiment of a method and equipment according to the present invention for making a second embodiment of a fluid management composite according to the present invention;
DETAILED DESCRIPTION OF THE INVENTION
[0023] Referring now to FIG. 1 of the drawing, there is schematically illustrated a first embodiment of a method and equipment according to the present invention for making a first embodiment of a fluid management composite 11 according to the present invention which is illustrated in FIGS. 2 and 3.
[0024] Generally the method illustrated in FIG. 1 involves providing a sheet of porous material 7 ; extruding spaced generally parallel elongate strands 13 of molten thermoplastic material on a first rotating corrugating roll 4 forming the plurality of extruded strands 11 to have arcuate portions 14 projecting in the same direction from spaced anchor portions 13 of the plurality strand material; thermally bonding the anchor portions 13 of strand material to the porous material with the arcuate portions 14 of the strand material projecting from corresponding elongate side surface portions of the porous material 7 .
[0025] As illustrated in FIG. 1, the equipment for performing the method includes first and second generally cylindrical corrugating members 4 and 5 each having an axis and including a multiplicity of spaced ridges 9 defining the periphery of the corrugating member 4 or 5 , the ridges 9 having outer surfaces and defining spaces between the ridges adapted to receive portions of the ridges 9 of the other corrugating member in meshing relationship with the strand material 3 therebetween; means for mounting the corrugating members 4 and 5 in axially parallel relationship with portions of the ridges 9 in meshing relationship; means for rotating at least one of the corrugating members 4 or 5 so that when the strand material 3 is fed between the meshed portions of the ridges 9 the strand material will generally conform to the periphery of one of the corrugating members 4 or 5 to form arcuate portions 14 of the strand material in the spaces between the ridges 9 of a corrugating member 4 or 5 and to form anchor portions 13 of the strand material along the outer surfaces of the ridges 9 of a first corrugating member 4 or 5 ; optionally means (e.g., including a surface of a corrugating member 4 or 5 being roughened by being sand blasted or chemically etched or being heated to a temperature generally in the range of 25 to 150 Fahrenheit degrees above the temperature of the first sheet 12 of flexible material) for retaining the strand material along the periphery of a corrugating member 4 or 5 for a predetermined distance after movement past the meshing portions of the ridges 9 ; means in the form of an extruder feeding a die with a changeable die plate 2 (see FIG. 1) with spaced through openings for extruding thermoplastic material to form a multiplicity of generally parallel elongate molten strands 13 of the thermoplastic material extending in generally parallel spaced relationship and for positioning the molten strands 13 along the periphery of a corrugating member 4 within the predetermined distance. Also, that equipment further includes a feed means such as roll 10 for feeding the porous material to a nip between the generally cylindrical bonding roll 6 having an axis and the corrugation member 5 carrying the strands 3 ; means for rotatably mounting the bonding roll 6 in axially parallel relationship with the corrugating members 4 and 5 with the periphery of the bonding roll 6 closely spaced from and defining a nip with the periphery of the corrugating member 5 at a predetermined distance from the meshing portions of the ridges 9 ; optionally the bonding roll and/or the corrugating roll can be supplied with heating means to assist in bonding the strands to the porous material 7 ; and means including a nipping roller 25 for moving the sheet-like composite 10 for a predetermined distance around the periphery of the cooling roll 24 past the nip with the strands 16 in contact with the cooling roll 24 to cool and solidify the strands 16 .
[0026] The structure of the sheet-like composite 10 made by the method and equipment illustrated in FIG. 1 is best seen in FIGS. 2, 3 and 4 . The fluid management composite 11 comprises the multiplicity of generally parallel elongate strands 3 of thermoplastic material extending in generally parallel spaced relationship. Each of the strands 3 is generally a flattened cylindrical or oval-like shape that is spaced from and is adjacent another strand. The spaced anchor portions 13 of the strand are thermally bonded at strand bonding locations 12 to longitudinally spaced sections of the porous material 7 along its first surface 18 , and the arcuate portions 14 of the strand material project from the first surface 18 of the porous material 7 between the strand bonding locations 12 . The first strand bonding 17 locations are spaced about at predetermined distances from each other and aligned in generally parallel rows extending transverse to the strands 3 to form continuous rows of the arcuate portions 14 projecting at a predetermined first distance from the first surface 18 of the porous material. Because the strands 13 have been extruded in molten form the anchor portions 13 of the strand material can generally be pressed onto the first surface 18 of the porous material the ridges 9 on the corrugating member 5 and the periphery of the bonding roll 6 , in which case the still mobile thermoplastic polymer strands 16 form around and are indented by the ridges 9 . The bonds between the strand 3 anchor portions 13 and the porous material 7 at the first strand bonding locations extend along the entire part of the strand's surfaces that are closely adjacent the ridges 9 . As is illustrated in FIG. 4, those parts of the strand's surfaces that are closely adjacent the ridge 9 are widened along the surfaces of the anchor portions 13 by indentations of the strands 16 by the ridges 9 . Thus the areas of bonding between the strands 3 and the porous material can advantageously be made wider at the strand bonding locations to increase bond levels.
[0027] Alternative structures that could be provided for the fluid management composite include spacing the ridges 9 around the corrugating members 4 and 5 to produce repetitive patterns of different spacings between the anchor portions 13 of the strands 3 , thereby causing the continuous rows of the arcuate portions 14 to project at different distances from the first surface 18 of the porous material 7 .
[0028] [0028]FIG. 5 illustrates a second embodiment of a method and equipment according to the present invention for making a second embodiment of a fluid management composite 31 according to the present invention, which is generally identical in structure to the fluid management composite shown in FIGS. 2 - 4 . The method illustrated in FIG. 5 is somewhat similar and uses much of the same equipment as is illustrated in FIG. 1, and similar portions of that equipment and product have been given the same reference numerals and perform the same functions as they do in the equipment illustrated in FIG. 1. In addition to the general method steps described above with reference to FIG. 1, the method illustrated in FIG. 5 further generally includes the step of directly extruding the strand material 3 into the nip formed by corrugating members 4 and 5 . This decreases the distance from the extruder to the bonding roll 6 reducing or eliminating the need for additional heat to be supplied to bonding roll 6 and/or corrugating member 5 . However, additional heat can of course be supplied if needed to increase the bond level to a desired level. The structure of the fluid management composite 3 made by the method and equipment illustrated in FIG. 5 is identical to that seen in FIGS. 2 - 4 .
[0029] The fluid management composite fabric is used primarily in dewatering high solids content fluid materials in low flow conditions. The product is also generally disposable where the basis weight of the porous media and the fiber denier of the filaments or strands are low to enhance bondability at low heat bonding levels. These conditions are found often in personal hygiene products such as incontinence products, baby diapers or menstrual pads. Low flow high solids content conditions are also possible in fluid filtration such as pool drain filters, medical filters or the like.
[0030] The porous backing layer is a preferably a nonwoven fibrous web formed of thermoplastic fibers such as a bonded carded web, a spunlace fabric, a melt blown web, a spun bond web, a needletacked nonwoven or the like. Generally the porous backing and preferably the nonwoven fibrous web has a basis weight of from 10 to 200 g/m 2 , preferably from 20 to 100 g/m 2 . At higher basis weights the web can become difficult to bond to the corrugated strands and provides lower fluid passthrough. At lower basis weights the web becomes difficult to handle and unstable in its final use form. However additional porous support webs can be used if desired and joined to the porous backing layer.
[0031] The filaments or strands generally are any resilient thermoplastic material capable of being extruded, such as polyesters, polyamides or polyolefins with polyolefin such as polyethylenes or polypropylene polymers (including copolymers or blends) being preferred.
[0032] The filaments can also be multi-component filaments such as sheath core filaments where the sheath layers have a melting or softening point less than the core layer material. This can aid in bonding difficult to bond or incompatible strand or filament material. Preferably the filament is formed at least in part of a polymer having a softening point less than the softening point of the fiber forming the porous backing layer. The composite fabric in a preferred embodiment is one where the filament is a polyolefin fiber and the back layer is a polyolefin.
[0033] The parallel longitudinally oriented thermoplastic filaments are bonded to the fibrous backing layer at spaced apart bonding locations along the lengths of the filaments where the filament form compression resistant arcuate portions between the bonding locations. The arcuate portion of the filaments will generally have a height from the front surface of the backing layer of greater than 0.2 mm but less than 4 mm, preferably from 0.5 mm to 3 mm. The filaments generally will have a diameter of from 10 mil to 100 mil, preferably from 10 mil to 50 mil. The web should be compression resistant such that it retains at least 50% of its initial caliper under a load of one pound per square inch.
EXAMPLES
Example 1
[0034] A nonwoven filter sheet composite similar to the sheet-like composite 17 illustrated in FIG. 2 was made using equipment similar to that illustrated in FIG. 1. A thermoplastic ethylene-propylene impact copolymer (8 MFI) commercially available under the designation 7C50 from the Union Carbide Corporation of Danbury, Conn. was placed in a 51 mm single screw extruder to form the filaments 3 . About 4.7 filaments per centimeter of the 7C50 copolymer were extruded at a melt temperature of about 238° C. through 0.76 mm orifices at 17 RPM onto an upper corrugating roll 4 . The upper corrugating roll was machined to have 4 axially parallel ridges per centimeter located completely around the periphery of the roll with a groove between each ridge. Each ridge was machined to have a flat top-surface having a width of about 0.7 mm. The upper corrugating roll was at about 88° C. The partially cooled strands were then corrugated in a nip formed by the upper corrugating roll and a lower corrugating roll 5 . The lower corrugating roll (113° C.) was machined with the same ridge and groove geometry as the upper corrugating roll and was in meshing relationship with the upper roll. A nip pressure of 100 pounds per lineal inch was used with a line speed of about 7.6 meters per minute. The corrugated strands were then bonded to a 30 gram per square meter spunbonded type polypropylene nonwoven 7 (available from Amoco Fabrics and Fibers Company of Atlanta, Ga., under the designation ‘RFX’) in a nip formed by the lower corrugating roll 5 and a smooth metal chill roll 6 . The chill roll was maintained at about 150° C. A nip pressure of 300 pounds per lineal inch was used to bond the strands to the nonwoven. The resulting nonwoven filter sheet composite had a basis weight of 58 grams per square meter with arcuate strand portions 11 of about 15 mm in height projecting from the nonwoven sheet 13 . The composite had a compression resistance of 93% measured as a ratio of initial caliper and caliper under a load of one pound per square inch. | A composite fabric for use in dewatering high solids content fluid materials comprising a multiplicity of corrugated strands of compression resistant material, and one or more sheets of porous material bonded along its length at sheet bonding locations to the strands, some of which strands have arcuate portions projecting from the strands between those sheet bonding locations. The sheet-like composite may be incorporated where there is a need to dewater high solids content fluids such as in disposable garments such as diapers or training pants. | 3 |
BACKGROUND OF THE INVENTION
Field of the Invention
The invention relates to a cardiac pacer for pacing a heart, in particular a human heart, wherein the pacing rate is controlled by a signal that is dependent upon physical activity or a measured physiological change in the body of a patient.
Related Applications
The subject matter of this application is related to the following co-pending applications filed simultaneously herewith: "Cardiac Pacer For Pacing A Human Heart," Elmqvist, Ser. No. 874,588; "A Cardiac Pacer For Pacing A Heart," Elmqvist, Lekholm, Hedberg and Amundson, Ser. No. 874,597; " "A Cardiac Pacer For Pacing A Human Heart," Lekholm and Amundson, Ser. No. 874,591; and "A Cardiac Pacer For Pacing A Heart," Lekholm and Amundson, Ser. No. 874,585; and "A Cardiac Pacer For Pacing A Human Heart," Amundson, Ser. No. 874,588.
Description of the Prior Art
Conventional cardiac pacers of this kind, in particular of the respiration rate responsive type, are for example described in the U.S. Pat. No. 3,593,718 and in the European patent application No. 0,089,014.
The conventional cardiac pacers can suffer from erroneous rate increases either due to instability or drift in the sensor itself or due to sensing of interference or due to a poor coupling between the sensed variable and the corresponding physiological need for cardiac output. As many of the elderly patients in whom rate-responsive pacemaker systems are implanted have low tolerance for the strain of a prolonged elevated heart rate, these conditions represent a potential hazard to the patient.
SUMMARY OF THE INVENTION
Objects
It is an object of this invention to provide for an improved cardiac pacer which is safe from hazardous erroneous rate increases.
Summary
According to this invention an improved cardiac pacer is provided which comprises
(a) means for generating pacing pulses at a predetermined basic pacing rate;
(b) means for transmitting the pacing pulses to the heart for pacing;
(c) means for sensing physical activity and for generating a control signal dependent thereon;
(d) means for varying the predetermined basic pacing rate dependent on the control signal; and
(e) means for forcing the pacing rate back to a lower rate if the pacing rate runs at or above a predetermined high rate for a predetermined time period.
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of a preferred embodiment of the invention, as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a first embodiment of a cardiac pacer comprising the invention in a schematic block diagram.
FIG. 2 shows a second embodiment of a cardiac pacer comprising the invention in a schematic block diagram: and
FIG. 3 shows the time base unit of the embodiment of FIGS. 1 and 2 in more detail.
FIG. 4 shows another embodiment of a cardiac pacer comprising the invention in a schematic block diagram having an impedence measuring electrode.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1 and 2 a human heart which has to be paced is generally designated with 1. A pacing electrode 2 is inserted in the human heart 1 in a manner and position such that the heart can most efficiently be paced. The pacing electrode 2 is connected through a pacing lead 3 with a pacing pulse generator 4. A timing circuit 5 controls the pacing rate of the pacing pulse generator 4 through line 6.
According to FIG. 1 an impedance pneumograph (also called a pneumatograph) 7 comprises an AC source 8 generating a continuous alternating current, a demodulator 9, a filter 10, a non-linear amplification circuitry 11, an integrator 12, and a voltage to pulse rate converter 13.
The AC source 8 is connected with the pacing lead 3 through leads 14, 15. The demodulator 9 is connected with the pacing lead 3 through leads 15, 16. Under the circumstances the current of the AC source 8 is supplied to the pacing electrode 2 together with the pacing pulses 17. This embodiment can be modified as shown in FIG. 4 wherein a separate electrode is provided for impedance measurement. In this case the AC source 8 and the demodulator 9 are disconnected from pacing lead 3 and instead are connected through additional lead 18 with the separate impedance measuring electrode 19. In both cases the output signal of the demodulator 9 is a measure for the breathing rate, i.e. a respiratory signal.
In FIG. 1 the pacing pulse generator 4, the timing circuit 5 and the impedance pneumograph 7 are all encapsuled in an implantable conductive (metallic) housing 20 which is the housing of the cardiac pacer. The conductive housing 20 defines both the indifferent electrode for pacing and the second electrode for impedance measurement as indicated in FIG. 1 with reference numeral 21.
As illustrated in FIGS. 1 and 2 the pacing pulse generator 4 comprises an output capacitor 26 which is switchable by means of switch 27 between battery 28 (switch position A) and pacing lead 3 (switch position B). In switch position A the output capacitor 26 is charged by the battery 28 to a voltage V1. In switch position B the output capacitor 26 is discharged through pacing lead 3 as pacing pulse 17.
In the embodiment of FIG. 2 the amount of discharge depends on the impedance variations of the patient's thorax during respiration. According to FIG. 2 the pacing pulse 17 discharges from V1 to V2 (amplitude decay D). The sample and hold circuitry 23 samples and holds the voltages V1, V2 of output capacitor 26. The difference former 24 forms the difference V1-V2 which is again a measure for the breathing rate, i.e. a respiratory signal.
In both embodiments of FIGS. 1 and 2 the non-linear amplification circuitry 11 amplifies the filtered respiratory signal such that signal portions having higher amplitudes are more amplified than signal portions having lower amplitudes. Under the circumstances signal portions of interest including the respiration signal, are enhanced with respect to low amplitude noise for further processing. Non-linear amplification circuits of this kind are well known in the art and need not be described in more detail. The output signal of the non-linear amplification circuitry 11 is integrated in integrator 12 over a period of time, e.g. in the range of 5 to 30 s. By integrating high-frequency noise is significantly reduced. The voltage to pulse rate converter 13 in FIGS. 1 and 2 converts the integrated signal into a pulse rate according to the breathing rate.
The voltage to pulse rate converter 13 controls the timing circuit 5 through line 29 such that a predetermined (e.g. programmable) basic pacing rate of the pacing pulse generator 4 is varied dependent on the respiratory signal. In FIG. 2 the line 30 is a control line from the time base unit 5 to the sample and hold circuitry 23 of impedance pneumograph 22.
According to this invention and as depicted in more detail in FIG. 3 the timing circuit 5 comprises a zero decoder 31, a decremented counter 32 having a reset input 33, a time base register 34, a logic gate 35, an analog signal to digital control word converter 36, a high rate comparator 37 for the output of the time base register 34 and a predetermined high rate value, e.g. 120 beats/min. of a high rate value generator 38, an integrator 39, a threshold discriminator 40, a time/threshold selector 41 connected with the threshold discriminator 40, a monostable multivibrator 42 and a time/pulse width selector 43 connected with the monostable multivibrator 42.
The analog signal to digital control word converter 36 converts the analog pulse rate signal of the voltage to pulse rate converter 13 into a digital control word. This digital control words is supplied through open gate 35 to the time base register 34. It controls the time base register 34 such that a basic pacing rate, e.g. 60 beats/min., is varied dependent on the respiration rate. When the breathing rate increases the time base register 34 increases the counting speed of the decremental counter 32 so that it reaches zero faster than at basic rate. Under the these conditions the zero decoder 31 generates switching signals at higher rates, so that the output capacitor 26 of the pacing pulse generator 4 charges and discharges at higher rates. As a result the pacing rate increases dependent on increasing breathing rate as desired.
However, as soon as the output of the time base register 34 reaches (and as long as it is running at or above) the predetermined high rate value of the high rate value generator 38, the high rate comparator 37 generates an output signal, e.g. a DC signal, which is integrated by integrator 39. After a certain time period, which is preselectable by means of time/threshold selector 41 through preselecting at a predetermined threshold at threshold discriminator 40, the output signal of integrator 39 exceeds the preselected threshold of the threshold discriminator 40. The threshold discriminator 40 in response triggers a monostable multivibrator 42 which generates an output pulse the width of which is programmable by means of time/pulse width selector 43. this output pulse of monostable multivibrator 42 continues until the end of the output pulse.
As a result the time base register 34 is disconnected from the output of the analog signal to digital control word converter 36. The time base register 34 switches back to basic pacing rate, e.g. 60 beats/min.
Under the circumstances this invention safeguards a patient, in particular elderly patient, against the strain of a prolonged elevated heart rate. If the pacer runs for a predetermined time at or above a predetermined high rate, then it will react as if the control signal which is dependent upon physical activity (here the respiration signal) disappeared so that the pacer automatically returns to its basic pacing rate. The time during which the pacer will run at basic rate after a forced return to basic rate is programmable. An additional criterion which may be used is that the control signal sensor input must return below the predetermined high rate to a lower value before the pacer starts tracking the control signal again.
A similar function has already been described, adding a slow time constant to the detector response so that a constant detector output will be regarded as a detector output that slowly returns to the resting, non-active state. The latter method has the disadvantage relative to this invention in the sense that it limits the exercise capacity of the patient for any activity that is longer than the time constant, which typically would be of the order of minutes or possibly up to one hour.
With the method described in this invention the heart rate may be elevated for may hours during normal physical activity. The rate limitation is only activated when the pacer stays at the high rate for the prolonged period of time.
Another variation of the invention allows for the forced return at a predetermined rate between the basic rate and the high rate of the pacemaker.
Having thus described the invention with particular references to the preferred forms thereof, it will be obvious to those skilled in the art to which the invention pertains, after understanding the invention, that various changes and modifications may be made therein without departing from the spirit and scope of the invention as defined by the claims appended hereto. For example the impedance measurement electrodes do not need to be implanted. They can also be secured on the patient's chest, if desired. Such a possibility is for example illustrated in U.S. Pat. No. 3,593,718. Also, instead of a respiratory signal any other signal of physiologic need for increased cardiac output, e.g. temperature, pO 2 signal etc., may be employed to control the rate of the pacer. | A cardiac pacer, which generates pacing pulses at a predetermined basic pacing rate, includes a device for sensing physical activity and for generating a control signal dependent thereon, a device for varying the predetermined basic pacing rate independent on the control signal and a device for forcing the pacing rate back to a lower rate if the pacing rate runs at or above a predetermined high rate for a predetermined time period. | 0 |
This is a division of application Ser. No. 335,401, filed Feb. 23, 1973, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a system and method for forming involute or elongate plastic articles from a sheet of thermoplastic material.
2. Description of the Prior Art
Current methods of forming thermoplastic material have certain basic deficiencies which restrict their utility in forming involute or elongate articles. Involute plastic structures, i.e., structures having a neck smaller than an interior cross-section, are generally formed by bonding two or more separately formed pieces of material together rather than forming the article from a single piece, and the seam of joint required degrades the optical properties of the article. Injection blow molding can be used to form thermoplastic articles, but this method is limited to relatively small articles due to the magnitude of the equipment involved. Extrusion blow molding can also be used to form thermoplastic articles, but the closure on the end opposite the opening forms objectionable marks and loss of optical properties.
The present invention discloses a system and method for forming elongated and involute articles from thermoplastic material having a variety of novel and innovative features which overcome deficiencies in the methods used to date. The invention provides a methodology for accurate control of the heating of a sheet of thermoplastic material, and the establishment of preselected concentric temperature zones within the thermoplastic material, to facilitate subsequent formation of the articles. The thermoplastic material is rapidly heated so that the material forms easily without unwanted stretching. After the sheet of thermoplastic material is heated, it is placed in a device for forming the thermoplastic material to the desired shape. The heated sheet of thermoplastic material is planarly supported by the device and held in accurately monitored compression to control slippage of the material toward the center thereof. A plug is used to project the center of the sheet of thermoplastic material through an aperture in the planar support, and the material "self-forms" around a sharp corner on the interior of the aperture into an elongated shape. The planar support disclosed herein also provides a means for inducing axial stress in the sheet of material to control the thickness of the thermoplastic material as it is formed from the flat sheet into the elongated piece.
In the formation of involute articles, the elongated piece is formed within an involute female mold. The involute female mold disclosed herein has a flat aperture section forming the entrance to the mold and a sharp corner is provided at the junction of the flat aperture section and the interior surface of the female mold to eliminate potential formation of stress cracks. The ambient environment of the thermoplastic material as it is elongated is closely controlled to prevent cooling of the material below its forming temperature so that it can be expanded within the mold by injection of pressurized air into the interior cavity of the elongate piece. As the material expands, the concentric temperature zones control relative expansion of different areas of the material so that the final article has controlled and approximately uniform wall thickness.
SUMMARY OF THE INVENTION
The invention provides an infrared oven with voltage and ambient temperature controls to rapidly and accurately heat a sheet of thermoplastic material. During the heating of the thermoplastic material, metallic screens are interposed between the oven heating elements and the thermoplastic material to establish radial temperature gradients in the material. After the sheet of thermoplastic material has been heated, it is placed between a pair of opposed platens which provide planar support. The pair of opposed platens have apertures through the centers thereof to allow for transverse extension of the thermoplastic material and allow for controlled slippage of the thermoplastic material toward the center thereof. A heated plug is used to transversely extend the thermoplastic material into an elongated conical piece. During the elongation process, the thermoplastic material self-forms as it translates from between the pair of opposed platens into the elongated shape, and a small radius corner must be provided at this junction to properly allow the material to self-form.
If involute articles are to be formed, the elongated conical shaped piece is formed within an involute female mold, and compressed air is injected into the interior cavity of the elongated conical shaped piece to expand and press the thermoplastic material against the surface of the mold. Proper design of the entrance of the involute female mold and proper maintenance of the temperature gradients in the thermoplastic material are essential for the proper formation of an involute article without optical defects. Throughout the entire process, maintenance of the proper ambient conditions and structural details of the forming mechanism are essential for proper operation of the process.
The novel features which are believed to be characteristic of the invention, both as to organization and method of operation, together with further objects and advantages thereof will be better understood from the following description considered in connection with the accompanying drawings in which several preferred embodiments of the invention are illustrated by way of example. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the apparatus used for heating the sheet of thermoplastic material.
FIG. 2 is an exploded view of the interior of the heating apparatus.
FIG. 3 is a perspective view of the apparatus used to elongate and form the involute plastic articles.
FIG. 4 is a cross-sectional elevation view of the apparatus illustrated in FIG. 3 showing the sheet of thermoplastic material in position to be formed.
FIG. 5 is the cross-sectional elevation view of FIG. 4 after the sheet of thermoplastic material has been formed into an elongated conical shaped piece.
FIG. 6 is the cross-sectional elevation view illustrated in FIGS. 4 and 5 after the elongated conical shaped piece of thermoplastic material has been partially formed into an involute plastic article.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a circular sheet of thermoplastic material 10 is mounted inside an oven enclosure 11. The circular sheet of thermoplastic material 10 is supported on a grid 12 of very fine, widely-spaced wires which are attached to a rotatable ring 13. The rotatable ring 13 is mounted on brackets 14 and 15 attached to the side of the oven enclosure 11. In this manner, contact of the mounting structure with the sheet of thermoplastic material is minimized, and only the thin wires are interposed between the thermoplastic material and the heating mechanism.
The sheet of thermoplastic material 10 is heated by means of linear infrared heating elements 16. An array of heating elements is disposed adjacent both the top and the bottom faces of the thermoplastic material 10, but the upper array is hidden in the perspective view of FIG. 1. A scalloped reflecting structure 17 is used to direct the radiant heat from the infrared heating elements 16 in the direction of the thermoplastic material 10. Potential heating irregularities due to the linear nature of the array are compensated for by rotating the sheet of thermoplastic so that the heating is concentrically uniform.
In the present invention, it is absolutely essential that the heating of the sheet of thermoplastic material 10 be accurately and precisely controlled, since only slight deviations from the desired heating will seriously degrade the integrity of the entire forming process. Hence, a voltage regulator 18 is used to provide a precisely controlled and constant input voltage to the linear infrared heating elements 16 through leads 19. However, the heat loss or gain of the sheet of thermoplastic material 10 and the radiant output of the heating elements 16 is dependent on the ambient air temperature within the oven enclosure 11. Therefore, it is not sufficient to merely control the input voltage to the heating element 16 in order to accurately control the heating of the sheet of thermoplastic material 10, but the ambient air temperatures within the oven enclosure 11 must also be controlled. Such control is provided by a venting mechanism which exhausts heated air out vent 20. The venting mechanism 19 controls the venting of air and maintains the ambient temperature of the air inside the oven enclosure 11 at a constant temperature. The door 21 to the oven enclosure 11 does not fully seal off the enclosure, but rather provides for a slight intake of air to compensate for the heated air vented through the exhaust vent 20. By accurately and precisely controlling the radiant heating of the sheet of thermoplastic material 10, the process becomes very repeatable and provides constant quality control of the end product.
To control subsequent formation of the material, it is not sufficient to control only the general heating of the sheet of thermoplastic material 10, but it is also desirable to set up various temperature gradients throughout the thermoplastic material. FIG. 2 is an exploded view illustrating the sheet of thermoplastic material 10 separated from its support grid 12 of thin, widely spaced wires attached to ring 13. Both the upper and lower arrays of linear infrared heating elements 16 with their scalloped reflecting structures 17 are illustrated. The mechanism for mounting and rotating the ring 13 is not illustrated in FIG. 2. To establish radial temperature gradients in the sheet of thermoplastic material 10, concentric rings of metallic screen 30 and 31 are interposed between the sheet of thermoplastic material 10 and the support grid 12. Although shown separately in the exploded view, in actual operation they are positioned one on top of the other. In the Figure, two concentric rings of metallic screen are illustrated for simplicity, but in practice a multitude of concentric rings of metallic screen are normally utilized, with some rings having internal cutout sections as in concentric ring 31 and some without such cutouts as in concentric ring 30. The purpose of the concentric rings of metallic screen is to block a portion of the radiant energy from the infrared heating elements 16 to prevent it from reaching the sheet of thermoplastic material 10. Since the metallic screen is formed in concentric rings a set of radial temperature gradients will be established.
The heating apparatus is designed to heat the sheet of thermoplastic material 10 such that the edge of the sheet is heated to a greater extent than the central area of the sheet. Concentric heat zones are formed by the metallic screens so that the center is heated to a temperature near the low end of the forming temperature range, the edge is heated to a temperature near the high end of the forming temperature range, with possible intermediate zones between the center and the edge.
After the sheet of thermoplastic material 10 is heated, it is immediately transferred to the forming apparatus illustrated in FIG. 3 and placed between a pair of opposed platens consisting of an upper platen 40 and a lower platen 41. The upper platen 40 is attached to air actuators 42 and 43 which control the compression that the pair of opposed platens 40 and 41 maintain on the heated sheet of thermoplastic material 10. An aperture 44 is formed through the upper platen 40 and the lower platen 41 whereby the center of the heated sheet of thermoplastic material 10 is exposed. A plug 45 mounted on shaft 46 is passable through the aperture 44 through the pair of opposed platens 40 and 41 to form the heated sheet of thermoplastic material into an elongated conical shaped piece. The elongated conical shaped piece is formed within an involute female mold 47 if involute articles are to be produced. If merely elongated conical articles are to be produced, the involute female mold 47 is not necessary.
During the formation of the elongated conical shaped piece of thermoplastic material, it is desirable to gradually increase the compression of the pair of opposed platens 40 and 41 on the sheet of thermoplastic material 10 to prevent flange wrinkling and to control slippage of the thermoplastic material relative to the pair of opposed platens. The preferred method of controlling the increase in compression is by means of a closed loop control system wherein the pressure exerted by air actuators 42 and 43 is increased based on the amount of thermoplastic material which has been used in the forming process. To provide such a closed loop control system, a row of thermoinsulative pegs 48, 49 and 50 is provided which are placed in a row of radially disposed holes on the upper platen 40. As the edge of the sheet of thermoplastic material 10 moves in the direction of the aperture 44 during the formation process, switches 51, 52 and 53 attached to the pegs 48, 49 and 50 are successively actuated by the falling of the pegs through the holes to monitor the movement of the thermoplastic material toward the aperture. The switches successively increase the pressure exerted by air actuators 42 and 43 whereby the compression exerted by the pair of opposed platens 40 and 41 is gradually increased.
A plurality of pegs 54 are located in a ring of holes in the upper platen 40 disposed about the aperture 44. Switches 55 are connected to the pegs 54, and the interior peg 50 and connecting switch 53 of the radically disposed row of pegs form part of the ring. The ring of pegs is adapted to cause the air actuators 42 and 43 to exert sufficient pressure to clamp the heated sheet of thermoplastic material 10 between the pair of opposed platens 40 and 41 to prevent any slippage of the thermoplastic material relative to the opposed platens. Any one of the ring of pegs 54 and 50 will activate the clamping procedure so that no part of the edge of the sheet of thermoplastic material 10 can enter the aperture 44.
In order to control the exact temperature of the sheet of thermoplastic material 10 at all times, parts of the apparatus which come into direct contact with the thermoplastic material are heated. A heater 56 is attached to the plug 45, and a heater 59 is also attached to the involute female mold 47. Portions of the apparatus which are actively heated, i.e., the plug 45, and the mold 47, are constructed of thermoconductive material to evenly distribute the heat throughout the structure.
The involute female mold 47 can be split along seam 60 so that it can be divided into sections. Air holes 61 are provided to allow for exhaust of air from the interior of the mold 47 during the forming process.
The actual formation of the involute plastic articles can be more fully illustrated by viewing FIGS. 4, 5, and 6 in series. FIG. 4 illustrates the heated sheet of thermoplastic material 10 in position between the upper platen 40 and the lower platen 41. The plug 45 is in the raised position above the aperture 44 through the pair of opposed platens 40 and 41. Pegs 48, 49, 50 and 54 are in abutment with the sheet of thermoplastic material 10 and are thus maintained in position.
The upper platen 40 is composed of thermoconductive material, but has a coating of thermoinsulative material 70 on the face adapted to contact the heated sheet of thermoplastic material 10. The lower platen 41 is composed of an interior annular section 71 of thermoconductive material which is coated by a layer of thermoinsulative material 72 on the faces of the lower platen adapted to contact the heated sheet of thermoplastic material 10. Teflon is preferably used as the thermoinsulative material since it facilitates slippage of the thermoplastic material relative to the platens. The exterior section of the lower platen 41 is mounted circumferentially about the periphery of the interior annular section 71, and is preferably composed of semi-rigid thermoinsulative material such as wood. The exterior section 73 is slightly depressed relative to the interior section 71 such that a slight lip 74 is formed on the surface of the lower platen 41 at the junction between the interior section 71 and the exterior section 73. The slight lip 74 allows control of slippage through pressure without compressing the entire sheet of thermoplastic material.
If involute plastic articles are to be formed, the interior section 71 of the lower platen 41 is preferably attached directly to an involute female mold 47 such that the aperture 44 through the lower platen 41 forms the entrance opening to the female mold. The involute female mold illustrated in FIG. 4 is basically spherical, but the methodology illustrated herein is applicable to any shape wherein the neck of the article is smaller than an interior cross-section, i.e., wherein the article is involute, as well as to tapered, i.e. non-involute articles. The mold 47 has holes 61 therein adapted to allow for exit of air from the interior of the mold during formation of the articles. In addition, a sensor 76 is mounted on the interior surface of the involute female mold 47 and is adapted to sense contact of the thermoplastic material with the interior surface of the involute female mold to indicate that the formation of the article is completed.
Formation of the elongated conical shaped piece is illustrated by way of reference to FIG. 5. The outer diameter of the plug 45 with the thermoplastic material thereon is smaller than the interior diameter of the aperture 44 so that the thermoplastic material is not compressed between the plug and the walls of the aperture. Hence, the thermoplastic material self-forms as it translates from between the pair of opposed platens 40 and 41 into the aperture 44. Due to the self-forming nature of the process, the construction of the corner 81 over which the elongated conical shaped piece 80 self-forms is critical. Normal molding technology would dictate that a large radius corner by used to alleviate friction. However, one of the principal features of the invention disclosed herein is that a relatively sharp, small radius corner as illustrated is far preferable to a large radius corner.
In the formation of the elongated conical shaped piece 80, the thermoplastic material is drawn radially inwardly toward the aperture 44 as the plug 45 extends the material. As the edge of the heated sheet of thermoplastic material is drawn toward the aperture, the thermoinsulative pegs 48 and 49 successively fall whereby the compression exerted by the pair of opposed platens 40 and 41 on the thermoplastic material is increased. When the edge of the thermoplastic material is sufficiently close to the aperture so that one of the pegs 54 or 50 in the interior ring falls, sufficient compression is exerted by the pair of opposed platens to clamp the thermoplastic material in place between the platens.
The plug 45 extends to such a depth that the tip of the elongated conical shaped piece 80 is substantially adjacent the interior surface of the involute female mold 47 opposite the entrance opening 44. A lid 82 is mounted on the shaft 46 which holds the plug 45 and is adapted to fit over the aperture through the upper platen 40 whereby the interior cavity of the elongated conical shaped piece 80 is sealed. Hence, pressurized air can be introduced through nozzle 83 also located on shaft 46 in order to form the desired involute plastic article. The sequence of operations illustrated by FIGS. 4 and 5 are performed in a relatively short amount of time so as to prevent substantial cooling of the thermoplastic material. Hence, the elongated conical shaped piece 80 basically retains the temperature configuration imparted to it during the heating process. However, to facilitate formation of the involute article, the surface heat of the material is allowed to conduct to the center plane so that the material will more readily stretch when pressurized. The temperature zones remain basically unaffected.
As air is injected into the interior cavity of the elongated conical shaped piece, the walls of thermoplastic material do not expand simultaneously, but the formation of the article proceeds in various steps. The initial step in the formation of the involute plastic article is illustrated in FIG. 6. The first formation takes place in the area of the entrance to the involute female mold 47 as illustrated by contour 92. Since the original temperature zones established in the heating process has been maintained, thermoplastic material which was near the edge of the original sheet of thermoplastic material is at a greater temperature than material intermediate the edge and the center. The thermoplastic material which was adjacent the edge of the original sheet of thermoplastic material is now adjacent the entrance opening 44 of the involute female mold 47, and due to its greater temperature forms first. The thermoplastic material in the region of the entrance 44 to the involute female mold 47 comes into contact with the entrance opening and the interior surface of the female mold adjacent the entrance opening as air is first injected into the cavity. Although the involute female mold is heated, it is heated to a lesser temperature than the thermoplastic material, so that the thermoplastic material is cooled rapidly by the relative temperature differential when it comes in contact with the thermoconductive surface of the mold. Hence, the shape of the junction between the flat surface 90 and the interior surface of the female mold 47 is critical. The invention provides for a small radius corner 91 at this junction, rather than a large radius corner as would be expected, together with a vertical surface 90 of thermoconductive material at the entrance to the mold. As compressed air is introduced through nozzle 83, the hot plastic first contacts the vertical surface 90 and immediately cools. This prevents further slippage and eliminates stress cracking during the balance of the forming process.
It is apparent from FIG. 6 that the initial expansion, which took place near the entrance opening 44, is in a region wherein the material has only a short distance to travel before reaching the interior surface of the mold 47. Hence, the portion of thermoplastic material which is heated more than other portions has the shortest distance to travel to reach the interior surface of the mold. The thermoplastic material which was less heated has a relatively long distance to travel before it reaches the interior surface of the mold 47 in its final form as illustrated by the dashed contour 93. In this manner, the material which has the shortest distance to go stretches most rapidly, and the end result is the formation of an involute thermoplastic article with controlled wall thickness. | A system and method for forming elongated and involute thermoplastic articles is disclosed. Means are provided for controllably heating a sheet of thermoplastic material to form preselected temperature gradients throughout the sheet of thermoplastic material. Means are further provided for planarly supporting the heated sheet of thermoplastic material allowing for transverse motion of the heated sheet of thermoplastic material at the center thereof and further allowing for controlled slippage of the heated sheet of thermoplastic material toward said center thereof relative to the planar support means. Means are also provided for transversely forming a heated sheet of thermoplastic material into the shape of an elongated or involute plastic article. A plug is used to extend the heated sheet of thermoplastic material into an elongated conical shaped piece. To form involute thermoplastic articles, the elongated conical shaped piece is formed inside an involute female mold, and air is introduced into the interior cavity of the elongated conical shaped piece to expand and press the material against the interior surface of the mold. | 1 |
FIELD OF THE INVENTION
The present invention relates to variable speed friction disc transmissions having a pair of discs; the friction or driven disc having its periphery engaging the face of the drive disc. Friction disc transmissions of the type disclosed herein are used primarily for propulsion of small land traversing vehicles, particularly power lawn mowers.
A variable speed friction disc transmission of the type disclosed herein is shown in U.S. Pat. No. 2,942,487 of Claus. The transmission disclosed in the Claus Patent includes a driving disc rotatable about a vertical axis having a flat horizontal face normal to its axis of rotation and a driven disc rotatable on an axis normal to the axis of the driving disc and having its periphery engaging the face of the driving disc. As is known, the speed at which rotation is imparted to the driven disc is a function of the distance between the axis of the driving disc and the zone at which its face is engaged by the periphery of the driven disc. Further, the driven disc rotates in one direction on one side of the rotational axis of the driving disc and in the opposite direction on the opposed side. Thus, the driven disc may be rotated at any desired speed in either direction simply by moving the driven disc across the face of the driving disc.
The friction disc transmission disclosed in the Claus Patent has however several disadvantages. The friction disc transmission disclosed in the Claus Patent does not include a brake, stopping rotation of the driven disc and the driven disc is subject to wear, particularly when the driven disc is located in the center rotational axis of the driving disc. The latter problem has been recognized by the prior art which suggests the use of a neutral "button" as shown in U.S. Pat. No. 1,592,952 and 3,473,622. The prior art has not however made any significant improvement over the variable speed friction disc transmission disclosed in the Claus Patent or solved the problems described above.
The need therefore exists for a simple variable speed friction disc transmission having an improved variable speed control and a braking system. These and other improvements have been made in the variable speed friction disc transmission of the present invention.
SUMMARY OF THE INVENTION
The friction disc transmission of the present invention includes a drive disc rotatably mounted on a generally vertical axis and a driven friction disc rotatable about a horizontal axis normal to the axis of the drive disc and having a periphery engaging the face of the drive disc as disclosed in the above referenced patent of Claus. The friction disc in the preferred embodiment is supported on a pivot frame which is pivotally supported on a horizontal pivot axis spaced from the horizontal rotational axis of the friction disc. In the disclosed embodiment, a drive sprocket is rotatably supported on the pivot frame between the frame pivot and the rotational axis of the friction disc. The drive sprocket is driven by the friction disc and drives an axle sprocket mounted on a horizontal wheel axle for driving the wheel of a gound traversing vehicle.
In the disclosed and preferred embodiment of the friction drive transmission, the drive disc is rotatably supported on a swing arm or plate which is swingable about a vertical axis spaced from the vertical axis of the drive disc. In the disclosed embodiment, the swing axis is coincident with the drive shaft of the motor. The swing arm includes a control guide which has an upwardly facing vertically inclined camming face which engages and lifts the distal end of the pivot frame upon swinging lateral movement of the arm. The friction disc may thus be raised out of contact with the drive disc. In the disclosed embodiment, the control guide includes two opposed laterally spaced vertically inclined, upwardly facing camming surfaces for raising and lowering the friction disc and an intermediate notch for retaining the friction disc in a raised neutral position. The control guide is located relative to the rotational axis of the drive disc to lift the friction disc over the neutral axis of the drive disc, limiting wear of the discs and eliminating the requirement of a neutral "button" as described above.
The preferred embodiment of the friction disc transmission of the present invention also includes a clutch-brake mechanism which sequentially vertically lifts the pivot frame and friction disc out of engagement with the drive disc and stops rotation of the friction disc. The disclosed embodiment includes a foot pedal pivotally mounted on a rock shaft and a link means comprising a control link operably connected to the pedal for pivotal motion upon actuation of the pedal, a clutch link pivotally connected to the pivot frame to lift the pivot frame about its pivot axis and an L-shaped brake shoe connected to the control link and engaging the friction disc upon actuation of the pedal after the friction disc has been lifted out of contact with the drive disc.
The variable speed friction disc transmission of the present invention thus eliminates many of the problems inherent in the transmissions disclosed in the prior art. The friction disc transmission of the present invention includes a unique drive which eliminates the requirement of a gear speed reducer and results in a relatively simple positive drive. Other advantages and meritorious features of the present invention will be more fully understood from the following description of the preferred embodiments, the appended claims and the drawings, a brief description of which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of one embodiment of the friction disc transmission of this invention;
FIG. 2 is a top elevation of the embodiment of the friction disc transmission shown in FIG. 1;
FIG. 3 is a partial side view of the friction disc transmission shown in FIG. 1 following actuation of the clutch-brake;
FIG. 4 is an end view of the friction disc transmission shown in FIGS. 1 and 2; and
FIG. 5 is a schematic view of the chain drive utilized in the friction disc transmission shown in FIGS. 1 and 2 illustrating the self-energizing feature of the disclosed transmission.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As described above, the friction disc transmission of the present invention was specifically designed for small tractor-like vehicles such as power lawn mowers. It will be understood by those skilled in the art however that the self-energizing transmission of the present invention may be utilized in other applications, particularly the improvements disclosed and claimed herein. The transmission of the present invention will be described in regard to a fourwheeled lawn mower tractor or the like.
The power source 20 of the friction disc transmission may be a conventional four cycle gasoline motor or the like. The motor is supported with the drive shaft 22 extending vertically downwardly as shown in FIG. 1 and a pulley or hub 24 is secured to the shaft for rotation therewith. A conventional V-belt 26 is received on the hub 24 and the drive pulley 28 of the friction disc transmission. A conventional idler assembly 30 may be provided to maintain tension in the V-belt, particularly during idling of the transmission. The idler assembly includes a V-belt pulley 32, a spring-biased bracket 34 which rotatably supports the pulley 32 on shaft 36 and a conventional coil-spring, not shown. The bracket 34 is pivotally supported on plate or swing-arm 40 and a coil-spring urges the pulley 32 against the V-belt 26 as shown in FIG. 2.
The pulley 28 is rotatably supported on a vertical shaft 42 on bearing assembly 43. The drive or driving disc 44 in the disclosed embodiment of the friction disc transmission is rotatably supported on vertical shaft 42. Thus, motor 20 rotatably drives the drive disc 44 through pulleys 24 and 28 and V-belt 26.
The driven assembly includes the friction or driven disc 46 which is rotatably supported on a horizontal axis comprising shaft 48 and bearings 50. Shaft 48 is supported for rotation on pivot frame or bracket 52. As described above, the rim of the friction disc is received against the flat horizontal face 54 of drive disc 44, rotating the friction disc 46 in one direction on one side of the vertical axis 42 and in the opposite direction on the opposed side. Further, the speed of imparted rotation is dependent upon the distance from the axis 42. The speed being greatest at the periphery of the drive disc and zero or "neutral" at the axis. This form of friction transmission is described in more detail in the above referenced patent of Claus.
The pivot frame 52 includes side plates 56, support end bracket 58, which is welded or otherwise secured to a vertical plate of the tractor housing and an opposed end plate 60. The side plates 56 of the pivot frame are pivotally supported on bracket 58 in a conventional manner such as shown in FIG. 2. In the disclosed embodiment, a bolt 62 is received through the ends of the U-shaped bracket 58 and the side plate 56 and a nut 64 retains the bolt in place. A support and bearing element 66 is received between the side plates and washers may be provided between the side plates and the ends of the bracket 58. The distal end 60 of the bracket is thus free to pivot about the horizontal axis of bolt 62.
Power is transmitted to the rear wheels 70 of the tractor as follows. A hub-sprocket 72 is operably supported on friction disc shaft 48 for rotation with the friction disc. A first drive chain 74 is entrained on hub-sprocket 72 and sprocket 76, driving the larger sprocket. Sprocket 76 is rotatably supported on a second parallel horizontal axis provided by bolt 78 which is received through the side walls 56 of the pivot frame and secured by nut 80. In the disclosed embodiment, the sprocket 76 is secured to a bearing element 82 which rotates a second smaller hub-sprocket 84. A second drive chain 86 is then entrained on hub-sprocket 84 and the wheel axle sprocket 88 secured to the vehicle axle 90. The power of motor 20 is thus transmitted through the friction discs 44 and 46, through drive chains 74 and 86 to the rear axle 90 of the tractor to drive the wheels 70 forward or in reverse dependent upon the position of the friction disc 46 relative to the drive disc 44 as described above. As will be understood by those skilled in the art, the differential in size between hub-sprocket 72 and sprocket 76 and hub-sprocket 84 and sprocket 88 results in a substantial mechanical advantage.
In the disclosed embodiment, a spring-biased idler is provided in the second chain 86 to maintain tension in the chain during idle. As described below, tension is normally maintained in the chain during forward and reverse. The disclosed embodiment of the idler includes an idler-sprocket 94 which is rotatably mounted on an outwardly biased bracket 96. In the disclosed embodiment, the bracket is supported on a separate bearing element 98 on bolt 78.
As described above, the friction or driven disc in the friction disc transmissions disclosed in the prior art are spring biased against the drive or driving disc. The spring force is thus at a minimum when the discs are in contact and the spring force increases as the discs are separated. The preferred embodiment of the friction disc transmission of the present invention is self-energizing, wherein the force urging the friction disc into contact with the drive disc is proportional to the torsional load on the axle, providing maximum pressure during peak loads as when the tractor is moving up hill and minimal contact when the load is light, such as when the tractor is movng down hill. The self-energizing feature of the present invention is best illustrated in FIG. 5. As described above, the horizontal rotational axis 78 of hub-sprocket 84 is supported on pivot frame 52 between pivot axis 62 and axis 48 of friction disc 46. The rotational axis 90 of chain sprocket 88 is located vertically below the axis 78 of sprocket 84. The tension in chain 86 is thus transmitted to shaft 78, urging the friction disc 46 into frictional contact with drive disc 44. Further, the greater the tension the greater the downward force. Thus, when the tractor is under greatest load, as when the tractor is moving up hill, the force urging the friction disc into contact with the drive disc is greatest. As shown in FIG. 5, the upper run of the chain 86 is under tension when the vehicle is moving forwardly and the lower run of the chain is under tension when the vehicle is moving rearwardly. In either event, the axis 78 is urged downwardly, forcing the friction disc into contact with the drive disc.
The control of the disclosed embodiment of the friction disc transmission may be utilized to vary the speed of rotation of the friction disc and thus the wheels, set the friction disc in neutral or idle and brake rotation of the friction disc. The disclosed embodiment includes two sets of controls. The first to be described is the speed control.
As shown in FIG. 2, the speed control is operated by an operator lever or handle 100 which may be positioned adjacent the steering column of the tractor, not shown. The shaft of the control handle is supported in a support bracket 102 which permits forward and rearward motion of the handle. The handle is connected to one end of link 104 and an L-shaped latch pin 106 is disposed through the opposed end. The latch pin is received on the upper edge of the L-shaped control bracket 108 as described herein below. The center of link 104 is secured to control rod 110 by a bolt 112 or other means of securement. The opposed end of the control rod 110 is pivotally secured to swing arm extension or bracket 114.
The control rod 110 may be pivotally supported at its base, not shown, such that forward motion of the handle rotates extension 114 and swing plate 40 in a clockwise direction about the axis of drive shaft 22. In effect, the friction disc 46 is thus moved toward the periphery of the drive disc, toward the bottom of FIG. 2. The forward speed of the tractor is thus increased as the control lever or handle 100 is moved forwardly. Conversely, the speed of the tractor is reduced as the friction disc approaches the center or neutral axis of the drive disc. When the handle is moved sufficiently rearwardly for the friction disc to contact the opposed side of the drive disc, the upper portion in FIG. 2, the tractor mower is driven rearwardly at increasing speeds. The bracket 108 in the disclosed embodiment includes an upwardly extending portion which may include a series of notches for receipt of the latch pin 106, retaining the control rod 110 in the set position.
The preferred speed control also includes a unique control plate 116 which lifts the friction disc over the center neutral axis, eliminating wear in the neutral or idle position. The control plate is generally L-shaped having an upwardly extending portion 118 having a configured face. In the disclosed embodiment, the upper face includes opposed vertically inclined faces 120 and 122 which receives the extension 124 of the pivot frame 52 to lift the pivot frame about pivot axis 62 and friction disc 46 out of contact with the drive disc 44. A notch 126 may be provided adjacent the mid-portion of the control plate to retain the friction disc in the neutral position as shown in FIGS. 1 and 3. A line drawn along the swing plate 40 through the vertical axis of drive shaft 22 and vertical axis of shaft 42 is generally perpendicular to the control plate 116.
As described above, one important source of wear of the friction disc results from the friction disc contacting the drive disc at the center or neutral axis. As will be understood, a lawn tractor or the like is often set at idle, resulting in flat portions being ground on the friction disc. This problem has been solved in the friction disc transmission of the present invention by providing the configured control plate 116 which simply raises the friction disc when the friction disc is over the center or neutral axis of the drive disc.
As described above, the control of the friction disc transmission of the present invention also includes a clutch-brake. The clutch-brake includes an L-shaped foot pedal 130 which is mounted on a rock shaft 132. The rock shaft 132 is mounted for rotational movement (not shown) to the power lawn mower body as is conventional. Follower link 134 is connected at one end to rock shaft 132 for rotation with foot pedal 130. A C-shaped link 136 is pivotally connected at one end to follower link 134 and a U-shaped bracket 138 at the opposed end. Conventional Cotter pins retain the C-shaped link as shown in FIG. 1. The U-shaped link is pivotally supported by a bracket 142 having a pivot axis or pin 143. The control bracket is thus rotated in a clockwise direction about pivot axis 143 when the foot pedal 130 is depressed.
As best shown in FIG. 2, a C-shaped link is pivotally connected at one end to the control bracket and the link extends upwardly to be connected at the opposed end to an extension 144 of the pivot frame 52. Clockwise rotation of the control bracket 138 thus lifts the distal end of the pivot frame 52 to lift the friction disc out of contact with the drive disc. The control bracket 138 also includes an L-shaped brake shoe 146 welded or otherwise secured to the side of the control link. Further depression of the pedal 130 brings the end 148 of the control link into contact with the periphery of the friction disc, braking the friction disc. In the preferred embodiment, the clutching and braking operations are performed sequentially. That is, link 140 first lifts the friction disc from the drive disc. Then, face 148 of the brake shoe contacts the periphery of the friction disc, braking rotational motion of the friction disc. It will be understood that the clutching function may also be performed separately, wherein the clutch-brake pedal is partially depressed, releasing the drive mechanism and putting the transmission in neutral.
The control mechanisms of the friction disc transmission have therefore different functions. Control handle 100 may be utilized to increase and decrease the speed of the lawn tractor, shift gears and place the tractor in neutral. The clutch-brake pedal 130 may be utilized to clutch the transmission at any speed without returning the drive disc to neutral or for braking the tractor.
As described above, the transmission is shown in neutral in FIGS. 1 to 3. The control plate 40 has been rotated by control handle 100 to lift the friction disc. As shown in FIG. 2, the friction disc is located over the center neutral axis of the drive disc 54. In FIG. 3, the clutch-brake pedal 130 has been fully depressed, bringing the brake shoe 146 into contact with the friction disc, stopping the disc.
It will be understood that various details of the friction disc transmission of the present invention have not been disclosed as such details are considered conventional. Further, conventional materials may be utilized for the elements of the transmission. For example, many of the elements may be formed from sheet or rod steel. The drive and friction discs may be formed from synthetic rubber or various plastic materials preferably having a friction grit or filler material. It will also be understood that the various improvements utilized in the friction disc transmission of the present invention may be utilized separately. For example, the clutch-brake mechanism or the control plate may be utilized in the friction disc transmission disclosed in the Claus Patent. Alternatively, the unique self-energizing feature may be used with a conventional control. Having described the self-energizing friction disc transmission of the present invention, we make the following claims. | The disclosed friction disc transmission includes a conventional drive disc rotatable about a vertical shaft and a vertical friction disc engaging the top horizontal face of the drive disc to be driven about a horizontal axis. The friction disc is rotatably supported on a pivot frame having a sprocket drive connected to a sprocket on the wheel axle. The vertical drive disc shaft is mounted on a transversely swingable support for movement of the drive disc relative to the driven friction disc and control of the rotational speed and direction of the driven disc. The support includes a control plate having camming surfaces which lift the driven disc over the center neutral axis of the drive disc, reducing wear of the driven disc when the transmission is in neutral. The control also includes a clutch-brake mechanism independent of the control plate including a lever connected to a rotatable link means. The link means is operably connected to the pivot frame and a brake shoe and is operable upon actuation of the lever to sequentially vertically lift the frame means and the friction disc out of engagement with the drive disc and engage the brake shoe against the friction disc to stop rotational movement of the friction disc. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a divisional of U.S. patent application Ser. No. 12/951,260 filed on Nov. 22, 2010, which is itself a divisional of U.S. patent application Ser. No. 11/379,622 filed on Apr. 21, 2006, now U.S. Pat. No. 7,861,533. The entire contents of each of the foregoing is incorporated herein by reference.
TECHNICAL FIELD
The invention relates to the in-flight relighting of an aircraft turbofan engine.
BACKGROUND
FIG. 1 schematically illustrates a typical turbofan engine 10 for subsonic flight. The engine 10 generally comprises in serial flow communication a fan 12 through which ambient air is propelled, a multi-stage compressor 14 for pressurising the air, a combustor 16 in which the compressed air is mixed with fuel and ignited for generating a stream of hot combustion gases, and a turbine section 18 for extracting energy from the combustion gases. The engine 10 also comprises an auxiliary or accessory gearbox (AGB) 20 on which are located mechanical and electrical systems, such as fuel pumps, oil pumps, generators and a starter/generator. The main rotating parts of the engine 10 are connected in two subgroups, the low pressure (LP) spool and the high pressure (HP) spool, which are coaxially disposed. In use, the engine 10 is started by the starter which is mechanically connected to the HP spool using a set of gears and a tower shaft 22 . Once the desired HP spool speed is reached, fuel is provided into the combustor 16 and is ignited to start or “light” the engine 10 .
When the engine 10 is mounted on an airplane, in the unlikely event of a flame out or engine shutdown, dynamic pressure due to forward speed of the airplane creates a windmill effect to spin the LP and HP spools. This spinning is then further assisted by the starter to spin the HP spool up to the starting speed so that relight can successfully occur. In other arrangements, a shaft power transfer arrangement is provided to transfer windmilling energy from the LP spool to the HP spool to assist acceleration of the HP spool to relight speed. However, there is a continuing need for simpler and better systems.
SUMMARY
In one aspect, the present invention provides a method for in-flight relighting a turbofan engine of an aircraft, the engine having at least two shafts, one of which is a high-pressure shaft mounted to a high-pressure compressor and a high-pressure turbine, the high-pressure shaft drivingly connected to an accessory load, the method comprising the steps of: disconnecting the accessory load from the high-pressure shaft to substantially eliminate a parasitic drag load on the high-pressure shaft; permitting ram air to rotate the high pressure shaft; and relighting the engine.
In another aspect, the present invention provides a method for in-flight relighting an aircraft turbofan engine, the engine having at least two shafts, one of which is a high-pressure shaft mounted to a high-pressure compressor, a high-pressure turbine and an electrical generator, the generator electrically driving an accessory load, the method comprising the steps of: determining the presence of an engine-out condition of the engine; using the generator to reduce the rate of rotation of the high-pressure shaft to a desired rate within a relight envelope; and relighting the engine.
In another aspect, the present invention provides a method for in-flight relighting an aircraft accessory gearboxless turbofan engine, the engine having at least two shafts, one of which is a high-pressure shaft mounted to a high-pressure compressor, a high-pressure turbine and a concentrically-mounted electrical generator, the generator electrically driving an accessory load, the method comprising the steps of: using exclusively ram air through the engine to rotate the high-pressure shaft; and then relighting the engine.
In another aspect, the invention provides a method of relighting a gas turbine engine of a fixed-wing aircraft after an in-flight engine-out condition, the engine having at least one electromagnetic bearing apparatus and at least a bladed propulsor mounted to a first shaft and a compressor and turbine mounted to a second shaft, the first shaft drivingly connected to an electric generator, the method comprising the steps of: using windmill rotation of the bladed propulsor to drive the generator; using electricity from the windmill-driven generator to provide power to the electromagnetic bearing apparatus; and relighting the engine.
BRIEF DESCRIPTION OF THE FIGURES
For a better understanding of the present method, and to show more clearly how it may be carried into effect, reference will now be made by way of example to the accompanying figures, in which:
FIG. 1 schematic view of a typical turbofan gas turbine engine according to the prior art;
FIG. 2 is a schematic side view of an example of a turbofan gas turbine engine for use with the present method; and
FIG. 3 is block diagram illustrating the present method.
DETAILED DESCRIPTION
FIG. 2 shows a turbofan gas turbine engine 20 which generally comprises a low-pressure (LP) spool 21 supporting at least a fan and a turbine, and a concentric high-pressure (HP) spool 24 supporting at least a compressor and a turbine. An embedded or integrated generator or starter/generator 22 is coaxially mounted on the HP spool 24 of the engine 20 , and preferably a second generator or motor/generator 23 is mounted on the LP spool 21 of the engine 20 . Starter-generator 22 may be operated as a motor to light engine 20 , and also preferably as a generator to generate electricity, which a controller 26 may then provide in form suitable for driving accessories 28 such as electrically-driven pumps and other engine and aircraft services. Generator 23 may be used likewise to generate electricity for controller 26 to provide to accessories 28 (but are not necessarily the same controller or accessories/services as driven by generator 22 ), and if a motor/generator, may be used to selectively drive the LP spool 21 . Consequently, the need for an accessory gearbox is obviated, and is thus not present in engine 20 . The design of engine 20 is not new, however the present invention offers new functionality to the engine 20 to provide improved in-flight relighting, as will now be described.
After a flame-out or other shut-down of engine 20 occurs requiring the engine to be relit, in-flight windmilling causes the LP spool 21 and HP spool 24 to rotate, which thus rotates starter-generator 22 . During in-flight windmilling, controller 26 preferably partially or completely disconnects or stops supplying electricity to accessories 28 , so there is substantially no electrical load drawn from starter-generator 22 , and thus there is substantially no parasitic drag on the HP spool 24 caused by starter-generator 22 . For example, in one embodiment shown in FIG. 3 , a flame-out (or other engine-off) condition is initially detected by the controller 26 , which controls the fuel and oil pumps 28 . The controller also monitors electrical output from the generator(s), and includes suitable means to prevent power output to the aircraft electrical bus (also represented by 28 ) which does not meet the specification requirements—i.e. the controller 26 has control over whether the starter-generator 22 is connected to the bus in the ‘generate’ and ‘start’ modes. In a flame-out condition, an appropriate sensor signals the controller to stop the fuel pump from pumping fuel, and preferably also stops the oil pump, and the electrical output of the starter-generator 22 is also disconnected from the aircraft bus. Thus, electromagnetic drag on the HP spool 24 is reduced, and preferably effectively eliminated. Consequently, unlike the prior art, the accessories 28 are disconnected from the HP spool 24 , preferably prior to relight.
Referring again to the engine 10 of FIG. 1 , during in-flight windmilling AGB 20 remains drivingly connected to the HP spool, and thus a plurality of gears and accessories continue to be driven by the HP spool, which creates a parasitic mechanical drag on the HP spool which tends to decelerate the HP spool windmilling speed. As previously described, another energy source is required to overcome this drag and accelerate the engine to its relight speed. However, by disconnecting the load from the HP spool 24 of engine 20 , the parasitic drag of the accessory system is virtually eliminated and, in the right conditions, windmill speed alone becomes sufficient to spin the HP spool 24 at a desired starting speed, using only aircraft attitude if necessary to control windmill speed. Another external power source is not required, thereby simplifying the engine system. This greatly facilitates relighting of the engine 20 by extending the in flight relight envelope of the engine.
Therefore, the windmilling effect of ram air though the high spool may be used to rotate the engine to relight speed, particularly in very small turbofans having low inertia. Thus relight is achieved by disconnecting accessories and then using windmilling power, preferably alone and without the input of additional rotation energy from the starter-generator 22 , or any other power transfer mechanism, to increase the speed of the HP spool.
In fact, conversely to the prior art, in some situations such as when descending rapidly on flame out conditions, the rotor may tend to spin too quickly, and thus prevent optimum relight conditions (e.g. lean blow out may occur if there is too much speed at the low fuel flows generally desired for starting), adjustable “drag” may be provided to the high rotor, e.g. by providing a braking force to slow the HP spool speed down. In one approach, this is achieved by operating the starter/generator 22 as a sort of electromagnetic brake, for example by controlling the current of the starter-generator via the controller 26 . In another aspect, a mechanical braking arrangement may be employed to retard spool rotation. This may be used to put an upper limit on windmill speed under conditions requiring a specific relight speed, without requiring the pilot to set a different decent rate than was required for other reasons (for example, in the case where both engines flame out, descending to an altitude where there is air to breathe is often high on the pilot's list of priorities). Thus, controlling the windmill speed to an optimum value for relight, whether increasing or decreasing the rotor speed as necessary, is available with the present concept.
In another aspect of the present invention, in the case of flame-out, generator 23 may provide self-contained back-up electrical to power during windmilling to a magnetic bearings power system (indicated as among the elements of 28 ) to support the required shafts or spools during power-out situations. The LP spool generator does not induce parasitic drag on the HP spool, and thus no hamper relighting of the HP spool.
The above description is meant to be exemplary only, and one skilled in the art will recognize that other changes may also be made to the embodiments described without departing from the scope of the invention disclosed. For instance, the starter-generator can be any suitable design, and may in fact be provided by two different units (e.g. separate starter and generator). Although it is desirable to adjust parasitic drag (e.g. by disconnecting accessories and/or reducing rotor speed) prior to commencing relight procedures, the operations may be performed in any desired order. Although electrically disconnecting of the HP spool from accessory drive systems is preferred, any suitable selectively operable disconnect system may be employed. Still other modifications may be apparent to those skilled in the art, in light of a review of this disclosure, and such modifications are intended to fall within the appended claims. | The method and apparatus for in-flight relighting of a turbofan engine involve in one aspect selectively controlling an accessory drag load on one or more windmilling rotors to permit control of the windmill speed to an optimum value for relight conditions. | 5 |
GRANT INFORMATION
[0001] This invention was made in part with United States Government support under contract DE-AR0000616 awarded by the Advanced Research Projects Administration—Energy, part of the U.S. Department of Energy. The U.S. Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The presently disclosed subject matter provides a process to decompose hydrocarbons into carbon and hydrogen (H 2 gas), employing a cycle in which a secondary chemical is recycled and reused.
[0004] Background Information
[0005] Over 95% of hydrogen in the United States is produced from natural gas via steam-methane reforming (SMR) [http://energy.gov/eere/fuelcells/hydrogen-production-natural-gas-reforming], and is used to produce commodity chemicals such as ammonia, the chemical precursor for fertilizer, or is used as fuel. In SMR, natural gas (primarily methane, CH 4 ) reacts with water (H 2 O) to form hydrogen gas (H 2 ) and carbon monoxide (CO).
[0000] CH 4 +H 2 O→CO+3H 2
[0006] To increase reaction rates and yields, SMR is typically run at high temperatures and pressures (700-1000° C.) and high pressures (3-25 bar). Product CO is converted to carbon dioxide (CO 2 ) via the water-gas shift reaction, producing more hydrogen:
[0000] H 2 O+CO→CO 2 +H 2
[0007] Production of hydrogen will be improved with new processes that (a) allow production at lower temperatures and pressures, (b) do not produce CO 2 as a byproduct of hydrogen production, (c) require smaller energy input, and (d) do not deteriorate over time. The last issue is critical—for example, one process to produce hydrogen is thermal decomposition of methane into solid carbon and hydrogen, which occurs over suitable catalysts at temperatures typically greater than 900° C. Considering just the enthalpy of the chemical reactions involved, direct decomposition has a reaction enthalpy of 74.6 kJ/mol CH4 , or 37.3 kJ/mol H2 ; this is slightly less heat input than required for steam reforming (41.2 kJ/mol H2 ) and produces no CO 2 . Direct decomposition, unfortunately, leads to deactivation of the catalyst as it becomes coked with carbon. Furthermore, coking makes the catalyst difficult to recover for reuse.
SUMMARY OF THE INVENTION
[0008] The presently disclosed subject matter provides a process to decompose hydrocarbons into carbon and hydrogen (H 2 gas), employing a catalyst-free cycle in which a secondary chemical is recycled and reused. In the preferred embodiment of the process, the secondary chemical is primarily composed of anhydrous nickel chloride (NiCl 2 ). Other metal halides can also be suitable. First, hydrocarbons are input into the cycle and decomposed to carbon in a chemical reaction with nickel chloride at elevated temperatures in a dry and oxygen-free atmosphere to produce hydrogen chloride gas, nickel metal, and carbon. Then, these components are cooled until the hydrogen chloride gas reacts with nickel metal to re-form anhydrous NiCl 2 and hydrogen gas. The hydrogen gas is then collected as the reaction product. Carbon and NiCl 2 in the reaction chamber are separated by sublimating the NiCl 2 at temperatures near 1000° C., at which point the cycle can be run again. Carbon formed from this cycle can be removed from the reactor at any point.
[0009] Thermodynamic analysis of the process predicts a net heat input for the chemical reactions in the entire cycle of 37.3 kJ/mol H2 when the input hydrocarbon is methane. In the preferred embodiment, the process is operated at ambient pressures and at temperatures below that required for SMR or direct methane decomposition; the process can be repeated without deactivation of the secondary chemical; and the process produces no carbon dioxide from the feedstock.
[0010] Certain aspects of the presently disclosed subject matter having been stated hereinabove, which are addressed in whole or in part by the presently disclosed subject matter, other aspects will become evident as the description proceeds when taken in connection with the accompanying Examples and Figures as best described herein below.
BRIEF DESCRIPTION OF THE FIGURES
[0011] Having thus described the presently disclosed subject matter in general terms, reference will now be made to the accompanying Figures, which are not necessarily drawn to scale, and wherein:
[0012] FIG. 1 is a schematic representation of the chemical reaction steps in the presently disclosed method for producing hydrogen without carbon dioxide using reactants and chemical intermediates associated with a particular embodiment;
[0013] FIG. 2 shows the reaction free energy of different chemical reactions associated with hydrocarbon reforming: (a) steam methane reforming, (b) thermal decomposition of methane, (c) methane decomposition via reaction with nickel chloride, and (d) ethane decomposition via reaction with nickel chloride.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The presently disclosed subject matter now will be described more fully with reference to the accompanying Figures, in which some, but not all embodiments of the presently disclosed subject matter are shown. The presently disclosed subject matter may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Indeed, many modifications and other embodiments of the presently disclosed subject matter set forth herein will come to mind to one skilled in the art to which the presently disclosed subject matter pertains having the benefit of the teachings presented in the foregoing descriptions and the associated Figures. Therefore, it is to be understood that the presently disclosed subject matter is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims.
[0015] It will be obvious to practitioners familiar with the art that values for the energy required for chemical reactions described herein may be expressed as kJ/mol CH4 when referring to the energy per input methane molecule, or kJ/mol H2 when referring to the energy per output hydrogen molecule.
[0016] In some embodiments, the presently disclosed subject matter provides methods for transforming hydrocarbons (molecules comprised primarily of carbon and hydrogen atoms) to elemental carbon and hydrogen molecules (H 2 ).
[0017] The cycle to produce hydrogen is schematically illustrated in FIG. 1 , which lists the chemical reactions in the cycle, and their relative order. We arbitrarily assign Stage 1 of the process as that step in which a reactant stream of hydrocarbons are introduced into a reaction chamber containing anhydrous nickel chloride (NiCl 2 ); the atmosphere of the chamber does not contain oxygen nor water. If the particular hydrocarbon is methane, the following reaction occurs under these conditions at temperatures preferably above 600° C., and most preferably above 650° C.:
[0000] CH 4 +2NiCl 2 →2Ni+C+4HCl
[0018] By 2Ni+C is meant a reactant product comprised of nickel metal (Ni) and carbon (C) in the stoichiometric ratio of 2:1. FIG. 2 shows the Gibbs reaction free energy for this reaction and other reactions referenced herein as a function of temperature, calculated from thermodynamic property values freely available in databases maintained by the National Institutes of Standards and Technology (NIST). It is a well-known chemical principle that if the Gibbs reaction free energy drops below zero for a particular chemical reaction, the chemical reaction becomes favorable to proceed. In the general case of methane reacting with a chloride salt, one molecule of hydrogen chloride gas (HCl) is created for each hydrogen atom in the input hydrocarbon stream. As long as the ratio of hydrogen to carbon in the input stream is greater than unity, there will be a positive reaction entropy, and thus a temperature at which the reaction free energy will drop below zero. In the specific case of methane reacting with nickel chloride, the Gibbs reaction free energy becomes negative near 570° C. In the case of ethane (C 2 H 6 ) reacting with nickel chloride, the Gibbs reaction free energy drops below zero near 455° C.
[0019] It is possible that hydrocarbons containing one or more C—C bonds will be difficult to dissociate due to slow reaction kinetics, and that catalysts suitable for cracking alkanes, such as the zeolite HZSM-5 [F. C. Jentoft, B. C. Gates, “Solid-acid-catalyzed alkane cracking mechanisms: evidence from reactions of small probe molecules,” Topics in Catalysis, 4 (1997), 1-13], may be required to lower the activation barrier for these reactions. In the specific embodiment of methane decomposition, no catalyst is required to produce hydrogen.
[0020] In the preferred embodiment of this process, nickel chloride is chosen to react with hydrocarbons, because the temperature at which reaction is predicted to proceed between 500 and 1000° C., more preferably between 600 and 800° C., and most preferably at 675° C. (below the temperatures at which steam reforming or direct methane decomposition are typically performed). However, any anhydrous metal halide salt can be used in this reaction, as long as more than one hydrogen halide molecule is produced per molecule of hydrocarbon molecule input. In the examples, chloride is preferred, but other halides will work. Other metals such as Mn, Cu, Zn, Ca, and Mg may also work.
[0021] Stage 1 of the process produces dehydrogenated carbon, nickel metal, and hydrogen chloride gas, in a ratio dictated by the chemical reaction stoichiometry. For instance, in the decomposition of methane, two nickel atoms of nickel metal, and four hydrogen chloride molecules are produced for each carbon atom from one methane molecule.
[0022] In Stage 2 of the process, nickel, carbon, and hydrogen chloride gas are cooled to temperatures below ˜550° C. Below this temperature, nickel metal spontaneously reacts with HCl according to the chemical reaction
[0000] 2Ni+4HCl→2NiCl 2 +2H 2 .
[0023] (The stoichiometric coefficients of this equation have been adjusted to reflect that 2 hydrogen molecules are formed for each molecule of methane input into Stage 1 of the process.) When the system is cooled to below ˜550° C., nickel metal will be transformed back to nickel chloride via reaction with HCl. Carbon in the system is a spectator species to this chemical reaction. After the reaction is run to completion, hydrogen gas is removed from the reactor as the final reaction product.
[0024] At this stage, the cycle may be repeated. However, in certain embodiments, a Stage 3 may be added to the cycle where it of interest to separate the carbon from the nickel chloride as a second reaction product. In a preferred embodiment, nickel chloride is sublimed at 1000° C., and condensed away from the carbon, which can then be physically removed from the system. Other methods of separation will be known to those familiar with the art of chemical separations.
[0025] The following examples are intended to illustrate but not limit the invention.
EXAMPLES
[0026] The following Example is included to provide guidance to one of ordinary skill in the art for practicing representative embodiments of the presently disclosed subject matter. In light of the present disclosure and the general level of skill in the art, those of skill can appreciate that the following Examples are intended to be exemplary only and that numerous changes, modifications, and alterations can be employed without departing from the scope of the presently disclosed subject matter. The synthetic descriptions and specific examples that follow are only intended for the purposes of illustration, and are not to be construed as limiting in any manner to make compounds of the disclosure by other methods.
Example 1
[0027] 10 g of anhydrous NiCl 2 was loaded into an alumina tube and placed in a tube furnace. A flow of 100% argon (Ar) gas was passed through the tube, and bubbled through a water beaker to create a non-oxygen containing atmosphere within the tube. A mass spectrometer connected to the gas stream between the tube and the bubbler sampled and measured the composition of the tube outlet stream. The sample in the tube furnace was heated to 700° C., and then the inlet stream composition was switched to 95% argon, 5% methane. Immediately, a hydrogen chloride signal was observed in the mass spectrometer, and the reaction was run until the hydrogen chloride signal dropped to zero. The gas inlet stream was then switched back to 100% Ar and the tube was cooled. It was found that the nickel chloride had been transformed to a black powder that elemental analysis confirmed was comprised of nickel and carbon. According to the chemical reactions described for each stage of the process, the reaction should yield 0.46 g of carbon. The powder was dissolved in hydrochloric acid solution, and the carbon filtered, rinsed, and dried; 0.49 g of carbon was collected, which is equivalent to the expected yield within the experimental error of the system. Hydrogen was generated during the dissolution of the powder in hydrochloric acid; the expected quantity produced was too small to assay.
REFERENCES
[0028] All publications, patent applications, patents, and other references mentioned in the specification are indicative of the level of those skilled in the art to which the presently disclosed subject matter pertains. All publications, patent applications, patents, and other references are herein incorporated by reference to the same extent as if each individual publication, patent application, patent, and other reference was specifically and individually indicated to be incorporated by reference. It will be understood that, although a number of patent applications, patents, and other references are referred to herein, such reference does not constitute an admission that any of these documents forms part of the common general knowledge in the art.
[0029] Although the invention has been described with reference to the above example, it will be understood that modifications and variations are encompassed within the spirit and scope of the invention. Accordingly, the invention is limited only by the following claims. | A process to decompose methane into carbon (graphitic powder) and hydrogen (H 2 gas) without secondary production of carbon dioxide, employing a cycle in which a secondary chemical is recycled and reused, is disclosed. | 8 |
FIELD OF THE INVENTION
[0001] The present invention concerns a new method for the preservation of paper products which comprises the deacidification of the paper material with the diazo derivatives of general formula (I) hereafter reported.
STATE OF THE ART
[0002] It is universally acknowledged that one of the causes of the too rapid deterioration of cultural materials on paper is the presence of acidity in the material.
[0003] In modern paper, acidity is usually caused during the manufacturing stage in the paper factory; however, acidity can often be found even in papers or books that are made from acid-free paper, as it comes from some types of ink for manuscripts, that was widely used in the past.
[0004] Experts agree that in order to prolong the life of books and documents that are stored in libraries and archives (according to the experts from three to five times as much) it is necessary to eliminate the acidity from the materials, by using a technique that in the specialised environment is known as “deacidification”. Obviously, in order to avoid the errors committed in the past, new documents and books to be stored should be made with acid-free paper (UNI n. 10332—Paper for documents. Requirements for the maximum duration and durability and UNI n. 10333—Paper for documents. Requirements for duration).
[0005] In the Italian public libraries there are currently 30 million books; an equal amount of paper documents are kept in public archives.
[0006] From fragmentary surveys carried out in some Italian preservation environments, in agreement with similar research carried out abroad on a wider scale, it has been found that 20-30% of library and archive materials are now so fragile that they cannot be made available for free consultation; the risk of further damage would be too high. Alongside this relatively low percentage however, it has been found that 60-80% of preserved books and documents need to be deacidified or in some way stabilised; otherwise, it would only be a matter of time before all the acid material would become fragile, and no longer consultable.
[0007] In view of what above said, it is evident that, in order to protect the Italian book and document heritage, it is necessary to be able to intervene with mass deacidification techniques, or in any case with stabilisation techniques that would slow down deterioration; these would be techniques that allow the entire heritage to be restored in a time span of no more than ten, fifteen years. In Italy, unfortunately, deacidification is currently carried out using solely manual techniques that allow only a few hundred interventions each year on books and archive documents.
[0008] The use in Italy of other types of stabilisation techniques is not known to the Applicant. On an international scale, studies on mass deacidification techniques have been ongoing for about 35 years. During this time, about 15 or 20 different intervention techniques have been proposed but none of these is widely diffused as yet. Such a high number of proposals make one realise that there are still many problems to be solved. In a few cases, these are technical problems concerning the safety of the material, and also the safety of the people working on the interventions; in other cases there are doubts as to the effectiveness of the proposed technique or on the durability of the deacidification; or, further still, in many cases, the secondary effects on the materials have been found to be unacceptable.
[0009] It is therefore much felt the need for developed and improved techniques for the deacidification of paper products.
SUMMARY
[0010] The Applicant has found a new method for the preservation of paper products, comprising deacidification of paper by using as deacidifying agent with at least one compound of general formula (I) hereafter reported.
[0011] The method according to the present invention may be applied to any type of paper and has the following advantages:
[0012] unlike most of the known methods, no preliminary dehydration phase for the samples to be treated, with a consequent reduction in costs for a possible industrial process;
[0013] after treatment, the pH values remain over 8.5-9.0 in all samples. Even in the case of badly deteriorated papers, that have an initial pH of 2-3 units, the present method guarantees a suitable neutralisation;
[0014] homogeneous distribution of the deacidifying agent over all the sample, assisted by the high impregnation capacity of the solvent;
[0015] the solvent is easy to remove as it has a low boiling point and low evaporation heat, with consequent reduction in costs for a possible industrial process;
[0016] protection, as a result of the present method, from atmospheric acid pollutants (SO 2 and NO 2 );
[0017] long-term protection effect;
[0018] the organic solvent used cannot dissolve any water-soluble substances (colorants, pigments, inks, etc).
[0019] Subject of the present invention is therefore a method for the deacidification of paper comprising a deacidification step wherein at least one diazo derivative of general formula (I) is used as deacidifying agent
[0020] wherein R′ is chosen from H and methyl, and R is the group
[0021] where n=1, 2, 3, 4, 5; and R 1 and R 2 , equal to one another, are chosen from methyl and ethyl, or R 1 and R 2 , taken together, form with N a piperidine ring or a 4-morpholine ring.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 shows the pH value of paper samples from a book dating from 1954 before the deacidification treatment according to the present method (dotted line) and the pH trend vs. days after the treatment (continuous line) as described in Example 1.
DETAILED DESCRIPTION OF THE INVENTION
[0023] According to a particular embodiment of the invention, the present method comprises the following steps:
[0024] A) pre-treatment step, consisting of a preliminary and rough removal of any dust or foreign matter from the surface of the paper sheet, using compressed air jets;
[0025] B) deacidification step wherein at least one diazo derivative of general formula (I) as defined above, is used as deacidifying agent;
[0026] C) washing step, possibly repeated, of the paper coming from step B), and removal of the washing solvent;
[0027] D) possible conditioning step.
[0028] The pH of the material can be measured using the surface measurement method ( TAPPI T 529 om-99 method).
[0029] For pH measurement the cold extraction method (TAPPI T 509 om-96 method) and the hot extraction method (TAPPI T 435 om-96 method) can also be used; these techniques are however, damaging, and therefore cannot be used on paper of historical-documentary interest, but only on samples that are specifically prepared for laboratory tests.
[0030] The deacidification step B) of the present method is preferably carried out by completely immersing the paper sample in a special glass container, varying in size according to the amount of material to be treated, and which contains an ethereal solution of the compound of formula (I), freshly prepared and kept in the dark until that moment at a temperature of ≦−180° C.
[0031] According to a preferred embodiment, the ratio between the sample weight and the solution volume is about 10 g / 200 ml, with a concentration of the compound of formula (I) that ranges between 0.1 and 0.5 M, depending on the state of the paper to be treated (more concentrated for highly oxidised and acid paper and less concentrated for slightly deteriorated papers).
[0032] The container is then closed though not sealed, to avoid a dangerous increase in pressure inside it, and should be preferably kept at 4° C. for a period of 24 to 96 hours (depending on the state of the original material). After this time, the system should be returned to room temperature and the paper is extracted.
[0033] The preferred deacidifying agent according to the invention is 2-(1-piperidine) diazoethane, i.e. the formula (I) compound in which R is H, R 1 and R 2 , taken together, form with N a piperidine ring, and n is 1.
[0034] The diazo derivatives of formula (I) used in the deacidification method of the invention can be prepared by the process that is the subject of the co-pending patent application in the name of the Applicant.
[0035] According to a particular embodiment of the present method, the deacidifying agent of formula (I) is applied as steam, by creating a specific chamber in which a propelled vacuum is applied, that is able to create a saturated atmosphere in a short time.
[0036] In step C) of the present method the removal of the washing solvent is preferably carried out by drying the paper washed material under strong aspiration at room temperature on a glass surface for about 6 hours. The removal of the solvent can be speeded up via the application of a pressure that is lower than atmospheric pressure (vacuum).
[0037] The preferred washing solvent to be used is diethyl ether. Paper treated in this way can then undergo a conditioning step D), for example via storage for 1 week in a insulated container (T 23° C., 50% R.H.) in order to restore the normal content of water in the paper.
[0038] To obtain the positive results shown below, it is usually sufficient to apply only one cycle of treatment according to the present method. However, it may be useful to repeat the entire cycle of treatment twice or more.
[0039] The following examples are given to provide non-limiting illustrations of the present invention.
EXAMPLE 1
Deacidification of paper samples from a book dating from 1954
[0040] Preliminary measurements of pH were taken on a number of samples belonging to the book in question, in order to be able to provide an average pH of the whole volume.
[0041] After these measurements were taken, using the surface measurement method, and with the cold extraction and hot extraction methods, the entire book was given the average pH value of 4-4.2.
[0042] A) The surface of the samples were given a preliminary and rough clean (using compressed air jets) to remove dust and/or residues from the sheet's surface.
[0043] B) 20 samples (squares of paper about 4×4 cm) of the average weight of 0.15 g each (for a total of 3 g), were completely immersed in a glass weighing bottle (Ø100 mm, h 50 mm) containing 100 ml of an ethereal solution of 2-(1-piperidine) diazoethane (0.3 M) freshly prepared and kept in a dark place until that moment at a temperature ≦−18° C.
[0044] The weighing bottle was closed, but not sealed to avoid a dangerous increase in pressure inside, and kept at 4° C. for 72 hours, then it was gradually returned at room temperature and the samples were removed from it.
[0045] C) The paper samples were washed repeatedly with diethyl ether to remove any residue of non reacted 2-(1-piperidine)diazoethane.
[0046] After washing, the samples were left to dry under strong aspiration at room temperature on a glass surface for about 6 hours.
[0047] D) Finally, after the solvent was completely removed, the samples were conditioned for 1 week in an insulated box (T 23° C., 50% R.H.).
[0048] The pH of these samples was measured over 3 months to check the effectiveness of the method.
[0049] [0049]FIG. 1 shows the pH trend before treatment (dotted line) and after treatment (continuous line).
EXAMPLE 2
Deacidification of various paper substrates
[0050] In order to evaluate the effectiveness, the present method of deacidification was applied to a wide heterogenic range of paper under-layers. Several different paper samples were used for this purpose:
[0051] SAMPLE 1) Whatman n°1 chr grade paper, pre-treated with various deteriorating agents (NalO 4 , NaOCl, H 2 SO 4 , HClO 2 ) in order to create a considerable number of acid groups than can be neutralised with 2-(1-piperidine)diazoethane;
[0052] SAMPLE 2) Whatman n°1 chr grade paper artificially aged (T 80° C., 65% R.H.) for 3 months;
[0053] SAMPLE 3) paper from old books dating from the 1950s, in a considerably deteriorated state showing a natural acidity (pH=3.5-4).
[0054] These samples were subjected to the deacidification method of the invention in the conditions already described above in Example 1, using 2-(1-piperidine) diazoethane as the deacidifying agent.
[0055] In all cases, an increase in the pH by at least 4 units was found, going from definitely acid values before deacidification (pH ≡4-5) to clearly alkaline values after treatment (pH≡8-9). The pH trend of the various samples was monitored over a period of time and the alkalinity persisted after 3 months of natural aging (T 23° C., 50% R.H.).
[0056] In Table 1 below, for all the types of paper tested the pH values before the treatment according to the deacidifying method of the invention, and the pH values measured after fixed time intervals are reported:
TABLE 1 pH before pH after pH after pH after pH after sample treatment 1 day 1 month 2 months 3 months 1-NalO 4 4.5 9.0 8.8 9.0 8.9 1-NaOCl 5.0 8.5 8.7 8.5 8.5 1-HClO 2 3.5 9.5 9.3 9.2 9.0 1-H 2 SO 4 3.0 9.2 9.3 8.9 9.1 2 5.2 9.4 9.2 9.3 9.0 3 4.2 10.3 10.0 9.7 9.4
[0057] As a result of the experiments described above, it was found that using diazo derivatives of formula (I), according to the present method, as deacidifying agents, in particular 2-(1-piperidine)diazoethane, the pH value is increased to more than satisfactory alkaline values for the complete neutralisation of the treated paper samples and these pH values remain practically stable in time.
[0058] Also, no changes in colour were found in the period following treatment (yellowing), nor any side effects such as the appearance of stains or spreading of ink.
[0059] No unpleasant odours were formed. | A method for the preservation of paper products, comprising the deacidification of the paper by using diazo derivatives is described. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] This present invention relates to a method and apparatus for creating fail-safe electrical components that employ dynamic logic circuitry to switch large power loads or to otherwise control circuits.
[0003] 2. Description of Related Art
[0004] A thermal ink jet print head selectively ejects droplets of ink from a plurality of drop ejectors. The ejectors are operated in accordance with digital instructions to create a desired image on an image receiving member. The print head may move back and forth relative to the image receiving member to print the image in swaths or the print head may extend across the entire width of an image receiving member, to print the image without any scanning motion.
[0005] The ejectors typically comprise capillary channels, or other ink passageways, which are connected to one or more common ink supply manifolds. Ink is retained within each channel until, in response to an appropriate digital signal, the ink in the channel is rapidly heated and vaporized by a heating element disposed on a surface within a channel. This rapid vaporization of the ink adjacent the channel creates a bubble which causes a quantity of ink to be ejected through an opening associated with the channel to the print sheet. One patent showing the general configuration of a typical ink jet print head is U.S. Pat. No. 4,774,530, incorporated herein by reference in its entirety.
[0006] Within a device, such as a thermal ink jet print head, where control circuitry is used to control heating elements, an important design concern is the difference in voltage, and thus power, between the digital logic circuits used to fire the ejectors and the power circuits used to heat the ink or other fluids. In a typical thermal ink jet print head, for example, the digital logic signals which are used to activate particular ejectors at particular times to print an image typically operate at about 5 volts and the trend is to move to 3.3 V addressing logic. In particular, these relatively low voltage logic addressing circuits are used to switch drive transistors that turn on heating elements. In contrast, the heating elements typically require voltages in the range of 30 to 50 volts in order to provide the desired phase transformation of the liquid ink adjacent the heating element. In the case where it is desired to use lower voltages to operate the heating elements, more current is required, since joule heating is being employed.
[0007] Thermal ink jet print heads typically use integrated circuits which have large arrays of power transistors and associated heating elements, where only a subset of power transistors are to be switched on simultaneously. Typically, the heater element array is sequentially fired because the current draw per element is very large and activating all channels together could lead to rapid failure of the chip from over heating. Additionally, the firing order of the heating elements is frequently a ripple fire pattern and the shape of the heating pulses applied to each heater element is often complex and may be a function of the temperature of the print head. Finally, the increased resolution of inkjet print heads means that the amount of logic required to address at high resolution of inkjet print heads means that the amount of logic required to address at high resolution is increased. Accordingly, the logic circuits used to selectively address the power transistors have become increasingly complicated. To reduce the cost of this addressing logic and to reduce the area consumed by the addressing logic, dynamic, rather than static, logic circuits are used. Dynamic circuit elements retain information by storing charge. However, the charge is always leaking away from the dynamic circuit element storage nodes. The hold time of a dynamic circuit element is defined as the maximum amount of time before there is sufficient loss of stored charge such that the logic state of the circuitry becomes undefined. In many cases, the loss of stored charge is different for logic gates in the “1” state versus the “0” state so the output of the circuit is truly undefined. This may also be described as a “loss of state.”
[0008] To prevent the loss of state, most systems require that the dynamic circuit elements must be refreshed in a time period that is less than the hold time of the dynamic circuit elements. If for some reason, such as a loss of connection to power, or time-dependent logic failures, the refresh event does not occur before the dynamic circuit elements lose state, then faulty circuit operation will occur.
SUMMARY OF THE INVENTION
[0009] In integrated circuits, such as thermal ink jet chips, which have large arrays of power transistors, where only a subset of power transistors are to be enabled simultaneously, the loss of state can cause a high current condition which can melt the interconnections between the chip and the power supply, if not the chip itself. A fuse in the system will not react as fast as the chip, and at a minimum the chip will be destroyed. In the case where a fuse is blown by excessive current flow, it is still necessary to replace the fuse to regain proper operation of the circuit. Thus, there is a need in thermal ink jet print heads to provide protection for this circuitry. It would be most desirable if the protection circuit was truly fail-safe i.e., such that the circuit and the component are still fully usable after the event.
[0010] This invention provides systems and methods that reduce the likelihood that a catastrophic consequence of a dynamic circuit losing state will occur.
[0011] This invention separately provides a dynamic fail safe circuit that reduces the likelihood that a catastrophic consequence will occur upon one or more dynamic circuit elements losing state.
[0012] This invention separately provides methods for determining a safety factor hold time for a dynamic fail-safe circuit.
[0013] This invention separately provides a dynamic fail-safe circuit that is locatable in close proximity to the dynamic circuit elements to be protected against consequences from losses of state.
[0014] This invention further provides a dynamic fail safe circuit that, by being located in close proximity to the dynamic circuit elements to be protected, will experience substantially the same process variations as the protected dynamic circuit elements.
[0015] In various exemplary embodiments, the systems and methods according to this invention protect dynamic circuit elements against the catastrophic effects of loss of state by providing a dynamic fail-safe circuit. This dynamic fail-safe circuit is refreshed at the same clock rate as the protected dynamic circuit elements. However, this dynamic fail-safe circuit has a hold time that is less than the hold time of the protected dynamic circuit elements, but more than the nominal refresh time. Thus, if the refresh signal is disrupted sufficiently that the protected dynamic circuit elements lose state, the dynamic fail-safe circuit will have previously exceeded its hold time, such that the dynamic fail-safe circuit is placed into a protection mode that protects the protected dynamic circuit elements from experiencing one or more catastrophic effects that would otherwise be experienced after the protected dynamic circuit elements lose state.
[0016] In various exemplary embodiments, the dynamic fail-safe circuit includes a dynamic latch. Under normal operation, the dynamic latch is maintained by the refresh signal in a first state that allows the integrated circuit containing the protected dynamic circuit elements to operate normally. When the dynamic latch is not refreshed within its fail-safe hold time, the dynamic latch reverts to a second state that protects the protected dynamic circuit elements.
[0017] In various exemplary embodiments, the dynamic fail-safe circuit also includes a number of AND gates. Each AND gate has an input connected to the dynamic latch, either directly or indirectly. The other input to the AND gate is connected to the dynamic logic circuit. The outputs of the AND gates are connected to a drive transistor array.
[0018] In the first state, the output of the dynamic latch is such that, directly or indirectly, a high logic signal is placed on one of the inputs to the AND gates. Thus, the AND gates pass the dynamic logic signal to the drive transistor array. In contrast, in the second state, the output of the dynamic latch is such that a low logic signal is placed on one of the inputs to the AND gates. Thus, the AND gates do not pass the dynamic logic signal to the drive transistors, thereby reducing the chances of a catastrophic consequence.
[0019] The hold time of the dynamic latch is selected so that, within a selected safety factor, state, the hold time of the dynamic latch will cause the dynamic latch to shift from the first state to the second state before the dynamic circuit elements lose state.
[0020] In various exemplary embodiments, the dynamic latch is formed on the same integrated circuit chip as the protected dynamic circuit elements. Thus, the dynamic latch experiences the same process variations as the protected dynamic circuit elements. These process variations can cause the hold times of the dynamic latch and the protected dynamic circuit elements to vary from the nominal design hold times. Because the dynamic latch and the protected dynamic circuit elements experience substantially the same variations, their hold times will vary in substantially the same way, substantially maintaining the relative values of the hold times.
[0021] Other objects, advantages and salient features of the invention will become apparent from the following detailed description taken in conjunction with the attached drawing, which disclose an exemplary embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The invention will be described with reference to the following drawing, wherein:
[0023] [0023]FIG. 1 is a block diagram of a print head circuit according to a first exemplary embodiment of the invention;
[0024] [0024]FIG. 2 is a block diagram of a print head circuit without a fail-safe circuit;
[0025] [0025]FIG. 3 is a block diagram of a printing system which includes the print head circuit of FIG. 1; and
[0026] [0026]FIG. 4 is a block diagram of a print head circuit according to a second exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0027] Various exemplary embodiments of the circuits and methods according to this invention are described using thermal inkjet print head technology. It should be understood that many other micro-fluidic and micro-mechanical systems can also be addressed by dynamic logic circuitry, and may also have catastrophic states that could be encountered with a “loss of state” in the controlling logic section. All of these types of micro-fluidic and micro-mechanical devices are considered to be within the scope of this invention.
[0028] This invention provides a fail-safe circuit which continually monitors the print head circuit refresh event and protects the circuit elements of a circuit that contains one or more dynamic circuit elements when the refresh time τ r of one or more of the dynamic circuit elements approaches the hold time τ hd of the dynamic circuit elements. In one exemplary embodiment of this invention, a dynamic timer circuit is provided which measures the actual refresh time τ ra and compares it to some maximum allowable limit τ hf . The maximum allowable time limit τ hf is specified with a margin of safety based upon the expected variation in the hold time of the dynamic circuit elements formed on the integrated circuit chip, and the expected race timing between the dynamic fail-safe circuit and the failing dynamic circuit elements.
[0029] The race characterizes the importance of the dynamic fail-safe circuit detecting the failure of the refresh condition and sending its protection signal to the protected circuit elements in a time τ df . To protect the protected circuit elements, the time τ df must be before at least one of the dynamic logic circuits detects its failure condition and its erroneous state arrives at the protected circuit elements in a catastrophic signal arrival time τ dd .
[0030] Further, due to process variations, the timing parameters will vary from the nominal values. These timing parameters are the maximum allowable time limit τ hf , the hold time of the dynamic circuit τ hd , the time to send a protection signal τ df , and the time to detect a failure condition and erroneous state of the dynamic circuit, i.e., the catastrophic signal arrival time τ dd . If these parameters are distributed as a gaussian distribution, then each timing parameter will have a parameter (τ, σ) associated with the timing parameter which describes the width in the variation in timing of that timing parameter. These are denoted as σ hf , σ hd , σ df , σ dd .
[0031] Finally, if the timer circuit is a centralized function, the arrival time to the most distant protected circuit element will be the longest. In this case, the longest protected circuit interconnect delay time τ l is used as an offset term in the delay determination. Additionally, clock skew can be embedded in the delay calculations.
[0032] To guarantee that the fail-safe signal protects the protected circuit elements prior to the arrival of the undefined logic output most of the time, the following relationships can be defined:
T hf +4σ hf +τ df +4σ df +τ l <τ hd −4σ hd +τ dd −4σ dd ; and (1)
τ hf <τ hd −4σ hd +τ dd −4σ dd −(4σ hf +τ df +4σ df τ l ). (2)
[0033] The probability of time-dependent failure is related to the choice of safety margin. The safety margin is thus defined by the number of standard deviations (σ) used in Equations (1) and (2). The above exemplary embodiment uses four standard deviations (σ), but more or fewer standard deviations may be used in other exemplary embodiments.
[0034] [0034]FIG. 1 shows a block diagram of one exemplary embodiment of a fail safe circuit according to this invention. As shown in FIG. 1, a fail safe circuit 100 comprises a drop ejector array 140 , a drive transistor array 130 and a dynamic logic circuit 110 which provides control signals and/or drive signals to the transistor array 130 . A predriver array 120 is located between the dynamic logic circuit 110 and the drive transistor array 130 . The pre-driver array runs off an intermediate voltage and normally acts as an interface between the low voltage logic and the high voltage transistor array. As shown in FIG. 4, the predriver array 120 , includes in its circuitry an array of AND gates 160 -x.
[0035] As shown in FIG. 4, the array of AND gates 160 -x, which in this exemplary embodiment are located in predriver array 120 , along with a dynamic fail safe timer circuit 150 form a dynamic fail safe circuit 100 according to this invention. A clock 155 outputs a clock signal to both the dynamic fail-safe timer 150 and the dynamic logic circuit 110 . The clock signal refreshes the dynamic circuit elements in the dynamic fail-safe time 150 and the dynamic logic circuit 110 .
[0036] The AND gate array 160 , which is shown in FIG. 4, as being included in the pre-driver array 120 , includes a plurality of AND gates 160 -x, where x is an integer. It should be understood that the AND gate array 160 may be in a separate structure or portion of the fail safe circuit and need not be part of the pre-driver array 120 , as shown in FIG. 4. If the AND gate array 160 is located in the pre-driver array 120 , the AND gates are typically operated at the relatively high voltage of the pre-driver array. If the AND gate array is located separate from the pre-driver array 120 , the AND gates are operated at the relatively low voltage of the dynamic logic array 110 . Each AND gate 160 -x has one input terminal connected to the dynamic fail-safe timer 150 and one or more input terminals connected to outputs of the dynamic logic circuit. It should be appreciated that only those outputs from the dynamic logic circuit 110 that have a significant probability of causing a catastrophic effect to the protected circuitry of the drive transistor array 130 requires routing through one of the AND gates 161 et al. of the AND gate array 160 . However, it is possible that any output signal from the dynamic logic circuit 110 could cause a catastrophic effect on the protected circuitry of the drive transistor array 130 . Thus, any or all of the output signals from the dynamic logic circuit 110 may be routed through the AND gate array 160 . Similarly, the level of significant probability of catastrophic effect may be determined on a variety of bases such as risk/cost analysis such that the actual output signals routed through the AND gate array 160 can be a design choice.
[0037] It should also be appreciated that other types of logic circuit elements, such as other types of logic gates, multiplexers, flip-flops, latches, buffers, tri-slate devices or any other known or later developed logic element, and combinations of one or more of these logic elements, can be used in place of some or all of the AND gates 160 -x of the AND gate array 160 . Thus, in this case, the AND gate array 160 is more appropriately referred to as a logic element array 160 . Therefore, it should be appreciated that each “element” of the logic element array 160 can be any suitable combination of one or more known or later developed logic elements, so long as each such element of the logic element array 160 can react to the state of the signal from the dynamic fail-safe timer circuit 150 to reduce the likelihood of damage to the protected circuit elements form any catastrophic effects of loss of state in the dynamic logic circuit 110 .
[0038] As shown in FIG. 4, in this exemplary embodiment that uses the AND gate 160 -X as the logic elements of the logic element array 160 , the logic element array 160 includes a first AND gate 160 -1 and a second AND gate 160 -2. The AND gate 160 -2 is physically located at a position on the print head 10 , shown in FIG. 4, closest to the fail-safe timer circuit 150 . The first AND gate 160 -1 is physically located at a position on the print head 100 farthest from the fail-safe timer circuit 150 . An interconnect delay time τ l is the time that it takes for the signal from the dynamic fail-safe timer circuit 150 to pass the second AND gate 160 -2 and reach the first AND gate 160 -1. The AND gate array can be placed in any suitable location in the circuit, including, as shown in FIG. 4, between predriver 120 and dynamic logic circuit/ 110 .
[0039] As shown in FIG. 4, in various exemplary embodiments, the dynamic fail-safe timer circuit 150 is a dynamic latch which passes a logic “1” only when the period of the clock signal from the clock 155 does not exceed the nominal hold time τ hf of the dynamic latch used to implement the dynamic fail-safe timer circuit 150 . Of course, it should be appreciated that any suitable dynamic circuit, which is capable of outputting a signal to the logic element array 160 whose value is unambiguously based on whether one or more of the dynamic circuit elements of the dynamic fail-safe timer 150 have lost its state, can be used to implement the dynamic fail-safe timer 150 . A logic “1” is passed to the pre-driver array 120 as long as the period of the clock signal from the clock 155 does not exceed the normal hold time τ hf of the timer circuit 150 . Moreover, in various exemplary embodiments, the dynamic logic circuit 110 includes one or more dynamic latches as at least a portion of the dynamic circuit elements. In this case, in various exemplary embodiments the dynamic latch of this dynamic fail-safe timer circuit 150 is identical to the dynamic latches in the dynamic logic circuit 110 except for width and length adjustments of the transistors. The widths and length of the transistors forming the dynamic latch used to implement the dynamic fail-safe timer 150 are used to set the maximum allowable limit τ hf according to a desired safety margin.
[0040] In these exemplary embodiments, the nominal fail-safe hold time τ hf of the fail-safe timer circuit 150 will track very closely with the nominal protected dynamic circuit hold time τ hd , since the circuit elements of the fail-safe timer circuit 150 are substantially similar to the circuit elements that form the dynamic logic 110 , i.e., the protected dynamic circuit. Further, due to the physical proximity of the fail-safe timer circuit 150 and the dynamic logic circuit 110 , the ratio τ hf /τ hd will be nearly constant. Since the circuit delays of the two paths are affected equally by any process variations that occur during fabrication, the margin of safety will remain constant from chip-to-chip, regardless of any process variations. Typical refresh times τ r are between about 50 nanoseconds and about 10000 nanoseconds for clock 155 . Typical fail safe circuit hold times τ hs minimum values are about 300 microseconds. Typical dynamic logic hold times τ hd minimum values are about 600 microseconds. These values assume that τ r <τ hf <τ hd .
[0041] [0041]FIG. 2 shows a schematic diagram of voltage buffer type print head predrivers without the fail-safe feature of this invention. Without the failsafe feature of this invention, predriver 120 would interface between the dynamic logic circuit 110 and the drive transistor array 130 , and predriver 120 would act as a voltage interface between the relatively high operating voltage, of about 40V, of the drive transistor array circuitry 110 , and the relatively low operating voltage, of about 5 V, of dynamic logic circuitry 130 .
[0042] [0042]FIG. 3 shows a typical multicolor thermal ink jet printer 11 , which is disclosed and described in more detail in U.S. Pat. Nos. 5,107,276 and 4,571,599, the subject matter of which is incorporated herein by reference. Printer 11 is shown containing several disposable ink supply cartridges 22 , each with an integrally attached print head 10 . The cartridge and print head combination are removably mounted on a translatable carriage 40 . The carriage moves back and forth on for example, one or more guide rails 43 which are parallel to a recording medium 44 , as depicted by arrow 45 . The recording medium is held stationary while the carriage moves in one direction and, prior to the carriage 40 moving in the reverse direction, the recording medium is stepped in the direction of arrow 46 . Each print head has a driver circuit 49 , which is controlled by logic controller 58 , as shown in FIGS. 5A and 5B of the '276 patent. The fail-safe circuit of this invention may be used, for example, with the print head driver circuit array 49 shown in the '276 patent, the drive transistor array in FIG. 1 of this application being equivalent to the print head driver circuit array 49 in the '276 patent.
[0043] While the invention has been described with reference to the structure and method disclosed, it is not confined to the details set forth, but is intended to cover such modifications or changes as may come within the scope of the following claims. | A method and Apparatus for protection of semiconductor micromechanical devices that use circuits with dynamic logic addressing is disclosed. In one exemplary embodiment of the invention, a fail-safe circuit is provided for an ink jet print head integrated circuit which prevents a catastrophic consequence of the dynamic logic addressed integrated circuit losing its charge. | 1 |
FIELD OF THE INVENTION
[0001] The present invention generally relates to power hand tools of the type which have foot assemblies.
BACKGROUND OF THE INVENTION
[0002] Electric power hand tools such as portable electric jigsaws are well known in the art and have been the subject of continued research and development that has resulted in commercial products that are more convenient to operate and enable users to produce superior results. Generally, they include an AC, DC or universal electric motor contained in a housing and a tool such as a saw blade operatively driven by the shaft. In the case of a jigsaw as well as other cutting tools, a foot assembly is provided which is connected to the base of the tool housing and generally comprises a flat bottom surface platform for engaging a work piece during operation.
[0003] Most jigsaws and some other power tools have a foot assembly that can be tilted relative to the tool housing so that cuts can be made at an angle to achieve a beveled cut. While foot assemblies that can be tilted have been known in the art for decades, many of the early and some of the recent mechanisms for adjusting and/or locking the foot at a desired angle to the tool housing are often cumbersome to use. A screwdriver, wrench, or the like is often required to tighten one or more threaded locking members such as bolts, which can be time consuming and even difficult if one does not have the appropriately sized and configured tool at hand. Sawdust and other debris created by the jigsaw can also combine with saw lubricants to foul the threaded locking member.
[0004] Some hand tools have an onboard locking lever to lock the foot in place at a desired orientation to the tool housing, which solves the problem of having the correct tool at hand, but often such locking levers were relatively costly to manufacture and cumbersome to install and adjust. Some hand operating levers may not conveniently provide the requisite holding strength, which when coupled with the substantial vibration developed during operation of a jigsaw can result in an undesirably change in the orientation angle of the foot.
[0005] Other solutions to movement of the foot have included foot assemblies that combine an onboard hand operable locking lever in combination with plurality of guide openings that are selectively engageable with a locking extension which minimizes the possibility of the orientation angle changing during use.
SUMMARY OF THE INVENTION
[0006] A preferred embodiment of the present invention is a foot assembly for a power hand tool such as a jigsaw that has an angularly adjustable support foot with a generally flat bottom portion, at least two spaced apart supports connected to the support foot, with each support having a main aperture, an elongated rod extending through the main apertures of the supports in a configuration permitting limited sliding movement and the angular adjusting movement of the support foot relative to the hand tool, a retainer member associated with the hand tool for selectively engaging at least one of the supports to lock the support foot at predetermined angular positions, and a spring for urging the retainer member toward engagement with the at least one support.
[0007] A second embodiment includes a removable transparent plate that attaches to the support foot and has a faux laser line for a cutting aid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a right side view of a jigsaw having the preferred embodiment of the foot assembly of the present invention;
[0009] FIG. 2 is a front plan view of the jigsaw shown in FIG. 1
[0010] FIG. 3 is a right front perspective view of the jigsaw shown in FIG. 1 with portions removed, and illustrating the foot assembly locked in the 0 degree position;
[0011] FIG. 4 is a right front perspective view of the jigsaw shown in FIG. 1 with portions removed, and illustrating the foot assembly in the 0 degree position, and in an unlocked position;
[0012] FIG. 5 is a right front perspective view of the jigsaw shown in FIG. 1 with portions removed, and illustrating the foot assembly in a 45 degree position, and in an unlocked position;
[0013] FIG. 6 is a right front perspective view of the jigsaw shown in FIG. 1 with portions removed, and illustrating the foot assembly in a 45 degree position, and in an locked position;
[0014] FIG. 7 is a top plan view of a support foot of the foot assembly shown in FIG. 1 ;
[0015] FIG. 8 is cross section taken generally along the line 8 - 8 of FIG. 7 :
[0016] FIG. 9 is a perspective view of a retainer member of the foot assembly shown in FIG. 1 ;
[0017] FIG. 10 is a perspective view of a jigsaw shown in FIG. 1 , with a flat plate shown in position to be attached to the support foot of the foot assembly; and
[0018] FIG. 11 is a perspective view of a jigsaw shown in FIG. 1 , with a flat plate attached to the support foot of the foot assembly.
DETAILED DESCRIPTION
[0019] Turning now to the drawings, and particularly FIG. 1 , a jigsaw, indicated generally at 10 , has a housing 12 which encloses a motor such as an AC, DC, or universal motor, which is mechanically linked to and drives a reciprocating saw blade 14 . An on/off switch 16 controls the motor, which is powered by an electrical source via cord 18 . Alternatively, the jigsaw 10 may be configured to be powered by a battery pack as is known by those of ordinary skill in the art. Also, those who are knowledgeable in the art will appreciate that other components of jigsaws are generally known, and are not discussed in detail herein.
[0020] The jigsaw 10 has a foot assembly, indicated generally at 20 , which is secured to the jigsaw housing 12 in a manner whereby it can be tilted, i.e., angularly adjusted relative to the blade 14 . The foot assembly 20 can be adjusted to provide a perpendicular cut relative to the work piece or a 45° bevel cut in either direction. The angular adjustment of the foot assembly is easily made and requires no tools to be carried out. The user merely needs to push the foot assembly forwardly to release its locking mechanism and then tilt the foot assembly relative to the housing in one direction or the other and it will then be locked in a 45° bevel orientation.
[0021] It should be understood that while the illustrated embodiment will permit the angular positions of 0 and 45° in either direction, the foot assembly may be modified to provide other bevel angles, such as 22-½° , for example, if desired. In addition to the ease of operation of the present invention, it securely locks the angular orientation that is chosen so that there is little likelihood that the foot assembly can be unintentionally changed during operation. Also, the locking mechanism has a robust construction and should not be an impediment to a long useful life for the jigsaw.
[0022] The foot assembly 20 has a support foot 22 that has a generally flat bottom surface 24 which contacts a work piece that is being cut. The support foot 22 is preferably made of steel that is cut and stamped into its ultimate shape as shown in the drawings. As shown in FIGS. 1,6 and 7 , the support foot 22 has a front opening 26 , upturned sidewalls 28 and upturned front wall segments 30 . Since during making curved cuts, the support foot will be moved sideways as well as forwardly, the upturn sidewalls as well as the front wall segments 30 contributes to smooth movement of the jigsaw over the work piece surface. By having a curved portion at the interface between the bottom surface and the sidewalls and front walls, there is less likelihood that an edge of the jigsaw will be caught by a work piece during operation.
[0023] As shown in FIG. 6 , the opening 26 has an enlarged curved portions 32 on opposite sides of the opening which are centered around the position of the blade 14 . The enlarged portion enables the foot assembly to be moved to either of the 45° bevel positions and not have the blade contact the support foot 22 . In other words, the necessary clearance is provided by the enlarged portions 32 .
[0024] The support foot 22 also has a front opening 34 and a rear opening 36 which are produced as the result of a cutting and/or stamping operation whereby the metal that was present before cutting is bent to form an upwardly directed perpendicular front support 38 and rear support 40 . Each of the supports 38 and 40 has a main aperture 42 sized to receive an elongated rod 44 which provides an axis about which the foot assembly can rotate to be tilted between the desired positions. The rod 44 extends beyond both supports 38 and 40 and is retained by suitable recesses in the housing that are appropriately sized to hold the rod 44 firmly in place. In this regard, the housing 12 is preferably fabricated from two half sections, one of which is clearly visible in several of the drawings, including FIG. 1 .
[0025] As is also evident from FIG. 1 , the free ends of the supports 38 and 40 have a generally semi-circular outer shape which enables the support foot 22 to be rotated within the housing 12 . The front support 38 also has a number of spaced apart positioning apertures 46 a - e that are arranged in a semi-circular configuration that is also concentric with the rod 44 .
[0026] The foot assembly 20 has a retainer member 48 best shown in FIG. 8 , that has a top portion 50 , a pair of wing portions 52 and a main portion 54 , the latter of which has an aperture 56 sized to receive the rod 44 . The member 48 also has three protrusions 58 , 58 that are also spaced from one another and are aligned in a semi-circular orientation concentric with the opening 56 so that they match up with the positioning apertures 46 a through 46 e.
[0027] As best shown in FIG. 1 , the retainer member 48 is configured to fit within complementary recesses in the housing 12 so that when both housing sections are combined, the retainer member 48 will be firmly held in place. Because of the stresses that may be applied to the retainer member 48 during use, it is preferred that it be made of steel or other strong durable material. The member may be unitarily formed or cast with the protrusions being part of the casting or the casting may not include the protrusions 58 , with those being separately fabricated and being force fit into suitable openings in the main portion 54 .
[0028] A compression spring 60 fits over the rod 44 and bears against the face of the rear support 40 and against the side of the retainer member 48 . The spring is preferably sized to provide a biasing force that is not easily overcome during normal use. Stated in other words, the spring force should be sufficient to keep the foot assembly in a stable locked position and not be accidentally changed during normal use. In this regard, a spring having force characteristics of about 35 Newtons to lock the foot assembly and about 50 Newtons to fully disengage the protrusions 58 from the positioning apertures 46 has been found to be effective.
[0029] When the foot assembly is in the normal perpendicular cutting operating position as shown in FIG. 1 , the protrusions 58 are inserted in positioning apertures 46 b , 46 c and 46 d as shown. If the support foot 22 is pushed forwardly to disengage the protrusions 58 from the apertures 46 as shown in FIG. 4 , the support foot 22 is free to be rotated to one of the 45° tilted positions, such as shown in FIG. 5 . When the support foot 22 is released, the protrusions 58 will engage positioning apertures 46 c, d and e, as shown in FIG. 6 .
[0030] With any of the three possible positions that the support foot can be placed in, each of the three protrusions 58 will be inserted into one of the positioning apertures 46 . This provides a stronger configuration than would occur if only a single or two protrusions were used and thereby also contributes to the strength of the connection and useful life of the product.
[0031] An alternative embodiment can include a removable transparent flat plate, indicated generally at 62 , and shown in FIGS. 10 and 11 , that attaches to said support foot 22 and has a faux laser line 64 on a front end portion 66 that functions as a cutting aid since it is preferably exactly in line with plane of the blade 14 . The plate is preferably made from a strong transparent plastic or plastic-like material such as polycarbonite or ABS. Polycarbonite is preferred because it has excellent impact resistant qualities and high strength.. To contribute to its strength, the plate preferably has upturned side portions 66 that fit around the side portions 28 of the support foot. As shown in FIG. 11 , the front portion 66 extends forwardly of the front wall portions 30 of the support foot 22 so that the faux laser line 64 is easily visible to the user. The line 64 may be raised and painted or otherwise colored red (or other appropriate color) to approximate the appearance of a line generated by a laser. An elongated opening 70 is provided to permit the blade to extend through the plate. The elongated opening is preferably sized so that the plate can be attached to the support foot 22 without having to manipulate the blade height or remove it.
[0032] To attach the plate 62 to the support foot 22 , a pair of front retaining hooks 72 extend upwardly from the front portion thereof for engaging the upper edge of the front walls 30 of the support foot 22 a pair of deflectable clips 74 located at the rear portion thereof for engaging a rear edge of support foot. The clips 74 have a tab 76 that can be pressed by the user to deflect the clips 74 so that a retaining edge which engages the rear edge of the support foot can be released. This enables the clips 74 of the back portion of the plate to clear the support foot 22 and enable the plate to be moved forwardly so that the hooks can be separated from the front wall portions 30 . The hooks 72 and clips 74 are preferably integrally formed during the molding of the plate 62 , although they may also be independently formed and adhesively attached or sonically welded if desired.
[0033] It will be appreciated that although discussion and description has been made herein of a particular tool and housing embodiment, such treatment has been made only to illustrate the invention. Other invention embodiments and equivalents to various features of the invention as described will be apparent to those skilled in the art. Also, in considering the jigsaw 10 and the foot assembly 20 , it will be appreciated that exemplary embodiments of the present invention are directed to a tool such as the jigsaw 10 , while others are directed only to the foot assembly 20 . Indeed, those knowledgeable in the art will appreciate that the foot assembly 20 will provide benefits and advantages when used with power tools other than a jigsaw.
[0034] While various embodiments of the present invention have been shown and described, it should be understood that other modifications, substitutions and alternatives are apparent to one of ordinary skill in the art. Such modifications, substitutions and alternatives can be made without departing from the spirit and scope of the invention, which should be determined from the appended claims.
[0035] Various features of the invention are set forth in the following claims. | A preferred embodiment of the present invention comprises a foot assembly for a power hand tool such as a jigsaw that has an angularly adjustable support foot with a generally flat bottom, at least two spaced apart supports connected to the support foot, an elongated rod extends through apertures in the supports in a configuration that permits limited sliding movement and the angular adjusting movement of the support foot relative to the hand tool, a retainer member associated with the hand tool that selectively engages one of the supports to lock the support foot at predetermined angular positions, and a spring biases the retainer member toward engagement with the support. A second embodiment includes a removable transparent plate that attaches to the support foot and has a faux laser line for a cutting aid | 8 |
TECHNICAL FIELD
[0001] The present invention relates to a grease composition, particularly a grease composition having excellent rust preventing characteristics; and a mechanical part, in particular a bearing, employing the above-mentioned grease composition.
BACKGROUND ART
[0002] A variety of mechanical parts have the problem of corrosion. For example, the rolling bearing parts for the automotive electrical equipment and engine auxiliaries including alternators, electromagnetic clutches and the like have the problem of corrosion resulting from permeation of water on the road, salt water or sea water during the operation; the rolling bearing parts for industrial machinery including compressors, blowers and the like also have the problem of corrosion resulting from permeation of cooling water and penetration of rainwater or sea water when installed outside; and the rolling bearing parts for the motor of home electrical appliances such as washing machines, refrigerators, and bathroom ventilating fans and bathroom ventilator dryer system which have become popular in recent years also have the problem of corrosion because they are exposed to high humidities.
[0003] In the above-mentioned rolling bearings subject to corrosion, the corrosive substances are prevented from invading the bearings by provision of a proper sealing or modifying the mechanism.
[0004] For the above-mentioned rolling bearing in the automobile, for example, it is proposed to install the rolling bearing at a position where the rolling bearing does not come in direct contact with muddy water or the like or to mount a fender or the like to protect the rolling bearing.
[0005] In light of the mechanism of rolling bearing, however, complete sealing of the rolling bearing cannot be achieved. Then, a lubricating grease used for the rolling bearing is required to have rust preventing characteristics.
[0006] For example, JP 2883134 B discloses a grease composition comprising rust inhibitors, i.e., an oil-soluble organic inhibitor, a water-soluble inorganic passivator and a nonionic surfactant.
[0007] JP 5-140576 A discloses a grease composition to be enclosed in bearings, comprising barium sulfonate as a rust inhibitor.
[0008] Sodium nitrite, which has been considered to be good and widely used as the water-soluble inorganic passivator was found to produce a carcinogen, N-nitroso-amine when reacting with secondary amine. There is serious concern about an adverse effect on human body.
[0009] The organic sulfonate such as barium sulfonate has been widely used as the oil-soluble organic inhibitor. However, when the organic sulfonate is used alone, the rust inhibiting effect is found to be unsatisfactory under severe conditions, especially in the presence of salt water or seawater.
[0010] In addition, there is a movement to impose self-restraint on barium sulfonate as an environmentally damaging substance, as described in NTN Technical Review No. 73 (2005), pp10-13.
SUMMARY OF INVENTION
[0011] An object of the invention is to provide a grease composition which exhibits excellent rust preventing characteristics and causes little damage to the environment.
[0012] Another object of the invention is to provide a mechanical part, in particular, a bearing employing the above-mentioned grease composition.
[0013] The present invention provides a grease composition and a mechanical part using the above grease composition, as shown below.
[0014] 1. A grease composition comprising a base oil, a thickener and a rust inhibitor, characterized in that the rust inhibitor comprises an organic sulfonate and a fatty acid amine salt.
[0015] 2. The grease composition as described in the above-mentioned item 1, characterized in that the organic sulfonate is at least one selected from the group consisting of calcium sulfonate and zinc sulfonate.
[0016] 3. The grease composition as described in the above-mentioned item 1 or 2, characterized in that the fatty acid amine salt is a salt of amine with a fatty acid having 4 to 22 carbon atoms.
[0017] 4. The grease composition as described in any one of the above-mentioned items 1 to 3 for a rolling bearing.
[0018] 5. A mechanical part using the grease composition as described in any one of the above-mentioned items 1 to 4.
[0019] The grease composition of the invention has excellent rust preventing characteristics even under the severe conditions susceptible to corrosion.
DESCRIPTION OF EMBODIMENTS
[0020] The thickener used in the grease composition of the invention is not particularly limited. For example, metal soaps including lithium, sodium or the like, and non-soaps such as Benton, silica gel, urea compounds, fluorine-containing thickeners such as polytetrafluoroethylene and the like can be used. The urea compounds and lithium soaps are particularly preferred because those are practical thickeners in terms of fewer disadvantages and lower price.
[0021] The thickeners may be used alone or in combination.
[0022] Preferably, the grease composition of the invention may have a consistency of 200 to 400. The content of the thickener may be determined to obtain the above-mentioned consistency. Typically, the content of the thickener may preferably be in the range of 3 to 30% by mass, more preferably 5 to 30% by mass, and most preferably 8 to 25% by mass, based on the total mass of the grease composition.
[0023] The base oil used in the grease composition of the invention is not particularly limited. It is possible to use any kind of base oils, for example, mineral oils; and a variety of synthetic oils, such as ester type synthetic oils including diester oils and polyol ester oils, synthetic hydrocarbon oils including poly α-olefin oils and polybutene, ether type synthetic oils including alkyl diphenyl ethers and polypropylene glycols, silicone oils, fluorinated oils and the like. In particular, ester type synthetic oils, synthetic hydrocarbon oils, and ether type synthetic oils are preferable because the low-temperature properties and the heat resistance are excellent.
[0024] One kind of base oil may be used alone or two or more kinds of base oils may be used in combination.
[0025] The rust inhibitor used in the invention comprises as the essential components an organic sulfonate and a fatty acid amine salt.
[0026] With respect to the above-mentioned sulfonate, for example, petroleum sulfonic acid, dinonyl naphthalenesulfonic acid or the like can be used as a sulfonic acid component. The sulfonate may preferably be in the form of a metal salt, more preferably in the form of a calcium salt, magnesium salt, sodium salt, potassium salt, lithium salt, zinc salt or the like. Particularly, calcium salt or zinc salt is preferred.
[0027] In the grease composition of the invention, the organic sulfonate may be used alone or two or more organic sulfonates may appropriately be used in combination.
[0028] The content of the organic sulfonate in the grease composition of the invention may preferably be 0.1 to 10% by mass, more preferably 0.1 to 8% by mass, and most preferably 0.2 to 5% by mass on a basis of the active ingredient.
[0029] Preferable fatty acids for constituting the above-mentioned fatty acid amine salt may have 4 to 22 carbon atoms, more preferably 8 to 18 carbon atoms. The fatty acid may be a saturated or unsaturated fatty acid, and in addition, may be a straight-chain, branched, cyclic or hydroxyfatty acid. Specific examples of the fatty acid include stearic acid, palmitic acid, myristic acid, lauric acid, isostearic acid, octylic acid, undecylenic acid, oleic acid, hydroxystearic acid and the like.
[0030] An amine for constituting the above-mentioned fatty acid amine salt is not particularly limited, but preferably a saturated or unsaturated amine having 1 to 42 carbon atoms, more preferably a saturated or unsaturated amine having 4 to 22 carbon atoms.
[0031] Specific examples of the amine include octylamine, laurylamine, myristylamine, stearylamine, behenylamine, oleylamine, beef tallow alkylamine, hardened beef tallow alkylamine, aniline, benzylamine, cyclohexylamine, diethylamine, dipropylamine, dibutylamine, diphenylamine, dibenzylamine, dicyclohexylamine, triethylamine, tributylamine, dimethyloctylamine, dimethyldecylamine, dimethylstearylamine, dimethyl beef tallow alkylamine, dimethyl hardened beef tallow alkylamine, dimethyloleylamine and the like.
[0032] In the grease composition of the invention the fatty acid amine salt may be used alone or two or more fatty acid amine salts may be used in combination.
[0033] The content of the fatty acid amine salt in the grease composition of the invention may preferably be 0.05 to 5% by mass, more preferably 0.05 to 3% by mass, and most preferably 0.1 to 2% by mass on a basis of the active ingredient.
[0034] In addition to the above-mentioned organic sulfonate and fatty acid amine salt, the grease composition of the invention may further comprise any additives typically used in grease compositions, as required. The additives may be used alone or in combination. Examples of the additives include an antioxidant, a metal deactivator, a detergent dispersant, an extreme-pressure agent, an anti-foam, a demulsifier, an oiliness improver, an antiwear agent, a solid lubricant and the like.
EXAMPLES
[0035] Grease compositions were prepared as shown in Tables 1 and 2 from the components listed below. After addition of the predetermined amount(s) of additive(s) to each base grease, the mixture was thoroughly blended and kneaded using a three-roll mill.
[0036] Base greases:
[0037] (A) Thickener: Lithium 12-hydroxystearate
Base oil: Polyol ester with a kinematic viscosity of 34.0 mm 2 /s at 40° C. Consistency: 250
[0039] (B) Thickener: Diurea compound (i.e., a reaction product of p-toluidine (2 mol) with diphenylmethane diisocyanate (1 mol))
Base oil: Poly a-olefin with a kinematic viscosity of 48.0 mm 2 /s at 40° C. Consistency: 280
[0041] Rust inhibitors:
[0042] (C) Calcium sulfonate (calcium salt of dinonylnaphthalenesulfonic acid)
[0043] (D) Zinc sulfonate (zinc salt of dinonylnaphthalenesulfonic acid)
[0044] (E) Fatty acid amine salt (i.e., a mixture of a salt of fatty acid having 8 carbon atoms and an amine having 12 carbon atoms and a salt of fatty acid having 18 carbon atoms and mixed amines having 12 to 20 carbon atoms (at a ratio by mass of 2:1))
[0045] <Test Method>
[0046] Rust preventing characteristics: Emcor rust test (IP220) using synthetic sea water (ISO 7120)
[0047] Assessment method: by observing the presence of rust on the rolling surface of outer ring (n=2)
Acceptable Rating 0: no evidence of corrosion Unacceptable 1: no more than three tiny spots of corrosion
2: up to 1% surface area of corrosion 3: between 1% and 5% surface area of corrosion 4: between 5% and 10% surface area of corrosion 5: more than 10% surface area of corrosion
[0000]
TABLE 1
Ex. 1
Ex. 2
Ex. 3
Ex. 4
Ex. 5
Ex. 6
Base Grease
(A)
(A)
(A)
(A)
(A)
(B)
Rust
(C)
0.50
—
0.25
0.20
5.00
0.25
Inhibitors
(D)
—
0.50
0.25
—
—
0.25
(E)
0.50
0.50
0.50
2.00
0.10
0.50
Results of Emcor
0.0
0.0
0.0
0.0
0.0
0.0
Rust Test
[0000]
TABLE 2
Comp.
Comp.
Comp.
Comp.
Comp.
Ex. 1
Ex. 2
Ex. 3
Ex. 4
Ex. 5
Base Grease
(A)
(A)
(A)
(A)
(B)
Rust
(C)
1.00
—
0.50
—
0.50
Inhibitors
(D)
—
1.00
0.50
—
0.50
(E)
—
—
—
1.00
—
Results of Emcor
2.2
2.2
2.2
2.2
2.2
Rust Test
[0054] No corrosion was detected in Examples 1 to 6 where the organic sulfonate (rust inhibitors (C) and (D)) and the fatty acid amine salt (rust inhibitor (E)) were used in combination, which demonstrated excellent rust preventing characteristics.
[0055] Detection of the corrosion proved the inferior rust preventing characteristics in Comparative Examples 1, 2, 3 and 4 respectively using the rust inhibitor (C), the rust inhibitor (D), combination of the rust inhibitors (C) and (D), and the rust inhibitor (E) so that the total amount of rust inhibitor(s) might be the same as that in Examples 1 to 3.
[0056] Detection of the corrosion proved the inferior rust preventing characteristics in Comparative Example 5 using combination of the rust inhibitors (C) and (D) so that the total amount of rust inhibitors might be the same as that in Example 6.
[0057] As can be seen from the above-mentioned Examples, the grease compositions of the invention were found to have excellent ability to prevent corrosion under highly corrosive conditions because of combined use of the organic sulfonate and the fatty acid amine salt. | The invention provides a grease composition containing a base oil, a thickener and a rust inhibitor, characterized in that the rust inhibitor includes an organic sulfonate and a fatty acid amine salt. The grease composition of the invention exhibits excellent rust preventing characteristics and causes little damage to the environment. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a latch needle for stitch forming textile machines. The latch needle includes a needle shank and a needle hook following the end of the shank. A latch slot is formed in the needle shank and extends in the longitudinal direction of the needle. A latch is also mounted on an axle in the latch slot at a location so as to be pivotal about a transversely extending pivot axis. The latch is provided on one end with a latch spoon which cooperates with the needle hook when the latch is in the closed position. The latch has an end portion which extends from the region of a latch blade or stem near the axle to the end facing away from the latch spoon. The needle shank includes a groove-like depression following the latch slot which extends toward the end facing away from the needle hook. One end of an elongate spring element is anchored in the groove-like depression while he other end of the spring element projects into the latch slot. When the needle latch is in the closed position the spring element passes over an associated contact face at one end of the latch stem. The spring element is positioned and the end of the latch stem is shaped so that there is a partially open intermediate position in which the axis of the latch stem and the axis of the needle shank define an angle which is preferably less than 90°.
2. Discussion of the Prior Art
Latch needles whose latches can be held in a partially open intermediate position by an associated spring element have in the past been used exclusively in hand knitting machines. When casting on loops, i.e. at the beginning of the knitting process or when forming further stitches, the partially open intermediate position of the latch makes it possible to unimpededly place the yarn into the needle hook. The partially open intermediate position avoids the necessity of using a brush-shaped needle opener or of initially opening all needle latches by hand. Both of these methods for opening the latch are connected with a considerable amount of work.
Attempts have been made to employ latch needles which have spring tensioned latches in knitting machines, and in particular in flat frame knitting machines. These needles would take the place of the previously employed normal latch needles having freely pivotally mounted latches. The reason for this is that the us of these normally employed latch needles (particularly when they are configured as stitch transfer needles) involves the danger that when the needle is retracted the latch does not properly pivot into its closed position and the stitch becomes caught at the tip of the open needle latch. The result of improper closing is that the yarn becomes snagged or split open. The reason this happens is because the stitch has been widened by the transfer spring of the transfer needle and the stitch is not pulled beneath the completely opened needle latch. This causes improper pivoting as the needle is retracted. Another problem that may happen is that the stitch slides over the open latch and is then caught in the needle hook. All of these possibilities result in faulty merchandise and the possibility of these flaws occurring increases when several yarns are knit simultaneously or when coarse natural yarns are processed.
Attempts to avoid this source of flaws by the use of latch needles having spring tensioned latches have been only partially successful. This is because a specific spring force is required to bring the latch from its closed or its completely open position into the partially open intermediate position and t arrest it there elastically. In prior art latch needles of this type, the force exerted on the latch by the spring element produces a great amount of friction for the latch which results in making the movement of the latch sluggish. Over time this affects the brush-shaped latch openers of the knitting machine in a manner such that the latches will no longer open reliably. At the same time, the end portion of the latch stem as well as the spring element experience wear from the constant friction at the spring element. The wear that occurs at the latch stem end causes the latch edges to become rounder after a longer period of operation and the wear of the spring element causes a reduction in the spring force. Thus the time period during which the pivoting movement of the latch is performed also becomes irregular in length because of the irregular friction conditions. These irregular conditions lead to an irregular appearance of the stitches in the knit fabric.
Such a latch needle that is intended for a hand knitting machine and that is unsuitable in principle for fast running flat frame knitting machines is disclosed in German Pat. No. 1,113,537. This needle has the latch slot located below the needle latch and is provided with a steel wire spring underneath the needle latch which is placed loosely into upwardly open steps at both ends of the latch slot so that the spring is undisplaceable in the longitudinal and transverse directions. Two flattened portions attached to the end portion of the latch stem cause the latch to be pressed back into a partially open intermediate position after each opening an closing movement in which position the axis of the needle latch and the axis of the needle shank form an angle of about 45° with one another.
Such needles are very well suited for manually operated flat frame knitting machines where the above-mentioned drawbacks do not occur because, compared to a modern flat frame knitting machine, the knitting speed is extremely slow and the spring force of the spring inserted underneath the latch can be kept correspondingly low.
This also applies to another latch needle known in practice for hand knitting machines which has a spring tensioned latch. In this needle, the latch is pivoted back after every closing or opening movement into an approximately half-open intermediate position by means of a spring element configured as a circular, flat or square spring element. In this intermediate position, the axis of the needle latch and the axis of the needle shank form an angle of approximately 90° with one another. One end of the spring element is braced into a groove made in the upper side of the needle shank and the groove opens into the latch slot. In the mentioned half-open intermediate position when the latch is to an angle of about 90°, the free end of the spring element, which extends into the latch slot, presses against the upper side of the latch stem where the latter is essentially linear. If the latch is pivoted by the newly formed stitch from this intermediate position back into its completely open position, the upper side of the latch stem presses the freely movable front portion of the spring element downward. After the stitch has slid onto the needle shank and has released the latch, the spring element is able to pivot the latch back into the intermediate position in which the latch is elastically locked by the free end of the spring element which has returned to its starting position.
When the needle is retracted and the stitch hanging on the needle shank moves in the direction of the needle hook, the stitch grips the latch in its intermediate position and pivots the stitch until the latch spoon rests on the hook as the needle continues to retract. Therefore the needle reaches its closed position. During this latch pivoting movement the free end of the spring element is in constant engagement with the latch stem. As the latch pivots, the free end of the spring element travels on a contact face of the end portion of the latch stem. It travels from the region of the latch bearing to the vicinity of the frontal face of the latch stem end portion. While this occurs the spring element is simultaneously pressed upwardly and is thus tensioned. After the stitch has been knitted the latch is released thus enabling the spring element which acts on the contact face of the latch stem to pivot the latch back into its intermediate position.
Attempts to use these latch needles which are intended exclusively for us in hand knitting machines in fast running flat frame knitting machines failed. They have failed because the structure of the knit fabric turned out to be so irregular that the merchandise could not be used. As far as it is known, the reason for this is the sluggish movement of the latch and the fluctuating tension forces to which the stitch is subjected to because of the irregular pivoting movements of the latch.
SUMMARY OF THE INVENTION
It is therefore a object of the present invention to provide a latch needle having a latch which can be pivoted by an associated spring element into a partially open intermediate position so that such a needle can also be used for high operating speeds and is distinguished by accurate operation for the production of a uniform knit structure and by a long service life.
This is accomplished by a latch needle where the end portion of the latch stem is provided with a free surface which opens into the upper side or the end portion of the latch stem and releases the latch when the stem is pivoted from its intermediate position in the direction toward its completely open position. During this pivoting movement, this free surface extends at a distance from the frontal face of the spring element which is otherwise out of engagement with the end portion of the latch stem.
With this configuration of the latch, the spring element is in engagement with the end portion of the latch stem only as long as the latch takes on a position within the pivoting range between the stem's closed position and its intermediate position. The remaining pivoting range of the latch, from its intermediate position to its completely open position, is completely decoupled from the spring element. This allows the latch to be freely movable until a position shortly before the completely open position where the upper side of the latch shaft places itself onto the spring element. Then the newly formed stitch slides over the latch and presses the spring element downward thereby slightly tensioning the latch. After the stitch has released the latch during the further course of the needle retraction movement, the tensioned spring element pivots the latch back into its intermediate position where it is held by the spring element which grips over the contact face at the end portion of the latch stem.
Due to the fact that the latch is freely pivotable over a major portion of its pivoting range a low frictional stress on the part of the spring element results for the latch bearing. Also the wear occurring at the latch portions which come into engagement with the spring element is reduced to a minimum even at high operating speeds. Because the latch is freely movable over the major portion of its pivoting range and needs to be depressed by the stitch against the spring force only in the last part of the pivoting range high uniformity of the stitches is achieved.
The use of the novel latch needle in high-speed flat frame knitting machines has the advantage that it allows the distance between the tip of the closed latch and the outside radius of the hook to be omitted due to the automatic opening of the latches from their closed position. By eliminating this "latch projection", the formation of finer stitches is permitted. Since the latch is initially pivoted from its completely open position toward its closed position not by the stitch but by the spring element, the latch can be placed very flat on then needle shank or can even be completely buried in the needle shank, in its completely open position so that even tight and firm stitches can be pulled effortlessly over the open latch. This improves the quality of the merchandise.
The end portion of the needle shank is advantageously provided with a recess starting at the upper side of the shank with the edges of the recess forming at least the free surface. In a preferred embodiment, the arrangement may be such that the recess is disposed between the following regions: the region of the bearing location and the frontal face of the end portion of the latch stem and is delimited by the free surface which ends at the upper side and by the contact face starting at the frontal face.
The contact face may be disposed on, below or above the longitudinal center plane of the latch which passes through the center of the axle and may be oriented at least approximately parallel to this plane. Moreover, the mentioned recess may have a surface that forms an obtuse angle or may essentially be circular, concave and/or convex shaped.
It is advantageous if the end portion of the latch stem and the end of the spring element are held in the latch slot for each position of the latch within its pivoting range. This excludes interference with the sliding movement of the newly formed stitch over the opening latch due to elements projecting from the rear of the needle shank.
This feature is in contrast to conditions existing with some of the prior art discussed above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 to 3 illustrate the latch needle according to the present invention in a longitudinal sectional view showing the latch in three different positions.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The latch needle comprises a needle shank 1 which may have a butt (not shown) and which is followed by a needle cheek 2 and a needle hook 3. The needle shank 1 has a rectangular cross section and is provided with a latch slot 4 which extends in the longitudinal direction of the needle shank. The slot 4 starts from the upper side of the needle shank and extends toward the underside of the needle shank in such a manner that an opening 5 is created on the underside of the needle shank to permit lint to be discharged.
Within latch slot 4, a latch 6 is mounted in a bearing location so that the latch 6 is pivotal around a transversely extending axle or shaft 7. Latch 6 includes a latch blade or stem 8 provided with a bearing bore 9 which cooperates with axle 7 at the bearing location and is provided at its end with a latch spoon 10 which cooperates with needle hook 3 when the latch is in the closed position.
Extending from latch slot 4, a groove-like depression 11 is formed in needle shank 1 which ends at the upper side of the needle shank. The depression 11 extends in the longitudinal direction of the needle shank and has one end of an elongate spring element 12 anchored therein. The other end 13 of the spring element 12 projects into latch slot 4. Spring element 12, which is shown as a straight piece of spring wire, may also be a circular, flat or rectangular spring. The spring element 12 may also be linear, curved or angled to meet the intended purpose. At point 14, the end of spring element 12 is firmly braced into recess 11. The bottom 15 of recess 11 has a gentle slope toward the underside of the needle shank so that the end 13 of spring element 12 which is disposed in latch slot 4 can move up and down without interference.
Between the region of the bearing location 9 and the frontal face 16 of the latch 6 facing away from spoon 10, latch 6 has an extended end portion 17 such that latch 6 forms a double-arm lever which is pivotally mounted on axle 7. At end portion 17, a short contact face 18 is formed which starts at frontal face 16 and extends essentially parallel to and slightly above the longitudinal center plane 190 of latch 6. Contact face 18 is adjacent a free surface 19 which opens on the upper side 20 of latch stem 8. Both faces 18, 19 thus together define a recess 21 which extends in end portion 17 of needle shank 8 from upper side 20 to frontal face 16 and lies between the region of bearing location 9 and frontal face 16.
The free surface 19 may essentially have the shape of a circle segment or may be concave or convex. As an alternative, it may also be shaped of straight sections having softly rounded transitions at their ends as presently illustrated.
The length of spring element 12 is selected so that when latch 6 is in the closed position and latch spoon 10 is resting on needle hook 3, the end 13 of the spring element 12, passes over contact face 18 of end portion 17 of the latch stem. In this position, the end 13 of spring element 12 is simultaneously raised upwardly compared to the untensioned state shown in FIG. 1 thereby tensioning spring element 12.
The operation of the latch needle will now be described starting with the latch 6 in the closed position. When latch 6 is released from the closed position by a stitch (not shown), spring element 12 acts on contact face 18, moves latch 6 into the partially open intermediate position shown in FIG. 1. In this position the longitudinal center axis 190 of latch 6 and the axis 191 of needle shank 1 form an angle 23 with one another which is about 30° but in any case is less than 90°. Latch 6 is pivoted into this intermediate position by spring element 12.
In the course of forward movement of the latch needle, the stitch hanging in needle hook 3 moves onto latch 6 and pivots it clockwise with respect to FIG. 1. This moves latch 6 from the partially open intermediate position. At a certain point of pivoting, the end 13 of spring element 12 ceases to be in contact with contact face 18 and becomes positioned adjacent free surface 19 without contacting it. The free surface 19 is at a predetermined distance from the end 13 of spring element 12 as shown in FIG. 2. Latch 6 is therefore able to perform its pivoting movement without interference from the intermediate position to the completely open position shown in FIG. 3 without being influenced therein by spring element 12. Only at the end of this pivoting movement does the back of latch stem 8 of latch 6 contact spring element 12. Continued movement by the latch stem causes the spring element 12 to bend slightly downward by the stitch pressing onto the open latch until latch 6 reaches its end position shown in FIG. 3.
As soon as the stitch releases latch 6 in the course of the further forward movement of the latch needle, spring element 12, returns to its starting position shown in FIG. 1. This pivots latch 6 counterclockwise back to the intermediate position shown in FIG. 1 in which it is held by end 13 of spring element 12 which acts on contact face 18.
The free surface 19 which releases latch 6 from spring element 12 when the latch 6 pivots from the intermediate position shown in FIG. 1 toward the completely open position need not necessarily define a cutout-like, obtuse-angled recess in end portion 17 of the latch stem as described in connection with the drawing figures. Embodiments are also conceivable in which the recess has a circular shape as indicated by the dashed lines 21a in FIG. 2. Recess 21a is then disposed in the region of the upper side 20 of latch stem 8 or, more precisely, in the region of its end portion 17, on which also rests contact face 18a which is adjacent to frontal face 16. Of course, the circle segment-like recess 21a may also be combined in the lower contact face 18 in such a manner that it follows contact face 18. Finally, it is also not absolutely necessary for contact face 18 to be a planar surface. It may be a curved surface or form part of a semicircular recess.
As can be seen in FIGS. 1 to 3, end portion 17 of latch stem 8 and end 13 of spring element 12 are dimensioned and arranged in such a manner that in every position of latch 6 within its pivoting range, end portion 17 and end 13 of spring element 12 remain in the latch slot. In other words they do not project downwardly from opening 5. In this way a newly formed stitch sliding over the opening latch 6 is not impaired. Therefore, the loop of the old stitch hanging from this new stitch is not caught by projecting portions on the rear of the needle shank.
The present disclosure relates to the subject matter disclosed in the Federal Republic of Germany, No. P 37 02 019.6, Jan. 24, 1987, the entire specification of which is incorporated herein by reference.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | A latch needle having an elongated spring element, one end thereof attached to the bottom of a recess in one portion of the slot, the other end of said spring element bearing on the extended end portion of the latch biasing the latch to a partially open position. | 3 |
This application is a continuation-in-part of application Ser. No. 08/799,254, filed Feb. 14, 1997 now abandoned.
The invention relates to couplings for pipe lines and, more particularly, to a fitting for mechanically coupling a plain pipe end.
PRIOR ART
The repair of existing pipe systems often requires a pipe to be cut off at some point along its length and joined with a replacement length of pipe. In many cases, depending on such factors as the environment of the pipe, it is not practical to couple the new length by welding. An example of a frequently needed repair is a section of a riser in an off shore gas or oil line. The high frequency of repair in this type of service is the result of corrosion of the line at the water surface due to the effects of salt water, air and wave action. These effects accelerate the corrosion of the line at this area and cause it to need replacement substantially earlier than that of underwater sections.
U.S. Pat. Nos. 4,127,289 to Daspit and 4,239,266 to Mynhier disclose examples of mechanical "collet" type pipe couplings suggested for underwater use. Typically, such couplings incorporate wedges or "slips" which circumferentially grip the pipe. The wedges are tightened by axial bolts which, as they are tightened, cause the wedges to be cammed radially inwardly against the pipe. U.S. Pat. No. 4,832,379 to Smith et al. illustrates a similar type of riser fitting. In general, known types of these couplings can be relatively expensive to manufacture, complicated to assemble and install and bulky in size.
SUMMARY OF THE INVENTION
The invention provides an improved collet-type pipe fitting that is simple to manufacture and install and that also affords a high level of performance including end pull resistance. As disclosed, the fitting comprises four principle parts that can each be fabricated from elementary disc-like shapes by simple turning operations, for example. The parts, owing to their simple geometry, are economical to manufacture, jam-proof in assembly and installation and rugged in service.
In one preferred embodiment, the fitting includes an annular weld flange that is welded at one side to an end of one pipe section which in the case of the riser application is a replacement length of pipe. At its opposite side, this weld flange is proportioned to receive the end of another pipe length and includes an annular cavity for a packing ring that seals the other pipe length. An intermediate annular flange for assembly on the other pipe length has an annular extension adapted to compress the packing when associated bolts are tightened. A circular collar, also assembled over the other pipe length has a conical bore in which are received arcuate grip segments. The grip segments have outer surfaces complementary to the conical collar bore and inner surfaces complementary to the exterior of the other pipe length. The grip segments are relatively large parts and, advantageously, are few in number.
The fitting can be installed with a limited number of steps, each of which is straight-forward. With the main parts assembled over the other pipe end, draw bolts are tightened to pull the center flange towards the weld flange to thereby compress and seal the packing against the exterior of the other pipe end. Then, other draw bolts are tightened to pull the grip collar towards the center flange. At this time, the grips being axially confined by a face of the center flange, are cammed radially inwardly against the outside diameter of the other pipe end. Ideally, the draw bolts for the packing and for the grips are the same wrench size, preferably a large and robust size, that can be driven by power equipment ordinarily available to a pipe line installation or service contractor.
In another embodiment, similar to that described above, a fitting is arranged with bolts, for sealing and clamping, that are accessible for tightening from the same end of the fitting.
The disclosed fitting construction is particularly suited for use as a riser fitting to replace corrosion damaged pipes rising from the sea bed. The fitting's simplicity in construction and installation is advantageous and allows it to be successfully installed even in underwater environments. Additionally, the fitting construction permits it to be disassembled and re-used, if desired.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal cross-section of a pipe fitting constructed in accordance with a first embodiment of the invention and end portions of respective pipe lengths;
FIG. 2 is a transverse cross-sectional view of the fitting taken in the plane 2--2 indicated in FIG. 1;
FIG. 3 is an end view of the fitting taken in the plane 3--3 indicated in FIG. 1;
FIG. 4 is a longitudinal cross-sectional view of a pipe fitting constructed in accordance with a second embodiment of the invention;
FIG. 5 is an axial view taken in the plane indicated at 5--5 in FIG. 4;
FIG. 6 is a fragmentary view taken in the plane indicated at 6--6 in FIG. 4;
FIG. 7 is a fragmentary view taken in the plane indicated at 7--7 in FIG. 4;
FIG. 8 is an axial view of a pipe grip of the assembly of FIG. 4;
FIG. 9 is a longitudinal cross-sectional view of a pair of fittings used to join two pipe lengths;
FIG. 10 is a longitudinal cross-sectional view of a fitting used to close off a pipe end; and
FIG. 11 is a longitudinal cross-sectional view of a fitting used to attach a flange to a pipe.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A fitting assembly 10 for joining two pipe lengths or sections 11, 12 is typically made of steel or other suitable material. The fitting 10 principally comprises three circumferentially continuous annular parts 16, 17, 18 and an annular grip 19 in the form of arcuate segments 21.
One of the main annular parts 16 comprises a circular disc-like flange 22 and an integral axial extension 23. An internal bore 24 of the flange part 16 is sized to receive the ends 26, 27 of the pipe sections 11, 12. At an inner end of the flange 22, a counter bore 28 provides an annular recess or pocket for a pipe sealing gasket material 31. As shown in FIG. 2, four equally spaced holes 32 extend axially through the flange 22 providing clearance for four associated bolts 34.
The second or center main fitting part 17 is similar in shape to the part 16 having a circular disc or flange portion 36 and an integral axially extending projection or ring 37. An internal bore 38 is sized to receive the pipe section 12 with a slip fit. The axially projecting ring 37 has a generally radial end face 39 and a cylindrical outer surface 41 sized to fit in the counter bore 28 with limited clearance. The flange 36 is formed with a plurality of equally spaced axially extending internally threaded holes about its perimeter. In the illustrated case, these threaded or tapped holes 42 are twelve in number. The holes 42 lie on a common imaginary circle centered on the axis of the fitting 10 and pipe sections 11 and 12. The holes, ideally, are all threaded with the same thread geometry, i.e. diameter and pitch. The holes 42 are arranged so that they receive the four bolts 34 assembled in the fitting part 16.
The annular grip section or structure 19, in the illustrated case, comprises a pair of substantially identical arcuate segments 21. Each segment 21 has an inside generally cylindrical surface 43 adapted to frictionally engage the outside diameter of the pipe 12. The arcuate length of each segment 21 is slightly less than 180° so that a gap 44 exists on diametrally opposite sides of the pipe 12 between arcuate ends of the segments 21. As shown, the gap 44 runs the full axial length of the segments 21. A radial outer surface 46 of each segment 21 is conical and has a slope from the axis of the fitting of, for example, 15°. The segments 21 have a radial face 47 which abuts an adjacent radial face 48 of the central fitting part 17.
The third fitting part 18 is a circular collar or disc. The collar 18 has an internal conical central bore 49 that has an angle which is complementary to the 15° angle of the segments 21. An outer face 50 and an inner face 51 of the collar are substantially radial. As shown in FIG. 3, the collar 18 is drilled or otherwise formed with a plurality of axial extending holes 52. The holes 52 are sized with a clearance fit for bolts 53. As illustrated, the holes 52 are on centers coincident with the centers of the threaded holes 42 in the center flange 17. In assembly, the bolts 53, with reference to their heads, extend in an axial direction opposite that of the first described set of bolts 34.
The various described parts have simple geometries, for the most part with circular or conical surfaces and may be economically fabricated from standard flanges with a minimum of machining and with simple machining steps. For example, the welded flange 16 can be fabricated from a commercially available long welding neck flange, the center flange 17 can be fabricated from a commercially available welding neck flange and the collar 18 can be fabricated from a commercially available slip-on flange.
Where the fitting 10 is used as a riser fitting to repair a corrosion damaged section of the riser, a new piece of pipe represented by the pipe section 11 is welded to the fitting part 16 with a circumferential weld 56. As indicated, a short axial end portion of this pipe section 11 is received in the fitting extension 23. This relation makes it easy to weld the fitting section 16 to the pipe section 11. Typically, the weld 56 can be made on a barge which is being used by the contractor to install the riser fitting. The other pipe section 12 represents the existing riser pipe which has been cut off at the end face 27. The various parts of the fitting are slipped over the end of the existing pipe section 12 and manipulated into the general relation shown in the figures. Once the parts are loosely assembled on the existing pipe 12, the four screws or bolts 34 are tightened, typically by a power wrench to squeeze the packing 31 so that it constricts radially into tight sealing engagement with the exterior of the pipe section 12. Thereafter, the eight bolts associated with the grip collar 14 are progressively tightened to cause the grips to be cammed radially inward by interaction of the respective conical surfaces 49 and 46 of the collar 14 and segments 21. These bolt tightening operations are facilitated by the fact that the packing compression bolts 34 and grip operating bolts 53 are of the same diameter so that the same socket wrench fits them.
It has been found that the anchoring action of the grips 21 is substantial and more than adequate to resist normally expected end pull forces that might be applied to the pipe sections 11 and 12 while they are in service. An added benefit of the disclosed fitting assembly 12 is that it can be disassembled and, if desired, it can be reused. The disclosed grips 21 despite the presence of a smooth pipe generally cylindrical gripping surface at their interior surfaces 43 provide a surprisingly high end pull resistance. At the same time, the angle of the taper of their outside surfaces 46 is such as to not produce a tight interlocking effect with the collar 18 so as to prevent ready disassembly of the fitting from the pipe length 12.
While the disclosed arrangement shows the fitting assembly 10 to be configured to join pipe sections that are of the same diameter, it will be apparent to those skilled in the art that the principles of the invention may be applied to other arrangements where the pipe sections to be joined are of different diameter. If desired, the grips 21 can be more than two in number and/or can be held temporarily in a proper orientation during assembly by a suitable cage or by suitable tack welds or other suitable techniques.
Referring now to FIG. 4, there is shown another embodiment of a fitting assembly 60, constructed in accordance with the invention, that offers certain advantages in its installation. The assembly 60 includes circumferentially continuous parts comprising a seal flange 61, a middle flange 62 and a grip flange or collar 63. These parts and others to be described are ordinarily formed of steel or other suitable metal by machining, forging and/or with other known processes. The seal flange 61 has an annular weld neck 64 which is suitably beveled at its distal end for a weld bead 66 that connects it to a length of pipe or body 67 which can typically be a riser replacement. The main body of the seal flange 61 is circular and has a series of circumferentially spaced axially oriented holes 68, 69 through it. Alternate holes 68 are relatively large and intervening holes 69 are relatively small. As indicated in FIG. 5, the plane of FIG. 4 is angularly displaced to illustrate both the large and small holes and other construction details.
The interior of the seal flange 61 includes a central axial bore 71 and a counter bore 72. The bore 71 is sized to receive, with moderate clearance, the end of a pipe 73 that, for example, can be an existing part of a riser that has had an upper portion removed for replacement. The counter bore 72 receives a seal or packing 74. The packing 74 is positioned against a radial wall 76 at the inner end of the counter bore 72.
The middle flange 62 has a central cylindrical axial bore 77 sized to slip over the pipe 73 and a series of circumferentially spaced axially oriented holes 78, 79 aligned with respective holes 68, 69 in the seal flange 61. In the illustrated example, the alternate holes 78 are relatively large and the intervening holes 79 are relatively small. At one face of the flange 62 an annular extension or ring 81 exists which is received in the counter bore 72 behind the seal or packing 74. At a generally radial face 82, distal from the seal flange 61, shallow recesses or pockets 83 are machined or otherwise formed around the holes 79. The recesses are bounded by opposed flat surfaces 86 lying in axial planes. The opposed surfaces 86 are parallel to one another and have a predetermined spacing. Radially between the recesses 83 and the bore 62, the face 82 is uninterrupted.
The grip flange 63 is an annular body having a plurality of circumferentially spaced axially oriented cylindrical holes 88, 89 having a pattern corresponding to the holes in the other flanges 61, 62. Alternate holes 88 are relatively small and intervening holes 89 are relatively large. As shown in FIG. 7, the relatively small holes have associated recesses 91 machined or otherwise formed in a radial face 92 distal from the middle flange 62. The recesses 91 include opposed flat faces 93 lying in axial planes at a predetermined mutual spacing. The grip flange has a conical bore 94 tapering radially inwardly with increasing distance from a radial face 96 adjacent the middle flange 62.
An annular grip 97 of steel or other suitable material is disposed between the middle flange 62 and the grip flange 63. In is free state, the grip 97 has a cylindrical bore 98 sized to slip over the pipe 73. The grip 97 has an outer conical surface 99 that has a taper angle generally complementary to the taper angle of the grip flange bore 94 and in assembly is received in such bore. A radial face 101 of the grip is arranged to abut the radial face 82 of the middle flange. In the illustrated condition, the grip is a unitary C-shaped part formed by milling or otherwise forming a single longitudinal slot in an annular tapered body. The grip is illustrated in an axial view in FIG. 8.
Seal bolts 102 are assembled in the seal flange and middle flange holes 69, 79 and threaded into nuts 103. The nuts 103 are received in the recesses 83 such that the opposed surfaces 86 prevent the associated nut from rotating by engaging the flats of the nut. The holes 89 in the grip flange 63 are large enough to receive the seal nuts 103 without interference.
Grip bolts 104 are assembled in the seal flange, middle flange and grip flange holes 68, 78 and 88 and are threaded into grip nuts 106. The nuts 106 are received in respective recesses 91 where the surfaces 93 engage their flats to prevent them from turning. In the illustrated assembly 60, the seal and grip bolts 102 and 104 are made of suitable lengths of threaded rod stock on which are fixed hex nuts, as by welding, to form the heads of these bolts. An identical cylindrical collar insert 107 is provided in each of the large holes 68 in the seal flange 61. The outside diameter of the insert collar is smaller than the diameter of the holes 68 so that the insert collar can move freely in its respective hole. The inside diameter of the collar 107 is larger than the diameter of a grip bolt 104 so that the shank of the bolt can slide and turn in it. The ends of the collar 107 are formed by flat radial faces. One of the collar faces abuts the face of the middle flange and the other collar face abuts the head of the grip bolt 104 assembled through it. The length of the collar 107 is somewhat greater than the axial length of the rim of the seal flange 61 so that the inner collar face bears against the adjacent face of the middle flange while the outer face of the collar engages the bolt head at a plane spaced away from the rim of the seal flange.
As indicated, the fitting assembly 60 of FIG. 4 is particularly suited for use in repairing risers in undersea pipeline systems. In such applications, the neck 64 of the seal flange 61 is butt-welded to the end of the replacement length of pipe 67 and thereafter the fitting assembly 60 is used to mechanically couple this replacement length to a good part 73 of the original pipeline system. Ordinarily, this welding is performed with the packing 74 out of the counter bore 72. The fitting assembly 60 can be shipped by the manufacturer in a loosely assembled configuration corresponding to FIG. 4. The packing 74 can be removed by separating the seal flange 61 from the middle flange while the middle flange, grip and grip flange can remain bolted together. The seal flange 61 can be removed easily because the grip bolts 104 and collars 107 can pass through the seal flange holes 68. An end 108 of the original pipe 73 is preferably beveled and cleaned before the fitting assembly 60 is installed on it.
For installation on the pipe length 73, the fitting assembly 60 is put together in the configuration of FIG. 4. With the grip bolts 104 hand-tightened and the seal bolts 102 loose, the fitting assembly 60 is lowered by a crane or hoist, for example, axially onto the pipe length 73 so that the pipe end 108 passes into the flanges 61-63. The pipe 73 can be marked to ensure that its end is fully received into the seal flange 61 against a conical bore portion 109. When the pipe 73 is fully received in the fitting assembly 60, the seal bolts 102 are uniformly tightened to cause the middle flange extension 81 to axially compress the seal 74 and thereby cause it to extend radially inwardly into sealing engagement with the exterior of the pipe 73.
The grip bolts 104 are then uniformly tightened to draw the grip flange 63 towards the middle flange 62. The collars 107 transmit the compressive force developed by the bolt heads to the middle flange 62 and allow the bolts 104 to be sufficiently long that their heads are accessible above, i.e. axially outward of the seal flange rim. This grip flange movement, with axial displacement of the grip 97 prevented by abutment of the surfaces 82 and 101 causes the grip to be constricted radially inwardly onto the pipe 73 by camming action between conical surfaces 94, 99 of the grip flange 63 and grip 97. The grip 97 constricts relatively easily because of the circumferential discontinuity introduced by the through slot designated 111 in the wall of the grip and a reliable high clamping force can be developed on the pipe 73 to lock the fitting assembly and pipe together.
It will be understood that the seal bolts 102 and grip bolts 104 are accessible from the same end of the fitting assembly, that is, from the outer or upper side of the seal flange 61. This is an important feature in underwater applications because it allows a diver working with a power wrench to rest the weight of the wrench on the fitting during wrenching operations and minimizes the number of times the diver has to set-up his body position. The disclosed fitting assembly 60 is characterized by a design that involves relatively few parts that are simple to fabricate, are easy to assemble with minimal skill and dexterity and are durable in service. Importantly, the assembly 60 can be disassembled and reused.
FIGS. 9 through 11 show additional uses of the fitting assembly 60. In FIG. 9 there is shown two assemblies 60 welded together at their weld necks to form apparatus for mechanically coupling a pair of pipes or bodies 121, 122. In FIG. 10, a plate or body 123 is welded on the weld neck of a fitting assembly 60 to blank off a pipeline 127 or to pressure test a pipeline. Alternatively, the blank 123 may be in the form of a dome welded on the end of the weld neck. In FIG. 11, a standard weld neck flange or body 124 is joined to an assembly 60 by welding it to a short length of pipe 126 and the short length of pipe to the weld neck of the fitting.
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 collet-type pipe coupling of simplified construction includes three main flange parts and a grip structure. The main flange parts are machined or otherwise formed with plain shapes. One flange is welded to an associated length of pipe or other body and all of the flanges are assembled over a separate length of pipe. A first set of bolts is tightened to compress a packing carried in the welded flange with an intermediate flange. A second set of bolts draws a flange collar towards the intermediate flange to constrict the grip structure radially into locking engagement with the separate length of pipe to complete a coupling installation. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of and claims domestic priority benefits to U.S. patent application Ser. No. 13/481,947, filed May 28, 2012, now pending. U.S. patent application Ser. No. 13/481,947, filed May 28, 2012, now pending, is a continuation-in-part of International Patent Application No. PCT/CN2010/000765 with an international filing date of May 28, 2010, designating the United States, now pending. The contents of the aforementioned application, including any intervening amendments thereto, are incorporated herein by reference.
CORRESPONDENCE ADDRESS
[0002] Inquiries from the public to applicants or assignees concerning this document should be directed to: Matthias Scholl P.C., Attn.: Dr. Matthias Scholl Esq., 245 First Street, 18th Floor, Cambridge, Mass. 02142.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention relates to a method and device for automatically monitoring the production of fluid film.
[0005] 2. Description of the Related Art
[0006] To determine the accuracy of fluid film thickness is a common issue of many industries, for example, the glue film thickness of the adhesive pasting production, the grinding film thickness of the food processing industry and the color pigment production, and so on. For even grinding and steady dispensing of flour mixture in the food processing industry, if inappropriate amount of flour mixture is dispensed in the oven, under the fixed speed and steady temperature processing condition, pre-mature cooking or overcooking may occur, and it can also cause fire in the extreme situation. For the substrate pasting production, the correct amount of adhesive application is also an important issue. In normal pasting process, the operator can only execute the quality control inspection from the final product and determine whether the quality is satisfied. In any case of quality problems, such a production batch has already failed to meet standard quality and becomes the uncontrollable wastage.
[0007] In the printing industry, the evenness of color film thickness is an important issue to determine the production quality. The determination of the accurate and appropriate printing ink value is a hot topic in the printing industry. Nowadays, color adjustment solely relies on the operator's subjective judgment. Traditional color adjustment is based on the worker's skill. The trial method is employed to achieve the color balance condition. Each color station of a printing machine is equipped with many inking control zones, and a machine operator spends a lot of time to adjust the inking values, which can lead to a great delay of color correction and cause imbalance printing results. In daily life, the stamp surface of a traditional rubber stamp needs to pick up ink film from an ink pad, and stamps onto the paper. If the ink pad lacks of ink, for example, the stamp surface has carried thin thickness of ink film, the printing image will become light, and vice versa, the ink pad with excessive ink will have the too dark stamping. For the case of the imbalance of inking level condition between the ink pad surface, the stamping image will be imbalance and results in stamping failure. Hence, trial methodology has to be applied before every time of stamping. First of all, it has to find out whether the ink pad has sufficient ink, and then proceed of stamping until satisfaction before actual stamping production begins. This is a typical problem which needs to be fixed in the printing industry and the trial methodology is commonly used.
[0008] In traditional printing technology, color correction process has to collect the printing information from the printed sheet, and an operator has to use a visual or reading device to scan the traditional color bar to monitor and amend the color value. No matter which method is applied, manually or automatically correcting the color zones needs analysis from the finished product. As a result, the color correction respond time is delayed. During the high speed and large volume production process, the delay of color correction responding time can cause a large amount of defect products. Because of the above reason, the industry needs a direct and pro-active color controlling system to replace the indirect density retrieving method from the conventional color bar.
[0009] All industries quality control system needs to retrieve production data for amendment. The work flow of data collection is described as follows: the selection of data reading device; the analyzer installation location; the timing of collecting the production data, and so on. These can clearly distinguish the major different between this invention and the conventional data reading method.
[0010] By comparing this invention with the conventional method: This invention technology is overrided the traditional method, the major different of monitoring the fluid dispensing value hardware is installed at the up stream of the production work flow, the reading device has already begun to monitor the metering system and analyzing the material dispensing value before the actual product being made; this system will be repeatedly to compare the dispensing value accuracy with the pre-determined reference setting, it will be in a real time bases to conduct the closed loop adjustment if it is out of range condition, it will amend the fluid thickness continuously and maintain the product quality within tolerance, meanwhile it continues to feed onto the substrate for production and the goal is to deliver the product at the best quality perfect result, hence this is a pro-active and creative quality control technology. In order to have the conventional method of the closed loop fluid thickness control to keep within the tolerance, the amendment data must be collected from the quality control media tool which measures the finished product, the data reading device has to be installed at the down stream of the production work flow, the actual installation position must be at the products discharge location for the fluid thickness inspection from the immediate finished products, which is used to verify the applied material whether it is acceptable or needs to be adjusted. Because of the inspection system can only inspect from the finished products, such inspection position will not be possible nor simultaneously to inspect the dispensing value at the up stream location of fluid metering system for controlling the material dispensing value: for the time being, the production line continues to apply the material dispensing value which has been set prior to the inspection, therefore the defect gets worse as the excessive material are still dispensing until the new dispensing value generates from inspection completion, a passive way of quality control technology.
[0011] This invention is a pro-active inspection method, which is different with the passive type of operation. The pro-active method is repeatedly control in production, which is a creative up stream technology. It is a totally vise-verse technology by comparing with conventional passive way technology which inspects the finished products at the downstream location.
[0012] The fluid application industry does not record any pro-active way inspection technology at the up stream work flow so far, therefore this invention is the innovative way to adopt the pro-active technology background; creatively changes the conventional passive quality inspection mode from the downstream end product data collection to the up stream position to become a new technology which has a pro-active mode of controlling.
[0013] Regardless the described passive way or pro-active way, the data collecting condition can be retrieved from flat or rotating surface; both reading conditions will not affect this invention data retrieving work flow and location setting.
SUMMARY OF THE INVENTION
[0014] This invention can solve the technical problem such as, how to provide a method and device which can initiatively, proactively, accurately, appropriately pre-determine and monitor the production of the fluid films at the upstream process. In printing process, applying this initiative and proactive monitor method to accurately adjust the color value against the pre-determined color zone inking value, and achieve the ultimate inking value before production will reduce the unnecessary adjustment time and material wastage and maintain the products in the highest quality level.
[0015] This invention provides an initiative and pro-active intelligent controlling method for fluid films in the material metering process, based on measuring the fluid film thickness to automatically control the material metering production system.
[0016] The invention provides an initiative, pro-active, intelligent monitoring method for fluid films, comprising:
activating a dispenser to deliver appropriate material from a storage duct to a metering system for even distribution of a fluid film; allowing the fluid film to pass a sample retrieving roller; measuring the fluid film on the sample retrieving roller using a data reading device to obtain film thickness data; transmitting the data to an analyzer to examine the data against a predetermined reference value; transmitting a comparison result in real time by the analyzer to a production equipment controlling console; controlling the storage duct to dispense material through the material metering system and adjusting the film thickness; repeating the above steps to make a film thickness within the reference range; and maintaining the thickness at the narrowest tolerance deviation, and continuously delivering onto a substrate for production.
[0025] Printing ink is also a kind of fluid type material. Color pigment becomes a printing ink film after passing through the metering system. The thickness of the printing ink film is measurable. Such an ink film is a color measuring media. The retrieved ink film data can analyze the color value after such material being measured.
[0026] In a class of this embodiment, the fluid film is a printing ink film.
[0027] The method of the invention can be used to maintain an even ink film color value, to cover up the printing plate surface by accurately adjusting the ink zones.
[0028] Each ink zone requires sufficient storage of printing ink, from the material storage duct and the metering system to the printing plate surface, to cover up the printing area, and finally transfers onto the substrate surface for production. For different printing area and each ink zone, different amount of inking value is required. A good printing product needs an even and consistence supply of ink and metering system in order to provide an appropriate inking distribution. The ultimate goal is to accurately maintain and continuously amend the inking system operation without using the finished printing product as the inking value correction aim.
[0029] This invention provides an initiative and proactive method, comprising pre-examining the fluid type film thickness, determining the even metering volume, continuously monitoring and maintaining the film thickness within tolerance range, then transferring to the application system for production. The result of each finished product shall be the best and uniform quality as well as at the minimum deviation tolerance level, the high accuracy of the finished products prediction at the best quality result.
[0030] In a class of this embodiment, the pre-set fluid film reference target adopts a neutral grey balance technology. Pre-determined black “K” neutral black color value functions as the reference blue print for the neutral grey formation inking units which are the composition of the primary and subsequent color group as reference aim. The analyzer uses the pre-determined black “K” value to compute each related production color unit in appropriate matching condition by determining the desire ink film thickness, proceeds with even metering, amends the ink film when necessary to the uniform condition, continuously transfers to the substrate for production.
[0031] This invention can adopt the neutral grey balance technology disclosed International Patent Application Nos. PCT/CN2008/001021 and PCT/CN2009/001490. Based on the neutral grey balance theory, the primary color is the commonly used material for the color printing production, e.g. cyan shaded as blue, magenta shaded as red and yellow. Combining the three primary color in different values forms the color picture. In theory, equal portion of the primary color mixed with each other will form a dark black color called “neutral black”. The “neutral grey” is the result of the equal portion of pre-determined percentage of halftone. Further combination of a primary color and a secondary color such as a primary color with its opponent color can also form the “neutral grey” which comprises cyan+red, magenta+green, and yellow+blue. To combine more subsequent color groups with the appropriate condition can be also form the “neutral grey”.
[0032] This invention related to the usages of neutral grey balance theory. The primary and subsequent color have their color balance relationship, which provides the accurate balanced color value information for pre-determining the ink film thickness. Using the initiative, pro-active control of each color ink film thickness, positively monitoring the requirement of each color printing unit ink film thickness shall maintain the neutral grey condition. This invention also involves the usages of many different measuring methods, continuous determination, automatic adjustment of the inking value to even distribution on the printing plate surface, and then transferring to the substrate surface. Such printed area shall receive an even inking value/ink film thickness/ink density for executing production.
[0033] This invention is the method of initiative, pro-active pre-determination of ink setting which can rapidly and accurately control the ink film thickness, and then the ink film is transferred to the printing plate for continuous production. The printing result of each printed sheet can achieve the consistency and keep within the tolerance. The advantage of this invention is fast to set up the equipment, greatly reduce the ink and material wastage, less demand of operator's color technical skill, remove the subjective decision of color adjustment, and unrestricting of reproduction. High accurate prediction and control of the product's quality is the ultimate advantage.
[0034] This methodology of this invention is an intelligent proactive color determination system, which is combined with the neutral gray balance color theory. During the printing process, the individual production unit inking evenness does not represent the color values in all units and the color imbalance may significantly affect the printing results. Based on the grey balance theory, the primary colors and subsequent colors must be in appropriate proportion to form a neutral gray balanced printing. The pure black (neutral black) color film is used to determine the color value of density/brightness reference for each color composition to form the neutral gray, such a result can ensure the entire printing job achieving balanced color.
[0035] The invention adopts the working principle of the neutral gray balance and monitoring system: the ink dispensing system of each color production unit is equipped with the ink film thickness reading device, continuously measures and extracts of data, calculates and adjusts. By using the grey balance theory, the pre-determined value of black color becomes the reference target for the grey balance component colors to form the appropriate ink film thickness for the grey balance printing. This invention device can prepare the desire ink film in advance and then automatically adjust within its color production unit and no needs to retrieve the inking correction information from the printed job; hence the result can greatly reduce the examination time as well as the speed of grey balance correction.
[0036] Neutral grey color balance component is based on the combination of color values between the primary and subsequent color density and brightness of color gamut value. This invention is creative, initiative, and proactive in measuring the color film thickness to interpret the pigment density, color gamut, brightness value for the color correction value of each color. It is a practical, effective, simple, direct, fast and accurate measuring method compared with a traditional measuring method.
[0037] The invention provides an initiative and proactive intelligent fluid type film monitoring device, comprising a data reading device, a sampling roller, a data conversion system, a comparison system, and a production control system. The data reading device is attached on the drive shaft, and scans film thickness values from the surface of the sampling roller, and then the data will be transmitted through a signal line to a data conversion system, the comparison system sends the correction instructions to the production control system for conducting the correction.
[0038] The device is equipped with an intelligent control system. Such a device comprises the data reading device, the comparison system, and the production control system, and the data conversion system. The data reading device for each production unit will obtain data, and sends the data to the comparison system via the data conversion system. After the comparison system analyzes and determines the film thickness correction plan for each production unit, the production control system executes the control process. The steps are repeated for intelligent control.
[0039] Referring to FIG. 21 , the controlling work flow circuit diagram of determining the grey balance value, measuring, analysis, calculation and execution are summarized as follows: to begin with, the comparison system has been set with the default neutral grey balance value, and then sends the default color film thickness to the reference value circuit. At the same time, the PLC programmable control device attached to the printing units 1 , 2 , 3 , 4 , and etc sends commands to the data reading device, to execute the ink film data collection operation. The thickness value is forwarded to the signal receiving system for analysis, and then the ink film thickness comparison unit compares the value against the default setting and determines whether the correction is necessary, if necessary, the amended data will be processed by the amplifier. Finally, the selector will determine the color correction requirement and then return signal to the comparison system. By referencing from the color value and ink film thickness look up table, the correction command will transmit the correction value in real time through the production control system for repeating operation.
[0040] While in production, the device allows an operator to input the new reference value based on the actual requirement to the data comparison system for the real time appropriate adjustment and controlling operation.
[0041] The data reading device of the device can be installed independently, and work back and forth along the drive shaft to scan the surface of the sampling roller for the film thickness data collection (as shown in FIGS. 4, 5, 6A, 6B ).
[0042] The data reading device can also be installed with a rotational measuring head for changing the measurement direction (as shown in FIGS. 7A, 7B ).
[0043] The data reading device can also be installed on the drive shaft with the reflector or similar reflection device which is in 90 degrees angle of measurement between the sampling roller to collect the film thickness information (as shown in FIGS. 8A, 8B ).
[0044] The data reading device can be installed on a fixed rack with a plurality of reading heads; such heads collect the film thickness data from the sampling roller surface (as shown in FIGS. 9, 10, 11A, 11B ).
[0045] The measuring device can be equipped with the following elements:
[0046] i) a single scanning head, which can be traveled back and forth, or work with a rotational reflection device to travel back and forth over the ink film thickness sampling roller to collect data from each color zone (as shown in FIGS. 4, 5, 6A, 6B, 7A, 7B, 8A, 8B ); or
[0047] ii) a plurality of scanning heads, a series of connected reading heads. The quantity is based on the spacing between the number of ink zones and they will be placed along the sampling roller to collect data from each ink zone (as shown in FIGS. 9, 10, 11A, 11B ).
[0048] The reading speed of a plurality of scanning heads system is faster than that of the single head.
[0049] This invention has a comprehensive evaluation on color values with initiative proactive adjustment features. The data reading device can collect ink zone values from each color production unit, such values will pass through the analyzer to determine the requires ink film for achieving the evenness inking coverage, and then to adjust the suitable inking quantity according to the actual requirement.
[0050] The device is equipped with a compensation system to assess production environment changes such as production speed, operation temperature, humidity and etc for making film thickness compensation and controlling the tolerance deviation.
[0051] There are two choices of selections:
[0052] i) Grey Balance analyzing system: Grey balance analyzing system takes into account the relationship between color unit inking values for achieving the grey balance condition, and compares the value with the “K” Black ink value to achieve grey balance production, then the analyzing system transmits the suitable inking values to each color production unit for increasing or decreasing the ink zones correction for the best grey balance result at minimum deviation.
[0053] ii) Non Grey Balance analyzing system: For special color production, the grey balance analyzing system will be switched off, each color printing unit will resume its independent color assessment initiative proactive analyzing function, each color unit does not have the inter color balance relationship, the operator has the choice of using the number of printing unit and determines the inking value to meet the product requirements.
[0054] The data reading procedure of the device of the invention is:
[0055] 1) Grey Balance production: Based on the product requirement, the pre-determined black “K” value will transmit to the color comparison system for continuous analyzing of the color correction values. The ink film thickness data reading device will continuously collect the inking values from each ink zone through the sampling roller, and the data will be directly provided to the grey balance analyzer for determining each color correction scheme, repeatedly to execute the amendment of ink zone values adjustment through the production control system.
[0056] 2) Non Grey Balance production: Based on the product requirement, specially define each production unit inking value, then transmit the values to the data reading device for continuous analysis of the ink zone values adjustment. The ink film thickness data reading device in each inking unit will continuously collect the ink zone values through the film thickness sampling roller for determining color correction scheme, repeatedly to execute the amendment of ink zone values adjustment through the production control system.
[0057] The use of the neutral grey balance analyzing system requires to input the pre-determined grey balance value as the standard reference data, which comprise precise ink film thickness of the primary and subsequent colors and the density or color brightness values. The reference data is converted into the ink film thickness. The data reading device will be continuously monitor and verify with the pre-determined reference data for correction purpose. The excessive or in-sufficient inking value will be immediately delivered to the production control system console for real time amending of each color production unit for accurate ink film thickness adjustment.
[0058] The installation of data reading device can be classified into internal and external type. The internal type needs to follow the design of the production machine metering system and to determine whether there is enough space available to do so, needs an appropriate installation fixture, and needs permanent fastening of the reading device onto the metering system. The single unit data reading device can be in the form of back and forth traveling. The reading device can be fixed in position with reflective device traveling back and forth or in rotational operation as well as multi units fixed position data reading devices installed on to the fixture, and collects the data from the sampling roller by direct or in-direct contact method for accurate scanning and retrieving the data.
[0059] The external type is the special design of independent mechanical fixture, and the reading device needs to be fastened. The single unit data reading device can be in the form of back and forth traveling. The reading device can be fixed in position with reflective device traveling back and forth or in rotational operation as well as multi units fixed position data reading devices installed on the fixture, and have the installation screws to fasten it onto the metering system, with direct or in-direct contact method to collect data from the sampling roller. In additional, the external unit can also be divided into with and without sampling roller, which depends on the selection method of data collection.
[0060] The film thickness data collecting system can be more than one unit to collect the multiple film thickness measurement data from the metering system. The purpose of multiple data collection can provide more film thickness samples to achieve accuracy by mathematical analyzing method.
[0061] To increase the scanning capability, more than one type of data reading device can be installed within one sampling system for data reading operation.
[0062] The data reading device can employ mechanical type reading, or employ a resistive tensioning reading to detect the surface tension resistance value during the ink film metering, and the value can be used to determine the ink film thickness; besides, it can also be an electromagnetic type, ultrasonic scanning type, or a laser and optical scanner.
[0063] The device can select a particular color data reading device to collect the measurement, which uses the individual color printing unit's independent ink film thickness analyzer to continuously collect the ink film thickness value, to perform real time analyze on each ink zone inking condition, then forwards the amended inking value to the ink dispensing system accordingly.
[0064] This invention device can be used in combination with mechanical, electronic, and digital production equipments.
[0065] The data reading device scanning system can be classified as following: Mechanical reading device, using the mechanical contact to measure the actual ink film thickness; the resistive tensioning reading to detect the surface tension resistance value to determine the film thickness; electromagnetic reading device, using the suitable magnetic wave energy, to absorb, to reflect or to penetrate the ink film on the roller surface; an ultrasonic sensor, comparing the sound wave time traveling difference between the ink film and sensor to determine the changes of film thickness; the laser measuring device, using the laser ray emission and receiving time difference to measure the micro meter distance; the optical reading device such as densitometer, spectral densitometer, imaging device, spectrometer, it can be used to directly analyze the ink film density, contrast, color strength, chromatic result. The above measuring data can determine the grey balance condition by using the reference black (neutral black) color, this is used to initiatively and proactively determine the particular production color printing unit ink film thickness in balancing to each other to form neutral grey, and then proceed printing onto the substrate. Those color without the grey balance relationship will become a special color, that particular production unit can select the pre-determined ink film thickness and disable the neutral grey balance analyzing system, automatically scan, monitor, amend such ink film thickness to fulfill the even coverage on the application roller system to execute printing process.
[0066] The data reading device obtains data through the PLC programmable controller to compute and digitize the result, and then transmit in optical, electronic, digital form to the computer to calculate and determine the ink film thickness, this can provide appropriate correction values to the production control system for amending the ink film thickness.
[0067] FIG. 20 is the conversion chart for the ink film thickness, density, and color brightness value. The market available color substance has carried different fluid body; the fluid type printing ink film thickness is based on its physical characteristic to represent the ink density, color brightness relationship. The look up table is used to record each color unit ink film thickness, density, and color brightness values.
[0068] Based on the above scanning methods, installation means, creating the look up tables, data retrieving, all of these can provide the information for the grey balance analyzer to predict each primary color ink film thickness to achieve the grey balance, and then compare the grey value with the pre-determined “K” reference value. When necessary, increasing, decreasing, or maintaining each color unit's inking value through the optical, electronic, digital transmission method for sending the amendment to the production control console in real time, to initiatively, pro-actively, and continuously execute the color adjustment. Such color value information will be forwarded to each color printing unit's ink zone for pro-actively pre-determining the appropriate ink film for the high quality and accurate grey balance production.
[0069] This invention relates to a kind of initiative, proactive, intelligent controlling device for fluid films. The device can install more than one unit of data reading device or more than one unit of sampling device; it can also be installed more than one unit of data reading devices and more than one unit of sampling device within the metering system to collect multiple fluid films thickness data along the same fluid dispensing zone for determination of the correction value whenever necessary to improve the accuracy of fluid film thickness evenness production.
[0070] This invention provides the device for the initiative proactive intelligent control on the fluid type films, which is equipped with an intelligent controlling system, and the device comprises the data reading device, the comparison system, the production control system, and the data conversion system. The data reading device for each production unit's will obtain data, and deliver the data through the data conversion system to the comparison system to analyze and determine the film thickness correction plan for each production unit to execute the amendment through the production control system and execute the control process in closed loop operation.
[0071] The fluid film correction system and device can be a direct type, which comprises a sampling roller, doctor blade, container, data reading device, PLC programmable control device. The data reading device is used to collect the excess fluid film information and then transmits the command in real time to the PLC programmable control device to control the gap spacing for controlling the allowable fluid to pass through for forming the film thickness.
[0072] The fluid films correction system and device can be an indirect type, which comprises a sampling roller, roller, doctor blade, container, data reading device, PLC programmable control device. The data reading device is used to collect the excess fluid films information then transmits the command in real time bases to the PLC programmable control device to control the gap spacing for controlling the allowable fluid to pass through for forming the film thickness.
BRIEF DESCRIPTION OF THE DRAWINGS
[0073] FIG. 1 : a schematic diagram of an initiative proactive fluid type films controlling method and device.
[0074] FIG. 2 : a schematic diagram of an initiative proactive fluid type films controlling method and device with adoption of the neutral gray balance monitoring system.
[0075] FIG. 3 : a schematic diagram of an initiative proactive fluid type films controlling method and device, each production color unit has its own individual inking control and continuously maintain the color correction continuously and each production color unit does not have any grey color balance relationship.
[0076] FIG. 4 : a schematic diagram of an internal type single unit data reading device, back and forth measuring.
[0077] FIG. 5 : a schematic diagram of an external type single unit data reading device, back and forth measuring without sampling roller attachment.
[0078] FIG. 6A : a schematic diagram of an external type single unit data reading device, back and forth measuring with sampling roller attachment.
[0079] FIG. 6B : a three-dimensional diagram of an external type single unit data reading device, back and forth measuring with sampling roller attachment.
[0080] FIG. 7A : a schematic diagram of a fixed external type single unit data reading device with adoption of the rotational mirror or similar device, by diffract the measuring angle direction back and forth the sampling roller.
[0081] FIG. 7B : a three-dimensional diagram of external type single unit data reading device.
[0082] FIG. 8A : a schematic diagram of a fixed external type single unit data reading device with adoption of the mirror or similar device, by diffract 90 degree the measuring angle back and forth the sampling roller, and this system has attached with the sampling roller.
[0083] FIG. 8B : a three-dimensional diagram of an external type single unit data reading device.
[0084] FIG. 9 : a schematic diagram of a fixed internal type multi unit data reading device measuring.
[0085] FIG. 10 : a schematic diagram of an external type multi unit data reading device without the sampling roller attachment.
[0086] FIG. 11A : a schematic diagram of an external type multi unit data reading device with the sampling roller attachment.
[0087] FIG. 11B : a three-dimensional diagram of external type multi unit data reading device with the sampling roller attachment.
[0088] FIG. 12 : Laser theory
[0089] FIG. 13 : a schematic diagram of a laser distance measurement of the bare sampling roller without carrying the color film.
[0090] FIG. 14 : a schematic diagram of a laser distance measurement of the sampling roller carrying with the color film.
[0091] FIG. 15 : Ultrasonic theory
[0092] FIG. 16 : a schematic diagram of an ultrasonic distance measurement of the bare sampling roller without carrying the color film.
[0093] FIG. 17 : a schematic diagram of an ultrasonic distance measurement of the sampling roller carrying with the color film.
[0094] FIG. 18 : a schematic diagram of an optical color density and color gamut value reflection measurement.
[0095] FIG. 19 : a schematic diagram of an optical color density and color gamut value transmission measurement.
[0096] FIG. 20 : Look up table for Ink film thickness, color density, and color gamut value.
[0097] FIG. 21 : Grey balance color value determination, measurement, analyzing, calculation, and correction execution control circuit diagram.
[0098] FIGS. 22, 23 : Fluid type film direct correction system and device schematic diagram.
[0099] FIGS. 24, 25 : Fluid type film in-direct correction system and device schematic diagram.
[0100] FIG. 26 : The proactive intelligent controlling method for fluid printing ink film thickness value vs the traditional passive system color film thickness controlling method.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0101] The following embodiments of this invention with the content for further elaboration:
Example 1
Initiative Proactive Intelligent Controlling Method and Application Device for Fluid Type Films
[0102] See FIG. 1 , an initiative proactive intelligent controlling method for fluid type films device comprises a production control system console 7 , production units 1 , 2 , 3 , and 4 , metering unit 52 , a data reading device 5 , and a referencing quality analyzing system 6 .
[0103] To implement this invention which is a kind of initiative proactive intelligent controlling method for fluid type films device comprising: entering the predetermined metering material reference value to the analyzing device 6 as the monitoring reference usages. The analyzing device determines the metering film thickness from the look up table (table 20) which is the relationship between the film thickness and material requirement value. By giving command to the dispensing system for delivering the appropriate amount of material to the metering unit 52 and execute the even film metering via the sampling roller 9 ; operate the data reading device 5 to measure the film thickness from the sampling roller 9 , obtain the data and transmits to the analyzing system 6 against the film thickness reference for comparison. If the comparison result is not acceptable, the analyzing system 6 will deliver in real time the film thickness correction value to the production control system 7 for controlling the dispensing system through the metering unit to correct the production film thickness. The above description is a repeatedly operation process, it can rapidly provide the film thickness to achieve the reference range, and maintain within the narrowest tolerance deviation, continuously deliver onto the substrate for production. It can maintain the highest quality result and achieve the closest tolerance as well as minimum wastage. For each production unit, the even film thickness does not have any color balance relationship, the operator can freely determine the film thickness setting to achieve the product requirement.
[0104] Any similarity of the following examples' methodologies and devices to this example will not be repeated.
Example 2
Initiative Proactive Intelligent Controlling Method and Application Device for Fluid Type Films with the Adoption of the Neutral Grey Balance Production Technology
[0105] See FIG. 2 , a device comprises a production control system 7 , production units 1 , 2 , 3 , and 4 , metering unit 52 , data reading device 5 , and the neutral grey balance comparison system 6 . Based on the pre-determined printing color sequencing order, freely place the black, cyan, magenta, and yellow ink onto the printing units 1 , 2 , 3 , and 4 . Enter the pre-determined black ink value to the neutral grey balance analyzing device 6 as the neutral grey balance requirement referencing usages. The analyzing device will determine the metering film thickness from the look up table (table 20) which is the film thickness and material dosage value. The black, cyan, magenta, and yellow inking unit data reading device 5 will measure the film thickness from the sampling roller 9 , by using the initiative and proactive method to provide the neutral grey balance information to the analyzing device 6 to compare with the pre-determined black inking value. If it is not acceptable, it calculates the grey balance value for the neutral grey balance component colors to determine the correction ink film thickness value, and transmit to the production control system 7 , by giving command to each printing unit inking dispensing system to deliver the appropriate amount of printing ink to the metering unit 52 and execute the ink film metering. The above process is a repeated operation, it can be highly accurate to provide the film thickness for achieving the reference range and maintaining within the tolerance, before delivering to the production line for production, as it is an initiative proactive mode, automatically makes correction in real time bases, continuously maintain the highest quality result and achieves at the closest tolerance as well as minimum wastage.
Example 3
Initiative Proactive Intelligent Independent Production Controlling Modular for Controlling the Fluid Type Film Thickness
[0106] See FIG. 3 , for example in each printing unit, the special color ink can be chosen in printing unit 1 for production. The data reading device 5 will initiatively and proactively measure the color data from each ink zone. The unevenness ink zone result will be sent directly to such unit's ink zone controller 8 in real-time for repeated adjustment, without using the production control system 7 for correction. The operator can also use the production control system 7 as the optional choice for changing the ink value(s). Any similarity to this embodiment will not be repeated.
Example 4
Built-in Monitoring Type of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
[0107] See FIG. 4 , provided is a housing of the production equipment 13 . A single data reading device is attached to the drive shaft 10 , the data reading device 5 travels back and forth as the arrow direction along the drive shaft 10 , carries the scanning head back and forth, accurately reads the ink film thickness from the surface of the ink film thickness sampling roller 9 . Using optical, electronic, digital transmission connection 11 delivers the data to the PLC programmable control device 12 for digitize the reading; it is an initiative and proactive production system for continuous monitoring and correction usages.
Example 5
Independent Single Piece External Type Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
[0108] See FIG. 5 , the production machine is not equipped with a sampling roller. This invention system needs to design an independent mechanical anchorage device, equipped with a frame 40 , by using fastening screws 41 to secure the connection bars 42 against the production machine's metering system housing 13 . Drive shaft 10 is equipped with a single data reading device 5 with operating back and forth as the arrow indication direction and working along the drive shaft 10 , to accurately scan the ink film thickness from the surface of the sampling roller 9 for the thickness value. Any similarity to this example will not be repeated.
Example 6
Independent Single Piece External Type Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
[0109] See FIGS. 6A, 6B , the system is equipped with a sampling roller. The system basic functionality is similar to that of FIG. 5 , and the only different is that the ink film thickness sampling roller 9 is installed at the frame 40 as part of the single piece monitoring modular. Any similarity to the embodiment 4 will not be repeated.
Example 7
Independent Single Piece External Type Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
[0110] See FIGS. 7A, 7B , the system is equipped with a sampling roller. The system needs to design an independent anchorage device, equipped with an installation frame 40 , by using fastening screws 41 to secure the connection bars 42 against the production machine metering system housing 13 . A single data reading device 5 is fixed onto the bracket. The reading device can collect the ink film thickness from the rotational reflector or similar reflection device, by changing the angle of measurement in between the sampling roller 9 surface, to accurately scan the ink film thickness for reading the value. Any similarity to the example 4 will not be repeated.
Example 8
Independent Single Piece External Type Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
[0111] See FIGS. 8A, 8B , the system is equipped with a sampling roller. The system needs to design an independent mechanical anchorage device, equipped with an installation frame 40 , by using fastening screws 41 to secure the connection bars 42 against the production machine metering system housing 13 . A single data reading device 5 is fixed inside the frame 40 , the reflector or similar reflective device is attached to the drive shaft 10 , back and forth traveling as arrow indicated direction, the reflector or similar reflective device has changed the measurement direction by 90 degree angles between the sampling roller 9 surface. Any similarity to the example 4 will not be repeated.
Example 9
Built-in Type Multi Units Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
[0112] See FIG. 9 , the production equipment housing 13 with permanent frame equipped with multi data reading devices 5 , accurately read the film thickness values from the surface of the film thickness sampling roller 9 . Any similarity to the example 4 will not be repeated.
Example 10
External Type Independent Multi Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
[0113] See FIG. 10 , the system is equipped with a sampling roller. The system needs to design an independent mechanical anchorage device, equipped with an installation frame 40 , by using fastening screws 41 to secure the connection bars 42 against the production machine metering system housing 13 . The multi unit data reading device 5 is fixed onto the permanent structure to accurately scan the ink film thickness values from the surface of the sampling roller 9 . Any similarity to the example 4 will not be repeated.
Example 11
Independent Multi Heads External Type Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
[0114] See FIG. 11A, 11B , the system is equipped with a sampling roller. The system basic design is similar to that of FIG. 9 , and the only different is that an ink film thickness sampling roller 9 is installed onto an independent anchorage device 40 . Any similarity to the example 4 will not be repeated.
Example 12
Laser Type Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
[0115] See FIG. 12 , provided is a laser construction. The system comprises active material 17 , which is placed between two reflective type mirrors 15 , 16 . A resonator 19 is formed by two reflective mirrors and the laser reflective material, by using this to provide the light beam. The atom of the laser active material has been activated by the external energy 21 , excited to the higher energy lever condition. The light beam bounces back and forth 20 between two mirrors and then forms an accurate fixed speed of light beam. To release the light beam from the resonator, one of the mirrors 16 can only rebound half of the light beam; this can allow the other half of the laser light beam 18 to freely go through the mirror.
[0116] See FIG. 13 , the data reading device 5 has been equipped with the laser resonator device, laser beam resonator, and light beam receiver to measure the light beam emission and receiving time, and calculate and record the non ink film bare roller surface 22 and the distance 31 between the data reading device. The mathematical formula is as below: displacement=speed of light×the total light traveling time between emission and receiving/2 times (Back and forth journey).
[0117] See FIG. 14 , the data reading device 5 has been equipped with the laser resonator device to measure the time between the light emission and receiver, and calculate and record the ink film thickness surface 23 and the distance 32 between the data reading device. The displacement result is used to calculate the ink film thickness. The ink film thickness mathematical formula as: the ink film thickness=the bare sampling roller without the ink film displacement 31 −the sampling roller adhering with ink film displacement 32 .
Example 13
Ultrasonic Scanning Type Monitoring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
[0118] See FIG. 15 , provided is an ultrasonic emitter 24 which is an electro-gas type ultrasonic generator 27 . Piezoelectric emitter comprises two pieces of transmitter chip 25 and a resonance plate 26 , and the ultrasonic resonance is generated by applying an external pulse signal onto the transmitter chip and creates vibration. Conversely, the ultrasonic receiver 30 comprises two piezoelectric chips 25 , the resonance plate 26 receives the external ultrasound 29 , and the ultrasonic wave energy will vibrate the resonance plates, which can convert this mechanical motion to electrode signal for time computing usages.
[0119] See FIG. 16 , the data reading device 5 is equipped with the ultrasonic emitter to measure the time between the sound wave emission and receiving, and calculate and record the bare roller surface 22 without ink film and the distance 31 between the data reading device. The ink film thickness mathematical formula as: displacement=340 (the speed of sound)×the total sound wave traveling time between emission and receiving/2 times (Back and forth journey)
[0120] See FIG. 17 , the data reading device 5 is equipped with the ultrasonic emitter, to measure the time between the sound emission and receiver, and calculate and record the ink film thickness surface 23 and the distance 32 between the data reading device. The displacement result is used to compute the ink film thickness. The ink film thickness mathematical formula as: the ink film thickness=the bare sampling roller without ink film displacement 31 −the sampling roller adhering with ink film displacement 32 .
Example 14
Optical Type Measuring Device of an Initiative Proactive Intelligent Controlling Modular for Controlling the Fluid Type Film Thickness
[0121] See FIG. 18 , provided is an optical color density and color gamut brightness reflective measuring. The measuring system comprises a standard illumination lighting 43 , optical lenses construction component 44 , filter 45 , spectrometer 46 , and optical computing device 50 . The reading method is to measure the light reflective data 48 from the reflective material 47 . By using the appropriate light source D50, D60 to shine over the measuring subject, the reflective measurement such as paper 47 . Such light source penetrates through the examination material to the substrate layer, and then bounces back through the examination material with carrying certain density (the rate of filtering) to reduce the intensity for computing the color density or color brightness or individual color value digitally. The measuring material under illumination by lighting system, the amount of light of reflection, through the optical lenses component and filter, are directly transmitted to the spectrometer or digital imaging device (CCD, CMOS) for measurement. Use the optical computer to accurately analyze the color density or color gamut brightness values.
[0122] See FIG. 19 , provided is an optical color density and color gamut brightness penetration measuring. The measuring system comprises a standard illumination lighting 43 , optical lenses construction component 44 , filter 45 , spectrometer 46 , and optical computing device 50 . The reading method is to measure the light penetration data 48 through the sampling material 49 . Use the appropriate light source D50, D60 to shine onto the measuring subject, and get the penetrative measuring from the transparent film media 49 density. Such light source will depend on the density of the measuring material (rate of transparent) to reduce the intensity for computing the color density or color gamut brightness or individual color value digitally. The measuring material under illumination by lighting system, the amount of light of penetration, through the optical lenses component and filter, are directly transmitted to the spectrometer or digital imaging device (CCD, CMOS) for measurement. Use the optical computer to accurately analyze the color density or color gamut brightness values.
[0123] Implementation of the method for the fluid type films is equipped with the direct and indirect controlling systems and devices.
[0124] Set a fixed distance 33 in mechanical way that the fluid thickness can pass through. The excessive fluid film 37 will be collected by the adjustable mechanical spacing roller 34 and doctor blade 35 . This controlling system is equipped with data reading device 5 for monitoring whether there is any excessive fluid film and real time re-adjust the dispensing value and re-set the distance 33 for controlling the film thickness. The doctor blade installation can be a direct and in-direct method.
Example 15
[0125] FIG. 22 and FIG. 23 show a direct-type system and device. The sampling roller 9 is equipped with a doctor blade 35 with pre-determined distance for collecting the excessive fluid type film. Such a distance 33 is the spacing which can make the fluid films pass through. The excessive fluid film 37 will be removed by the doctor blade and store at the container 36 for re-cycling back to the dispensing duct. The container is equipped with a data reading device 5 , which is used to monitor whether there is any excessive fluid film collected. If the device 5 has detected signal, then the amendment command will be sent in real time to the PLC controlling unit 12 for digitize the signal. The material duct changes the dispensing value and the spacing 33 by the doctor blade 35 for direct control of the film thickness. This system is an initiative and proactive consistent monitor to amend the fluid film thickness requirement.
Example 16
[0126] FIG. 24 and FIG. 25 show an indirect-type system and device. The sampling roller 9 is equipped with a roller 34 with pre-determined spacing to collect the excessive fluid film. The roller surface is equipped with a tight fit doctor blade 35 . Such a distance 33 is the spacing for fluid films to pass through. The excessive fluid films 37 will be removed by the pre-determined spacing roller; the tightly contacted doctor blade will continuously collect the excessive fluid from the pre-determined spacing roller and store at the container 36 for re-cycling back to the dispensing duct. The container is equipped with a data reading device 5 , which is used to monitor whether there is excessive fluid films collected. If the device 5 has detected signal, then the amendment command will be sent in real time to the PLC controlling unit 12 for digitizing the signal. The material duct amends the dispensing value and re-determines the spacing 33 by the pre-determined spacing roller 34 for direct control of the film thickness. This system is an initiative and proactive consistence monitor to amend the fluid film thickness requirement.
Example 17
[0127] FIG. 26 : show the different work flow for the proactive intelligent controlling method for fluid type color printing ink film thickness value vs the traditional passive color film thickness controlling method.
[0128] The proactive intelligent controlling method for fluid printing ink film thickness value work flow has begun with:
a) color film delivered by production equipment to begin the production; b) by using the proactive control system for checking color film thickness value to analyze the color film thickness whether acceptable or out of range; c) if out of range, the closed loop repeated adjustment for color film thickness to determine the new thickness value for color film delivered by production equipment and continuous the next production cycle; and d) if acceptable, the correct color film will deliver onto the substrate for finishing printing to become finished product.
[0133] The traditional passive color film thickness controlling method work flow has begun with:
a) color film delivered by production equipment to begin the production; b) whatever color film thickness on the equipment will deliver onto the substrate for finishing production to become finished product; c) after the product being made, the passive system of quality control module to conduct the quality inspection process for analyzing whether the finished product is unacceptable or not; d) for any unacceptable product shall become defect products which has already been produced; and e) based on the defect result to determine the correction value, and then execute the delivering correction color film thickness process for entering the next production cycle. | A method for monitoring production of a fluid film, including: activating a dispenser to deliver appropriate material from a storage duct to a metering system for even distribution of a fluid film; allowing the fluid film to pass a sample retrieving roller; measuring the fluid film on the sample retrieving roller using a data reading device to obtain film thickness data; transmitting the data to an analyzer to examine the data against a predetermined reference value; transmitting a comparison result in real time by the analyzer to a production equipment controlling console; controlling the storage duct to dispense material through the material metering system and adjusting the film thickness; repeating the above steps to make a film thickness within the reference range; and maintaining the thickness at the narrowest tolerance deviation, and continuously delivering the film onto a substrate for production. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a CATV system, and to a data transmission process in a CATV system for transmitting data from terminal equipment to a head end system at a rapid rate.
Many CATV systems are characterized by two-way data communication through cables between the head end system and terminal equipment so that the head end can obtain data from a number of terminal devices and provide for communication with the remote terminals. The two-way communication is normally carried out by polling or interrogation to identify a terminal device. With an increased number of terminal devices, however, each terminal device should still be polled and data should be received in response to such polling. This requires a long total period to poll all of the terminal devices individually, and results in a variety of difficulties. For example, security service requires that data identifying the occurrence of a fire, burglary, gas leakage or the like in a home equipped with a terminal device be transmitted without delay in order to minimize danger and damage. Accordingly, it is undesirable to be required to have a long polling period under these circumstances.
SUMMARY OF THE INVENTION
With the foregoing problem in view, the present invention provides a data transmission process in a CATV system wherein a plurality of addressable terminal devices having addresses are grouped into sets, and the terminal devices in each set are connected to an addressable data transmitting and processing device having an address by a conductor, so that the terminal devices associated with each data transmitting and processing device are addressably interrogated thereby and data from each terminal device is stored in the data transmitting and processing device, and can be transmitted to a head end at a rapid rate by addressably interrogating or polling the data transmitting and processing devices.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the invention may be had by reference to the following description, taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a schematic diagram illustrative of a CATV system; and
FIG. 2 is a block diagram showing an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Generally, a CATV system is characterized in that a center or head end system is wired with a number of terminal devices equipped in individual homes for transmitting a radio wave picked up by the head end or a program produced by the head end to a television receiver at each individual home. This system allows the head end to be connected to each home by a conductive cable for mutual exchange of information by way of two-way-communication between the head end and each home, so that a variety of applications are possible as well as transmission of TV programs to individual television receivers.
Such CATV system will be described with reference to FIG. 1. The system comprises a single center or head end 1 and an addressable 28 located in each of several tens of thousands of homes 2, the head end 1 being connected by coaxial cables to the terminal devices 28 in the homes 2. A main cable 3 extends from the head end 1 and has in predetermined positions main cable amplifiers 4 and branching circuits 5, from each of which there extend a plurality of branch cables 6 each having a predetermined positions booster amplifiers 7 and tap-offs 8. A plurality of branch cables 9 extend from each tap-off 8 and each are led into individual ones of the homes 2. The terminal device 28 in the home 2 comprises a main remote box 10, a television receiver 11, and a control box 12. The distal end of each branch cable 9 is connected to the main remote box 10, to which the television receiver 11 and the control box 12 are connected. Stated otherwise, the head end is branched and connected to the terminal devices 28 in the individual homes in a network which assumes the shape of a "christmas tree" as a whole.
The head end 1 has an outdoor antenna 13 connected to a demodulator 15 in a group 14 of signal sources, such as a video disk player 16, a video tape recorder 17, and a studio 18. A modulator and transmitter 19 which receives signals from the signal source group 14 consists of two systems, one including an IF modulator circuit 20, a scramble circuit 21, and an up-converter circuit 22, and the other including an IF modulator 23 and an up-converter circuit 24. The outputs of the up-converters 22, 24 are connected to the main cable 3. The main cable 3 is connected to a data transmitter and receiver 25 for data transmission with each main remote box 10, the data transmitter and receiver 25 being connected to a computer 26 which is connected to peripheral equipment 27 such as a printer and a display unit.
Operation of the CATV head end system is as follows: The television receiver 11 is switched on with a certain unused channel being selected, and the remote control box 12 is actuated such that the channel to be utilized by the main remote box 10 is frequency-converted into the unused channel. Channels selectable by the remote control box 12 are grouped, for example, into (A) re-transmission channels in which television radio waves are received as they are, (B) channels for sustaining programs (free of charge), and (C) channels for free-charging programs. Each group has 10 channels and the viewer has a total of 30 channels to choose from.
(A) Re-transmission
The television radio wave picked up by the antenna 13 is first demodulated by the demodulator 15, which produces an output to the modulator and transmitter 19, wherein it is modulated by the IF modulator 23. A modulated signal is then processed by the up-converter 24 so as to have a predetermined higher frequency according to a new frequency arrangement for rearranging channels. The signal which is thus modulated for assignment to a predetermined channel is fed through the main cable 3, the branch cable 6, and the branch cable 9 to the television receiver 11 for reproduction.
(B) Sustaining program
This is represented by a weather forecast, a news program and the like. A recorded program reproduced by the video disk player 16 or the video tape recorder 17 or a live program produced in the studio 18, is modulated by the IF modulator 23 and the up-converter 24, and its frequency is multiplied up to a predetermined channel frequency before being fed through the main cable 3. The program is free of charge regardless of frequency and time interval of reception and each home can receive such programs by paying a basic rate each month.
(C) Chargeable program
This includes a newly arrived movie or a certain other program. A recorded program reproduced by the video disk player 16 or the video tape recorder 17, or a live program produced in the studio 18, is modulated by the IF modulator 20, and is processed by the scrambler 21 into a signal that cannot be properly reproduced if received as it is. Then, its frequency is multiplied by the up-converter 22 up to the frequency for a predetermined channel before it is fed through the main cable 3. When this chargeable program is to be received at each home 2, the fed signal is descrambled by the main remote box 10 into a normal video signal, which is then fed to the television receiver 11 for normal reproduction. Reception of chargeable programs leads to calculation of a predetermined rate, and the subscriber will be billed monthly for a special subscription rate (measured rate) in addition to a monthly basic rate.
While the head 1 and each home 2 are interconnected by the coaxial cable, it is necessary to ascertain which home 2 is receiving which channel during a certain time to tell whether a program being received is chargeable or not, so that the CATV system will be commercially feasible. To this end, the data transmitter and receiver 25 sends out an interrogation signal at a given interval of time to poll each terminal device 28 with its own address number, thereby ascertaining which channel is being received on such inspection. An addressable data transmitter 36 within the terminal device 28 then gives an answer as to which channel is being received, to the data transmitter and receiver 25. Transmitted and received data in the data transmitter and receiver 25 is sorted and stored by the computer 26, and is displayed or printed by the peripheral equipment 27. Such polling is carried out at a given interval of time (every several minutes or several tends of minutes), so that popularity ratings and the like for programs are available immediately.
In such a program which involves participation of viewers, the viewers actuate the remote control boxes 12 to respond to the program while looking at the receivers 11, the responses being fed to the head end 1 through the coaxial cables.
FIG. 2 shows an embodiment of the present invention, in which branch cables 6 from branching circuits 5 have data transmitting and processing devices 30-33 at predetermined intervals. The data transmitting and processing devices 30-33 are connected to a plurality of terminal devices 28 separated into groups A, B, C and D. Each of the data transmitting and processing devices 30-33 has its own address and is capable of polling or calling the addresses of the terminal devices 28 in one of the groups A-D to which it is connected. The data transmitting and processing devices 30-33 each have data store 40 providing a capability of storing data from the terminal devices 28 and function to serve as branch devices.
Operation of this embodiment is as follows: A downstream signal from the head end 1 is fed through the main cable 3, the branching circuits 5, the data transmitting and processing devices 30-33, and the branch cables 9 to each terminal device 28 for reception of a television program. Each data transmitting and processing devices 30-33 has a polling device 42 which always polls the terminal devices 28 to which it is connected, and a receiver 44 which receives data from the terminal devices 28 and processes such data and stores the results. Independently of the polling by the data transmitting and processing devices 30-33 of the terminal devices 28, the head end 1 polls the addresses of the data transmitting and processing devices 30-33. Assuming that a data transmission and processing device 30 is polled, it sends out, through an addressable transmitter 46, data stored therein in response to its polling, as an immediate upstream signal to the head end 1. Thus, all data in the terminal devices 28 in the group A is transmitted to the head end 1 by a single polling. By successively polling the other data transmitting and processing devices 31-33, data in the terminal devices 28 in the groups B, C, D are transmitted to the head end 1. Thus, in addition to the polling by the head end 1 of the data transmitting and processing devices 30-33, the latter also poll the terminal devices 28, with the result that the period of polling can be reduced as compared with the polling by the head end 1 of all of the terminal devices 28.
With the present invention thus arranged, the total polling period is shortened to allow much faster transmission of data from all terminal devices. The present invention is therefore applicable to a CATV system having a multiplicity of terminal devices. | In a bidirectional CATV system, terminal devices at individual subscriber locations are arranged in sets, with each terminal device in a set being coupled to an intermediate polling processor which includes means for storing status data as to each of the terminal devices. The head end system polls the intermediate processors for their consolidated reports, with the result that tens of thousands of subscriber locations can be serviced without inordinate delays by a single head end system. | 7 |
.[.This application is a continuation of application Ser. No. 022,275, filed Mar. 5, 1987, now abandoned, which was a continuation-in-part application of Ser. No. 870,010, filed Jun. 3, 1986, now abandoned..]..Iadd.
CROSS REFERENCE
This application is a Re-issue of Ser. No. 07/296,411 filed Jan. 09, 1989, U.S. Pat. No. 4,996,320, which is a Continuation of Ser. No. 07/022,275 filed Mar. 05, 1987, (abandoned), which is a Continuation-in-part of Ser. No. 06/870,010 filed Jun. 03, 1986 (abandoned). .Iaddend.
BACKGROUND OF THE INVENTION
The present invention relates to a N-fluoropyridinium salt and a process for preparing same. The N-fluoropyridinium salts according to the present invention are very useful as a fluorine atom introducing agent as seen from the examples 66-133 hereinafter illustrated. The salts according to the invention have a widespread use because of their high reactivity with a wide variety of compounds and selectivity for any desired products. For example, said salt can be used for the preparation of 3-fluoro-4-hydroxyphenlacetic acid which is useful as a thyroid inhibitor by reacting the former with p-hydroxyphenylacetate followed by a common hydrolysis reaction as illustrated in examples 79 to 82 referred to hereinafter.
Heretofore, it has been well known in the art that fluorine compounds are significantly distinguished from chlorine compounds, bromine compounds, and iodine compounds in their physical properties and reactivities, because fluorine atom have characteristics such as very high electronegativity, high ionization energy, extremely high bonding ability with other atoms, small Van der Waals diameter, lack of a d-electron orbit and the like (N. Ishikawa & Y. Kobayashi; FLUORINE COMPOUNDS; THEIR CHEMISTRY AND APPLICATIONS; KodanshaSchientific, pp. 69-70. 1979). Therefore, fluorination reactions naturally have significantly different aspects from other halogenation reactions such as chlorinations, brominations and iodinations.
In reactions with organic compounds, fluorine, contrary to chlorine, bromine and iodine, reacts very violently, readily giving rise to the fission of the C--C bond of organic compounds and in cases where the reaction is excessively violent, fire or explosion in turn can break out. The abnormality of fluorination reactions relative to other halogenation reactions may be readily understood from the comparison of heat of formation in halogenation reactions (see the description on pages 69-75 of the above article) as follows:
______________________________________ ΔH (Kcal/mol)type of reaction X = F Cl Br I______________________________________C═C + X.sub.2 --CX--CX -111 -36 -23 -16C--H + X.sub.2 --C--X + HX -105 -25 -9 +6______________________________________
As seen from the above Table, since the heat of reaction in the fluorination reactions amount to ever 100Kcal/-mol, while the bonding energy between carbon-carbon atoms is approximately only 60Kcal/mol, the control of fluorination reactions is very difficult, contrary to other halogenation reactions. Accordingly, the development of fluorination reactions having better selectivity has been an important subject matter in fluorination industries.
For the purpose resolving the above problem, a wide variety of compoounds for introducing fluorine atoms have heretofore been studied and developed. As such compounds, for example, trifluoromethyl-hypofluorite (CF 3 OF), trifluoroacetyl-hypofluorite (CF 3 COOF), acetyihypofluorite (CH 3 COOF), xenon difluoride XeF 2 ), FClO 3 , sulfur tetrafluoride (SF 4 ), die-thylaminosulfur trifluoride (ET 2 NSF 3 ), CClHFCF 2 NEt 2 ,CF 3 CFHCF 2 NEt 2 , heavy metal fluorides such as AgF, HgF, CoF 3 ,AgF 2 and the like were known in the art (see pages 79-94 of the above-mentioned article). However, these compounds have drawbacks such as poor selectivity for the desired reaction, are highly hazardous to handle, have high cost, unstableness, a limited scope of application, and the like which make them commercially unsatisfactory. On the other hand, hydrogen fluoride, hydrofluoric acid, potassium fluoride, cesium fluoride, and the like which are known as inexpensive agents for introducing fluorine atoms are inferior in electrophilic reactivity, which imposes such limitations that they cannot perform electrophilic substitutions for aromatic nuclei or negatively charged carbon ions. These compounds also present serious problems in handling because hydrogen fluoride or hydrofluoric acid, for example, are highly toxic. It has been suggested that a pyridine. F 2 complex can be used as a fluorine atom-introducing agent, but it can only offer low total yield of fluorination reactions [see, Z. Chem., 12, 292 (1972)] and moreover, said complex is highly hygroscopic and thermally unstable so that explosions may break out at above -2°C. [Z. Chem., 5, 64 (1965)]. From the above, it can hardly be said that the complex is a useful fluorinating agent. Recently, N-fluoro-N-alkylarenesulfoneamide have been reported as fluorine atom-introducing agents, but these compounds are low in reactivity and only effective for particular reaction species (negatively charged carbon ions) [J. Amer. Chem. Soc. 106, 452 (1984)]. Therefore, a strong need exists for the development of highly satisfactory fluorine atom-introducing agents.
As a result of a series of earnest investigations by the present inventors towards the development of a novel fluorine-introducing agent, they have succeeded in developing a novel fluorine-introducing agent which is active but stable allowing the easy handling of the agent which still retains high selectivity of a desired reaction, thus completing the present invention. The compounds according to the present invention have high reactivity with a variety of compounds and high selectivity for any desired compounds, which allows the compounds to be very useful for the synthesis of a variety of fluorine-containing compounds in a shortened process. For example, a thyroid inhibitor, 3-fluoro4-hydroxy-phenylacetic acid could easily be prepared from p-hydorxyphenylacetate available industrially (see, Examples 79-82 hereinafter described).
SUMMARY OF THE INVENTION
The present invention relates to a N-fluoropyridiuium salt represented by the formula: ##STR1## wherein R 1 , R 2 , R 3 , R 4 and R 5 represent a hydrogen atom, a halogen atom, an alkyl, aryl, acyl, alkoxycarbonyl, aryloxycarbonyl, carbamoyl, nitro, cyano, alkylsulfonyl arylsulfonyl, hydroxy, alkoxy, aryloxy, acyloxy, acylthio, amido, alkanesulfonyloxy, or arenesulfonyloxy group; X.sub.⊖ represents a conjugate base of Bronsted acid except for F.sub.⊖, Cl.sub.⊖, Br.sub.⊖ and I.sub.⊖ which are conjugate bases of hydrogen halides; and R 1 , R 2 , R 3 , R 4 and R 5 may be combined together directly or through a hetero atom or atoms in a variety of combinations to form a cyclic structure, while X.sub.⊖ may be combined directly or through a hertro-atom or atoms with R 1 , R 2 , R 3 , R 4 and R 5 in various combinations.
The present invention further relates to a process for producing the above N-fluoropyridinium salt by reacting a pyridine-compound having the general formula: ##STR2## wherein R 1 to R 5 represent the same meaning as defined above, with fluorine (F 2 ) and a Bronsted acid compound having the general formula:
XM (III)
wherein M represents a hydrogen atom, a metal atom, an ammonium residue, a pyridinium residue or a group SiR 6 R 7 R 8 in which R 6 ,R 7 and R 8 are an aklyl, aryl, alkoxy, aryloxy, acyloxy group, or a halogen atom; and X represents the same meaning as above.
DETAILED DESCRIPTION OF THE INVENTION
The pyridine-copmpounds set forth in formula (II) employable in the present invention are those which are easily available or which may be prepared readily and are exemplified by pyridine; straight or branched alkylated or cyclic alkylated pyridine such as methyipyridine, dimethylpyridine, trimethylpyridine, tetramethylpyridine, pentamethylpyridine, ethylpyridine, diethylpyridine, butylpyridine, dibutylpyridine, tributylpyridine, pentylpyridine, hexylpyridine, decylpyridine, (trifluoromethyl)-pyridine, bis(trifluoromethyl)pyridine tris(trifluoromethyl)-pyridine, (trichloromethyl)pyridine, (pentafluoroethyl)-pyridine, (perfluorooctyl)pyridine, (methoxymethyl)pyridine, ethyl pyridylacetate, pyridylacetonitrile, pyridylacetone, and the like; halopyridines such as chloropyridine, bromopyridine, fluoropyridine, dichloropyridine, difluoropyridine, trichloropyridine, tetrachloropyridine, pentachloropyridine, trifluoropyridine, pentafluoropyridine, chlorofluoropyridine, dichlorofluoropyridine, and so on; (trifluoromethyl)chloropyridine, (trifluoromethyl)dichloropyridine, (trifluoromethyl)trichloropyridine, (trifluoromethyl)fluoropyridine, methylchloropyridine, phenylpyridine, diphenylpyridine, triphenylpyridine,-dipyridyl, acetylpyridine, bisacetylpyridine, benzoylpyridine;(alkoxycarbonyl)pyridine or (aryloxycarbonyl)pyridine such as (methoxycarbonyl)-pyridine,(exthoxycarbonyl)pyridine,(butoxycarbonyl)pyridine, bis(ethoyxcarbonyl)pyridine,bis(trifluoroethoxycarbonyl)-pyridine, tris(methoxycarbonyl)pyridine,(-phenoxycarbonyl)-pryidine; 2,3-pryidinedicarboxylic anhydride,nitropyridine, cyanopyridine, dicyanopyridine, tricyanopyridine, benzenesulfonylpyridine, methylsulfonylpyridine, chlorocyanopyridine, formylpyridine, (haloformyl)pyridine, nicotinamide,picolinamide, (dimethylaminocarbonyl)pyridine, methoxypyridine, dimethoxypyridine, propoxypyridine, butoxypyridine, menthoxypyridine, trifluoromethoxypyridine, acetoxypridine, trifluoroacetoxypyridine, phenoxypyridine, acetylthipoyridine, methanesulfonyloxypyridine, benzenesulfonyloxypyridine, acetylaminopyridine,3-hydroxypyridine, and 1,2,3,4,5,6,7,8-octahydroacridine.
As the .[.Brosted.]. .Iadd.Bronsted .Iaddend.acid-compounds represented by the formula (III), there may be mentioned the following compounds: sulfonic acids or sulfuric acids such as methanesulfonic acid, butanesulfonic acid, benzensulfonic acid, toluenesulfonic acid, nitrobenzensulfonic acid, dinitrobenzensulfonic acid, trinitrobenzensulfonic acid, trifluoromethanesulfonic acid, perfluorobutanesulfonic acid, perfluorooctanesulfonic acid, trichloromethanesulfonic acid, diflurormethanesulfonic acid, trifluoroethanesulfonic acid, fluorosulfonic acid, chlorosulfonic acid, monomethylsulfric acid, sulfuric acid, camphorsulfonic acid, bromocamphorsulfonic acid, Δ 4 -cholestene-3-on-6-sulfonic acid, 1-hydroxy- p-methane-2-sulfonic acid, p-styrenesulfonic acid, β-styrenesulfonic acid, poly(p-styrenesulfonic acid), vinyl-sulfonic poly(vinylsulfonic acid), poly(2-acrylamide-2-methyl-1-propanesulfonic acid), and a copolymer of said propanesulfonic acid with styrene, perfluoro-3,5-dioxa-4-methyl-7-octenesulfonic acid, poly(-perfluoro-3,6-dioxa-4-methyl-7-octensulfonic acid) and a copolymer of said octnesulfonic acid with tetrafluoroethylene, and the like; phosphoric acid; nitric acid; halogen acids such as perchloric acid, perbromic acid, periodic acid, chloric acid, bromic acid, and the like; carboxylic acids such as acetic acid, formic acid, trichloro-acetic acid, trifluoroacetic acid, pentafluoropropionic acid, dichloroacetic acid, acrylic acid, poly(acrylic acid), poly-(perfluoro-3,6-dioxa-4-methyl-7-octenoic acid) and a copolymer of said octenoic acid with tetrafluoroethylene and so on; compounds resulting from hydrogen halide and Lewis acids such as HBF 4 , HPF 6 , HSbF 4 , HSbF 6 , HAsF 6 , HBCl 3 F, HSiF 5 and the like; metal salts of the above mentioned .[.Brosted.]. .Iadd.Bronsted .Iaddend.acids; a variety of ammonium salts or pryidinium salts of the above mentioned .[.Brosted.]. .Iadd.Bronsted .Iaddend.acids; silyl compounds resulting from the substitution of hydrogen atom or atoms of the above mentioned .[.Brosted.]. .Iadd.Bronsted .Iaddend.acids with a group SiR 6 R 7 R 8 wherein R 6 , R 7 and R 8 are the same as defined above, or metal bifluoride such as sodium bifluoride, for example. As the group SiR 6 R 7 R 8 , there may be listed, for example, trimethylsilyl, triethylsilyl, dimethylbutylsilyl, dimethylphenylsilyl, triphenylsilyl, trihalosilyl, triacetylsilyl, triacetoxysilyl, trimethoxysilyl, triphenoxysilyl. As the metals for the metal salts of Brosted acids reference is preferably made to alkali metals or alkaline earth metals from the aspect of economy and reaction efficiency. Further, as the variety of ammonium salts or pyridinium salts, there may be mentioned ammonium salts, trimethylammonium salts, triethylammonium salts, tetraethylammonium salts, benzyltrimethylammonium salts, phenylammonium salts, dimethylphenylammonium salts, naphthaylammonium salts, pryidinium salts, dimethylpyridinium salts, trimethylpyridinium salts, quinolinium salts and the like.
Of the N-fluoropyridinium salts represented by formula (I), in the case where X.sub.⊖ and R 1 , R 2 , R 3 , R 4 and R 5 are combined together in a variety combinations, the pyridinium compounds represented by formula (II) as the raw material include, for example, sodium pyridinesulfonate, pyridinesulfonic acid, ammonium pyridinesulfonate, potassium pyridylethylsulfonate, sodium pyridinecarboxylate and the like.
The pyridine.F 2 complex where X.sub.⊖ represents F.sub.⊖ which is the conjugatge base of hydrogen halide in the N-fluoropyridinium salts has a serious drawback in that it is unstable and explodes at a temperature above -2° C. and when the conjugate base is Cl.sub.⊖, Br.sub.⊖ or I.sub.⊖ the corresponding N-fluoropyridinium salts are difficult in synthesis.
The Brosted acid-compounds for achieving better reaction efficiencies should be equal to or in excess molar amount to that of the host material, but preferably should be an equi-molar amount from an economic viewpoint. Fluorine employed in the present invention should preferably be diluted with 50 to 99.9% by volume of an inert gas in order to suppress any violent reactions. The diluting gas includes, by way of example, nitrogen, helium, argon, tetrafluoromelthane, sulfur hexafluoride and the like.
The fluorine gas for achieving better reaction efficiencies should be used in an equi-molar or in excess molar amount to be the host material. However since the amount may vary depending upon the manner of introduction, reaction temperature, reaction solvent, reaction apparatus and so on, it may preferably be selected in amounts required for eliminating the last traces of the host material.
The reaction is preferably carried out by the sue of a solvent. As the solvent, acetonitrile, methylene chloride, chloroform, carbon tetrachloride, trichlorofluoromethane, trichlorotrifluoroethane, ethyl acetate, diethyl ether, tetrahydrofuran, and the like or a mixture thereof may be used.
A reaction temperature of -100° to +40° C. may be selected, but the range of temperature of from -90° C. to room temperature is being preferred for better reaction yields.
In carrying out the process of the present invention it is occasionally preferable for improving the reaction efficiency to employ a trapping agent such as sodium fluoride to capture hydrogen fluoride produced as a by-product.
Of the N-fluoropyridinium salts having the formula (I), N-fluoropryidinium salt having the formula ##STR3## (wherein R 1 to F 5 have the same meaning as above and Y represents a Lewis acid), can be prepared by reacting the pyridine-compound represented by formula (II) with fluorine (F 2 ) and a Lewis acid having the formula
Y (IV)
The Lewis acid, the starting material set forth in formula (IV), may include, for example, boron trifluoride, boron trichloride, triacetoxyboron, tri(tgrifluoroacetoxy)boron, aluminum trifluoride, aluminum trichloride, aluminum tribromide, phosphorous trifluoride, phosphorous pentafluoride, phosphorus pentachloride, arsenic trifluoride, arsenic trichloride, arsenic pentafluoride antimony trifluoride, antimony pentafluoride, antimony dichlorotrifluoride, silicon tetrafluoride, trimethylfluorosilane, dimethylphenylfluorosilane, sulfur trioxide, titanium tetrachloride, stannic chloride, ferric chloride, and iodine pentafluoride. Ethereal complexes of these Lewis acids may also employed without any problems. These Lewis acids may be employed in an equi-molar or in excess molar amount to he host material (II) for achieving a better reaction efficiency, but from the standpoint of economy the equi-molar amount be preferable. The manner in which fluroine is used and the amount of fluorine to be used are similar to the above embodiment.
A reaction of the present invention is preferably carried out by using a reaction solvent. The reaction solvent may include, for example, acetonitrile, methylenechloride, chloroform, trichlorofluoromethane, trichlorofluoroethane, ethylacetate, diethylether, tetrahydrofuran or a mixture thereof.
A reaction temperature may generally be in the range of .[.-100+'° C., .]. .Iadd.-100° to +40° C. .Iaddend.and preferably a range of .[.-90+° C. .]. .Iadd.-90° to +20° C. .Iaddend.may be selected for a better yield.
The compounds (I) according to the present invention can be readily prepared and are in most cases stable in air at room temperature. These compounds enable the simple and selective introduction of a fluorine atom to a comtemplated compound with good efficiency and therefore serve as a superior fluorine-introducing agent. Further, the compounds according to the present invention, after they have once been reacted, reproduce the pyridine-compounds or form protonic salts of silyl salts of pyridine-compounds which can readily generate the starting pyridine-compounds by neutralization or treatment with water.
The following examples will illustrate the present invention in more detail.
EXAMPLE 1
Preparation of N-fluoropyridiniumtrifluoromethanesulfonate ##STR4##
To a 50 ml trichlorofluoromethane solution containing 1.0 g (12.6 m moles) of pyridine a mixed gas of fluorine and nitrogen in a volumetric ratio of 1:9 was introduced at a rate of 30 ml/min. at -78° C. under vigorous stirring. The amount of the fluorine gas introduced amounted to 34.8 mmoles. Subsequent to the fluorine introduction, 20 ml of anhydrous acetonitrile and 2.2 g (12.8 mmoles) of sodium trifluoro-methanesulfonate as a XM reactant were added to the reaction solution after which the temperature of the solution was raised to -40° C., while removing the solvent with the aid of an aspirator. The solvent, after filtering sodium fluoride formed as a byproduct, was distilled off and the resultant residue was recrystallized from THF to give 1.75 g (yield: 67%) of N-fluoropyridinium trifluoromethanesulfonate, the physical properties of which are shown in Table 6.
EXAMPLE 2
Preparation of N-fluoropyridiniumtrifluoromethanesulfonate ##STR5##
To a 100 ml anhydrous acetonitrile solution containing 10 g (0.126 mole) of pyridine a mixed gas of fluorine and nitrogen was introduced at a rate of 90 ml/min. at -4020 C. under virorous stirring. The amount of the flourine gas introduced amounted to 0.18 mole. Subsequent to the fluorine introduction, 22 g (0.128 mole) of sodium trifluoromethanesulfonate as a XM reactant was added to the reaction solution after which the resultant reaction solution was maintained at -40° C. for 5 hours under stirring. Subsequently, the solvent, after filtering sodium fluoride, was distilled off and the resultant residue was recrystallized from methylene chloride to give 17.5 g (yield: 71%) of N-fluoropyridinium trifluoromethanesulfonate. The product thus obtained was repurified with methylene chloride/acetonitrile to recover 13.8 g (yield: 56%).
EXAMPLES 3-15
Example 3 was carried out as in Example 1 and Examples 4-15 were carried out as in Example 2. The reactants used and the results obtained are shown in Table 1 and the physical properties of the products are shown in Table 6.
Further, Example 12 employed sodium D-camphorsulfonate as the XM reactant and the angle of specific rotatory power of the product was [α] D 22 =+29.51 (c=0.664, CH 3 CN).
TABLE 1__________________________________________________________________________pyridine- yieldExamplecompound XM product (%)__________________________________________________________________________ ##STR6## CF.sub.3 SO.sub.3 Na ##STR7## 604 ##STR8## NaPF.sub.6 ##STR9## 345 ##STR10## NaSbF.sub.6 ##STR11## 516 ##STR12## NaClO.sub.4 ##STR13## 727 ##STR14## CF.sub.3 SO.sub.3 H ##STR15## 448 ##STR16## CF.sub.3 SO.sub.3 SiMe.sub.3 ##STR17## 459 ##STR18## CF.sub.3 SO.sub.3 H ##STR19## 4110 ##STR20## CF.sub.3 SO.sub.3 SiMe.sub.3 ##STR21## 6211 ##STR22## FSO.sub.3 H ##STR23## 4912 ##STR24## ##STR25## ##STR26## 5013 ##STR27## FSO.sub.3 H ##STR28## 5614 ##STR29## CF.sub.3 COOSiMe.sub.3 ##STR30## 7715 ##STR31## CF.sub.3 SO.sub.3 H ##STR32## 60__________________________________________________________________________
EXAMPLE 16 ##STR33##
In 20 ml of anhydrous acetonitrile 0.50 g (4.67 mmoles) of 2.6- dimethylpyridine and 0.803 g (4.67 mmoles) of sodium trifluoromethanesulfonate as the XM reactant were dissolved, and to the resultant solution a mixed gas of fluorine and nitrogen (1:9) was added at a rate of 30 ml/min. at -40° C. under vigorous stirring. The amount of the fluorine gas introduced amounted to 8.93 mmoles. After the completion of the reaction, sodium fluoride was filtered and the solvent was distilled off. The resultant residue was recrystallized from THF to give 0.88 g (yield: 73%) of N-fluoro-2,6-diemthyl-pyridinium trifluoromethanesulfonate. The resultant product was further recrystallized with THF/acetonitrile to obtain 0.82 g (yield: 69%), the physical properties of which are shown in Table 6.
EXAMPLES 17-26
Examples 17-26 were carried out as in Example 16 and the results are shown in Table 2 with the physical properties in Table 6. In Example 22, 2 -1-menthoxypyridine [[α]D 20 =-110.7 (c=0.994, CHCl 3 )] was used as the pyridine compound for the starting material and the specific rotary power of the resultant N-fluoro-2-1-menthoxypyridinium trifluoromethanesulfonate was [α]D 25 =-77.73 (c=4.16, CHCl 3 ).
TABLE 2__________________________________________________________________________Pyridine- YieldExampleCompound XM Product (%)__________________________________________________________________________17 ##STR34## CF.sub.3 SO.sub.3 Na ##STR35## 8218 ##STR36## CF.sub.3 SO.sub.3 Na ##STR37## 7219 ##STR38## n-C.sub.4 F.sub.9 SO.sub.3 Na ##STR39## 8720 ##STR40## CF.sub. 3 SO.sub.3 Na ##STR41## 6021 ##STR42## CF.sub.3 SO.sub.3 Na ##STR43## 7322 ##STR44## CF.sub.3 SO.sub.3 Na ##STR45## 5723 ##STR46## CF.sub.3 SO.sub.3 Na ##STR47## 9024 ##STR48## CF.sub.3 SO.sub.3 Na ##STR49## 1925 ##STR50## CF.sub.3 SO.sub.3 H ##STR51## 7526 ##STR52## CF.sub.3 SO.sub.3 Na ##STR53## 60Example 27 ##STR54##
To a 5 ml anhydrous acetonitrile solution containing 0.408 g (5.17 mmoles) of pyridine, 1.0 ml (5.17 mmoles) of trimethylsilyl trifluoromethanesulfonate as the XM reactant was added at -40° C. under stirring. To the resultant solution a mixed gas of fluorine and nitrogen (1:9), 10 minutes after the addition, was introduced at a rate of 15 ml/min. The amount of fluorine gas introduced was 15.5 mmoles. After the completion of the reaction, an amount of ether cooled to -60° C. was added to the solution to precipitate crystals which were filtered to give 0.99 g (yield: 78%) of N-fluoropyridinium trifluoromethanesulfonate.
EXAMPLES 28-38
Examples 28-38 were carried out as in Example 27 except that in Examples 34 the gas ratio of fluorine:nitrogen was 2.5:97.5. The results are summarized in Table 3 with the physical properties in Table 6.
TABLE 3__________________________________________________________________________Pyridine- YieldExampleCompound XM Product (%)__________________________________________________________________________28 ##STR55## CH.sub.3 SO.sub.3 SiMe.sub.3 ##STR56## 4229 ##STR57## CF.sub.3 SO.sub.3 SiMe.sub.3 ##STR58## 5530 ##STR59## CF.sub.3 SO.sub.3 SiMe.sub.3 ##STR60## 7931 ##STR61## CF.sub.3 SO.sub.3 SiMe.sub.3 ##STR62## 7132 ##STR63## CF.sub.3 SO.sub.3 SiMe.sub.3 ##STR64## 6933 ##STR65## CF.sub.3 SO.sub.3 SiMe.sub.2 Ph ##STR66## 7134 ##STR67## CF.sub.3 SO.sub.3 SiMe.sub.3 ##STR68## 6835 ##STR69## CF.sub.3 SO.sub.3 SiMe.sub.3 ##STR70## 3036 ##STR71## CF.sub.3 SO.sub.3 SiMe.sub.3 ##STR72## 2837 ##STR73## CF.sub.3 SO.sub.3 SiMe.sub.3 ##STR74## 5238 ##STR75## CF.sub.3 SO.sub.3 SiMe.sub.3 ##STR76## 86__________________________________________________________________________
.Iadd.EXAMPLE 39 .Iaddend. ##STR77##
In a 25 ml pear-shaped flask, 2,4,6-trimethylpyridine (1.21 g, 10 mmoles), sodium borofluoride (1.23 g 10 mmoles) as the XM reactant and anhydrous sodium fluoride (2.1 g, 50 mmoles) were dissolved in 15 ml of anhydrous acetonitrile and to the resulting solution a mixed gas of nitrogen/fluorine (9:1) was introduced at a rate of 50 ml/min. at -40 ° C. under vigorous stirring.
The amount of fluorine introduced was 20 mmoles. After the completion of the reaction, precipitates were filtered and then the solvent was distilled off. The resultant residue was recrystallized from acetonitrile/diethylether to obtain 1.59 g (yield: 70%)of N-fluoro-2,4,6-trimethylpyridinium tetrafluoroborate the physical properties of which are shown in Table 6.
EXAMPLE 40 ##STR78##
This example was effected as in example 39 to give N-fluoro-4-methylpyridinium trifluoromethanesulfonate in 90% yield, the physical properties of which are indicated in Table 6.
EXAMPLE 41-60
Further examples were carried out by using various pyridine compounds and XM. The experimental methods, the reaction products and the yeilds are shown in Table 4. The physical properties of the products are indicated in Table 6.
TABLE 4__________________________________________________________________________Ex- Ex-am- Pyridine Trapping perimental Yieldple Compound XM Agent Method Product (%)__________________________________________________________________________41##STR79## CF.sub.3 SO.sub.3 Na -- Ex. 16 ##STR80## 7642##STR81## CF.sub.3 SO.sub.3 Na NaF Ex. 39 ##STR82## 8643##STR83## NaBF.sub.4 NaF Ex. 39 ##STR84## 6544##STR85## CF.sub.3 SO.sub.3 Na NaF Ex. 39 ##STR86## 2645##STR87## NaClO.sub.4 -- Ex. 39 ##STR88## 8146##STR89## CF.sub.3 SO.sub.3 SiMe.sub.3 -- Ex. 27 ##STR90## 6047##STR91## CF.sub.3 SO.sub.3 Na NaF Ex. 39 ##STR92## 8748##STR93## CF.sub.3 SO.sub.3 Na NaF Ex. 39 ##STR94## 6249##STR95## CF.sub.3 SO.sub.3 Na -- Ex. 16 ##STR96## 7250##STR97## CF.sub.3 SO.sub.3 Na NaF Ex. 39 ##STR98## 3351##STR99## CF.sub.3 SO.sub.3 SiMe.sub.3 NaF Ex. 39 ##STR100## 1852##STR101## CF.sub.3 SO.sub.3 SiMe.sub.3 -- Ex. 2 ##STR102## 1553##STR103## CF.sub.3 SO.sub.3 Na NaF Ex. 39 ##STR104## 1.354##STR105## CF.sub.3 SO.sub.3 SiMe.sub.3 -- Ex. 1 ##STR106## little55##STR107## CF.sub.3 SO.sub.3 SiMe.sub.3 -- Ex. 1 ##STR108## little56##STR109## CF.sub.3 SO.sub.3 SiMe.sub.3 -- Ex. 27 ##STR110## 6857##STR111## CF.sub.3 SO.sub.3 Na NaF Ex. 39 ##STR112## 8458##STR113## CF.sub.3 SO.sub.3 Na NaF Ex. 39 ##STR114## 56 59*##STR115## CF.sub.3 SO.sub.3 Na Na.sub.2 CO.sub.3 Ex. 39 ##STR116## 1060##STR117## CF.sub.3 SO.sub.3 SiMe.sub.3 -- Ex. 1 ##STR118## little__________________________________________________________________________ *Acetonitrile-water (1:1) is used as a reaction medium.
EXAMPLE 61 ##STR119##
To a 30 ml anhydrous acetonitrile solution containing 0.71 g (8.98 mmole) of pyridine a mixed gas of fluorine and nitrogen (1:9) was introduced at a rate of 20 ml/min. at -40° C. under vigorous stirring, the amount of fluorine gas introduced being 26 mmoles. Subsequently, at the same temperature, 1 ml (8.13 mmole) of an ethereal complex of boron trifluoride as the Lewis acid was added and the resulting solution was stirred for 5 hours. The post treatment was effected as in example 13 to give 0.91 g (yield: 69%) of N-fluoropyridinium tetrafluoroborate, the physical properties of which are reproduced in Table 6.
EXAMPLES 62-64
These Examples 62 to 64 were carried out as in Example 61, and the results of which are summarized in Table 5 with the physical properties in Table 6. It should be noted that the appropriate amount of boron fluoride, BF 3 , was introduced in the form of a gas, because .[.BD.]. .Iadd.BF 3 .Iaddend.is a gas, while SbF 5 and SO 3 are introduced in liquid form.
TABLE 5__________________________________________________________________________ExamplePyridine- Lewis YieldNo. Compound Acid Product (%)__________________________________________________________________________62 ##STR120## BF.sub.3 ##STR121## 6263 ##STR122## SbF.sub.5 ##STR123## 3764 ##STR124## SO.sub.3 ##STR125## 46Example 65 ##STR126##This Example was carried out as in Example 16 except that borontrifluoride etherate was used in place of sodium trifluoromethanesulfonate to obtain N-fluoro- 3,5-dichloropyridinium tetrafluoroborate (yield:79%), the physical properties of which are given in Table 6.
TABLE 6__________________________________________________________________________Physical Properties of N-fluoropyridinium Salts Elemental analysis F-NMR (ppm) (Calculated)Example No. Melting Point (°C.) (CFCl.sub.3 internal standard in CD.sub.3 CN) Mass (m/e) C % H % N %__________________________________________________________________________1, 2, 7, 8, 27 185-187 -48.75 (1F, bs, NF) 227(M.sup.+ -HF) 29.17 1.99 5.66 77.61 (3F, s, CF.sub.3) (29.16) (2.04) (5.67)3 41-42 -46.89 (1F, bs, NF) 255(M.sup.+ -H) 34.72 3.35 5.07 77.75 (3F, s, CF.sub.3) (34.91) (3.30) (5.09)4 202 -48.58 (1F, bs, NF) 174, 172 24.84 2.10 5.65 (decomposition) 71.68 (6F, d, J = 715 Hz, PF.sub.6) 107, 97 (24.69) (2.06) (5.76)5, 63 >300 -48.82 (1F, bs, NF) 278, 276 18.02 1.50 4.09 69.0-175.0 (6F, m, SbF.sub.6) (M.sup.+ -3F) (17.96) (1.50) (4.19)6 225-227.5 -48.75 (1F, bs, NF) 156, 155, 97, 30.50 2.23 7.12 (with decompo.) 79 (30.38) (2.53) (7.09)9, 10, 29 99.5-110 -52.13 (1F, bs, NF) 299. 297 22.68 0.94 4.58 77.63 (3F, s, CF.sub.3) 295 (M.sup.+ -HF) (22.80) (0.96) (4.43)11 120-125 -48.18 (1F, bs, NF) 177 (M.sup.+ -HF) 30.56 2.57 7.03 -38.21 (1F, s, S) 149 (30.46) (2.56) (7.10)12 135-136.5 -17.25 (bs, NF) 151, 139 58.00 7.05 3.74 (58.20) (7.05) (3.77)13, 64 162-164 -38.25 (1F, s, SO.sub.2 F) 237 39.36 4.52 5.90 (decomposition) -17.25 (1F, bs, NF) 219(M.sup.+ -HF) (40.16) (4.60) (5.89)14 24-25.5 -17.63 (1F, bs, NF) -- -- -- -- 75.00 (3F, s, CF.sub.3) -- -- -- --15, 17 168.5-170 -17.25 (1F, bs, NF) 139 37.15 3.87 4.66 77.62 (3F, s, CF.sub.3) 121 (37.37) (3.84) (4.84)16 126-128 -24.75 (1F, bs, NF) 255(M.sup.+ -HF) 34.86 3.26 5.03 77.75 (3F, s, CF.sub.3) (34.91) (3.30) (5.09)18, 25, 34 140-143 -25.50 (1F, bs, NF) 227, 137, 69, 30.31 2.52 5.07 77.61 (3F, s, CF.sub.3) 59 (30.32) (2.53) (5.05)19 111-112 -48.37 (1F, bs, NF), 377(M.sup.+ -HF) 27.08 1.35 3.55 80.30 (3F, tt, J = 10.1, 3.0 Hz, CF.sub.3) (27.22) (1.27) (3.53) 114.2 (2F, m, CF.sub.2), 120.9 (2F, m, CF.sub.2), 125.2 (2F, M, CF.sub.2 S)20 119.5-120.5 -37.13 (1F, bs, NF) -- -- -- -- 77.25 (3F, s, CF.sub.3) -- -- -- --21 95-96 -0.75 (1F, bs, NF) 182, 179, 128 30.31 2.52 5.07 77.58 (3F, s, CF.sub.3) 113, 95, 69 (30.32) (2.53) (5.05)22 111-111.5 -0.75 (1F, bs, NF) -- 47.70 5.87 3.46 (decomposition) 77.62 (3F, s, CF.sub.3) -- (47.87) (5.77) (3.49)23 111.5-112.5 -51.00 (1F, bs, NF) 243, 187, 186 31.72 2.02 4.43 77.61 (3F, s, CF.sub.3) 137, 135, 113 (31.48) (2.30) (4.60)24 88- 91 -39.38 (1F, bs, NF) -- -- -- -- 77.63 (3F, s, CF.sub.3) -- -- -- --26 79-80 -25.05 (1F, bs, NF) 163 -- -- -- 77.98 (3F, s, CF.sub.3) 137 -- -- --28 55-58 -48.75 (1F, bs, NF) (*) 173 (M.sup.+ -HF) -- -- --30 108-109 -50.59 (1F, bs, NF) 263, 261 26.38 1.53 5.81 70.70 (3F, s, CF.sub.3) (M.sup.+ -HF) (26.52) (1.47) (5.17)31, 33 105-108 -54.22 (1F, bs, NF) 341, 199 23.81 1.12 3.98 61.50 (3F, s, CF.sub.3) 197 (24.05) (0.86) (4.01) 78.10 (3F, s, CF.sub.3 S)32 115-116 -50.02 (1F, bs, NF) 299 (M.sup.+ -HF) 33.74 2.73 4.28 77.68 (3F, s, CF.sub.3) (33.86) (2.85) (4.39)35 57-65 -53.25 (1F, bs, NF) -- -- -- -- 77.61 (3F, s, CF.sub.3) -- -- -- --36 110-115 -36.38 (1F, bs, NF) -- -- -- -- (decomposition) 77.61 (3F, s, CF.sub.3) -- -- -- --37 112-116 -54.75 (1F, bs, NF) -- -- -- -- 77.61 (3F, s, CF.sub.3) -- -- -- --38 115-116 -38.44 (1F, bs, NF) 137, 107, 79, 31.49 2.28 4.59 78.04 (3F, s, CF.sub.3) 78 (31.48) (2.30) (4.59)39 215-217 -17.25 (1F, bs, NF) 157, 139 42.37 4.75 6.24 149.6 (4F, s, BF.sub.4) (42.33) (4.88) (6.17)40 84-88 -40.50 (1F, bs, NF) 241 (M.sup.+ -HF) 32.12 2.87 5.25 77.48 (3F, s, CF.sub.3) (32.19) (2.70) (5.36)41 149.5-152 -19.75 (1F, bs, NF) -- -- -- -- 78.00 (3F, s, CF.sub.3) -- -- -- --42 116-118 -40.05 (1F, bs, NF) 268 (M.sup.+ -HF) 39.29 4.22 4.50 78.02 (3F, s, CF.sub.3) 135, 120 (39.60) (4.32) (4.62)43 143-145 -39.99 (1F, bs, NF) 138, 110 44.21 5.32 5.64 150.6 (4F, s, BF.sub.4) (44.85) (5.44) (5.81)44 112-114 -23.63 (1F, bs, NF) 210, 190 46.56 5.89 3.86 78.00 (3F, s, CF.sub.3) (46.80) (5.85) (3.90)45 146-148 -40.00 (bs, NF) 120 -- -- --46 144-147 -51.88 (1F, bs, NF) 343 (M.sup.+ -HF), 32.84 2.46 3.84 78.00 (3F, s, CF.sub.3) 248, 182 (33.07) (2.50) (3.86)47 32 -27.38 (1F, bs, NF) 258 30.35 2.61 5.02 77.25 (3F, s, CF.sub.3) 257(M.sup.+ -HF), (30.33) (2.55) (5.05) 6948 viscous -50.10 (1F, bs, NF) 108 -- -- -- 77.20 (1F, s, CF.sub.3)49 151-152 -37.5 (1F, bs, NF) -- -- -- -- 77.30 (3F, s, CF.sub.3)50 136-138 -28.88 (1F, bs, NF) 283 (M.sup.+ -HF) 39.84 4.36 4.41 78.00 (3F, s, CF.sub.3 ) 135 (39.60) (4.29) (4.62)51 97-97.5 -27.00 (1F, bs, NF) 168, 167 51.83 6.95 3.33 77.62 (3F, s, CF.sub.3) 149 (52.05) (6.99) (3.37)52 131-133 -19.50 (1F, bs, NF) 249 53.72 3.19 3.42 77.25 (3F, s, CF.sub.3) 231 (54.10) (3.26) (3.51)53 238-239 -17.25 (1F, bs, NF) 266, 246 41.20 4.75 4.33 77.25 (3F, s, CF.sub.3) 232, 205 (41.38) (4.70) (4.39)54 162.5-163.5 -15.75 (1F, bs, NF) 139 35.07 3.26 4.43 77.72 (3F, s, CF.sub.3) 121 (35.18) (3.26) (4.56) 226.5 (1F, dt, J = 45, 10.5 Hz, CH.sub.2 F)55 160-163 -14.63 (1F, bs, NF) 306, 305 32.65 2.70 4.14 77.62 (3F, bs, CF.sub.3) 157 (33.23) (2.77) (4.31) 228.0 (2F, dt, J = 45, 10.2 Hz, CH.sub.2 F)56 193-195 -54.75 (1F, bs, NF) 375 24.9 0.85 3.64 61.50 (6F, s, β-CF.sub.3) 271 (25.08) (0.79) (3.66) 78.00 (3F, s, CF.sub.3) 6957 94-96 -36.37 (1F, bs, NF) 361 43.63 2.72 3.58 77.40 (3F, s, CF.sub.3) (M.sup.+ -HF) (44.10) (2.91) (3.67)58 vsicous -46.88 (1F, bs, NF) 241 31.17 2.72 5.26 78.00 (3F, s, CF.sub.3) (M.sup.+ -HF) (32.18) (2.68) (5.36)59 159 -15.75 (1F, bs, NF) 359 48.04 6.27 3.68 76.87 (3F, s, NF) 338 (47.75) (6.14) (3.71) 19060 162-168 -15.75 (1F, bs, NF) 306, 305 33.11 2.68 4.20 77.68 (3F, s, CF.sub.3) 175, 172 (33.23) (2.77) (4.31) 119.3 (2F, dd, J = 52.5, 10.6 Hz, 157, 156 CHF.sub.2)61, 62 90-91 -48.75 (1F, bs, NF) 104 32.53 2.64 7.43 149.6 (4F, s, BF.sub.4) (32.43) (2.70) (7.57)65 208-209 -52.67 (1F, bs, NF) 169 167(M.sup.+ -HBF.sub.4) 23.62 1.11 5.44 150.5 (4F, s, BF.sub.4) 165 (23.66) (1.19) (5.52)__________________________________________________________________________
The Following Examples 66-133 are contemplated to elucidate the use of the compounds according to the present invention as the fluorine introducing agent.
EXAMPLE 66 ##STR127##
A methylene chloride solution (1 ml) containing 1.0 mmole of phenol and 1.0 mmole of N-fluoro-3,5-dichloropyridinium trifluyoromethanesulfonate was refluxed under an argon atmosphere for 5 hours. After the reaction was completed, the reaction solution was analysed by gas chromatography to reveal that it contained o-fluorophenol (0.44 mmole), p-fluorophenol (0.13 mmole), 2,4-difluorophenol (0.06 mmole), and phenol (0.27 mmole). Thus the yields of o-fluorophenol, p-fluorophenol and 2,4-difluorophenol were 60%, 18%, and 7% respectively. The total yield was 88% corresponding to the total conversion of 73%. It is noted that no m-fluorophenol was formed.
EXAMPLE 67 ##STR128##
A 1,1,2-trichloroethane solution (2 ml) containing 1.0 mmole of phenol and 0.5 mmole of N-fluoropyriinium trifluoromethanesulfonate was heated at 100° C. for 24 hours under an argon atmosphere and 0.25 mmole of additional N-fluoropyridinium trifluoromethanesulfonate, was added both after 3 hours and 6 hours, thus bringing the total amount of N-fluoropyridinium trifluoromethanesulfonate to 1.0 mmole. After the reaction, the resulting reaction solution was subjected to gas chromatography to reveal that it contained 0.40 mmole of o-fluorophenol, 0.14 mmole of p-fluorophenol, 0.05 mmole of 2,4-difluorophenol and 0.21 mmole of phenol. Therefore, the yields of o-, p-fluorophenols and 2,4-difluoro-phenol were 51%, 18% and 6% respectively, corresponding to the total yields to 75%, with the total conversion of 79%.
EXAMPLES 68-133
A wide variety of fluorine- containing compounds were prepared by reacting N-fluoropyridinium salts according to the present invention with an equi-molar amount of compounds contemplated to be fluorinated. These examples were carried out similar to Example 66 with the reaction conditions set forth in Tables 7-10. The results obtained are also indicated in Tables 7-10. The identification of the structures of the resulting compounds were effected by comparing those with a standard specimem or with spectroscopy.
In Tables 7-10, the N-fluoropydinium salts set foth below were expressed, for simplicity' sake, with the following No. of compounds: ##STR129##
TABLE 7 N-Fluoropyridinium Fluorine .sup.19 F-NMR (ppm) Example salt (indicated by Temperature Hours Conversion containing Yield (CFCl.sub.3 internal No. Aromatic Compound compound number) Solvent (°C.) (b) (%) compound (%) standard in CDCl.sub.3 68 phenol 3 CH.sub.2 CH.sub.2 room temp 18 78 o-fluorophenol 30 -- p-fluorophenol 24 -- 2,4-difluorophenol 3 -- 69 phenol 4 CH.sub.2 CH.sub.2 reflux temp 5 o-fluorophenol 40 -- p-fluorophenol 11 2,4-difluorophen ol 5 -- 70 phenol 5 CH.sub.2 ClCHCl.sub.2 100 16 80 o-fluorophenol 49 -- p-fluorophenol 14 -- 2,4-difluorophenol trace -- 71 phenol 6 CH.sub.2 ClCHCl.sub.2 reflux temp 72 73 o-fluorophenol 24 -- 72 phenol 7 CH.sub.2 ClCHCl.sub. 2 100 24 75 o-fluorophenol 47 -- p-fluorophenol 31 -- 2,4-difluorophenol 3 -- 73 phenol 14 CH.sub.2 Cl.sub.2 reflux temp 24 61 o-fluorophenol 84 -- p-fluorophenol 10 -- 2,4-difluorophenol 1 -- 74 phenol 16 CH.sub.2 ClCHCl.sub.2 120 10 70 o-fluorophenol 45 -- p-fluorophenol 15 -- 75 phenol 17 CH.sub.2 ClCHCl.sub.2 120 10 70 o-fluorophenol 42 -- p-fluorophenol 15 -- 76 anisole 2 CH.sub.2 ClCH.sub.2 Cl reflux temp 18 65 o-fluoroanisole 48 -- p-fluoroanisole 51 -- 77 anisole 1 CH.sub.2 ClCH.sub.2 Cl reflux temp 18 58 o-fluoroanisole 40 -- p-fluoroanisole 47 -- 78 anisole 3 CH.sub.2 Cl.sub.2 reflux temp 24 71 o-fluoroanisole 44 -- p-fluoroanisole 48 -- 79 2 CH.sub.2 Cl.sub.2 reflux temp 5 57 ##STR130## 71 140.3 80 ##STR131## 3 CH.sub.2 Cl.sub.2 reflux temp 3 79 ##STR132## 46 140.3 ##STR133## 23 149.6 81 ##STR134## 18 CH.sub.2 Cl.sub.2 reflux temp 50 85 ##STR135## 55 140.3 82 ##STR136## 2 CH.sub.2 Cl.sub.2 reflux temp 47 78 ##STR137## 51 140.3 83 ##STR138## 3 CH.sub.2 Cl.sub.2 reflux temp 25 62 ##STR139## 47 134.6 ##STR140## 31 149.6 84 ##STR141## 3 CH.sub.2 Cl.sub.2 reflux temp 48 53 ##STR142## 28 130.5 ##STR143## 24 117.8 85 ##STR144## 3 CH.sub.2 Cl.sub.2 reflux temp 32 68 ##STR145## 47 131.9 ##STR146## 32 119.1 ##STR147## 5 1158126.7 86 ##STR148## 2 CH.sub.2 Cl.sub.2 reflux temp 18 56 ##STR149## 71 133.1 87 p t butyphenol 2 CH.sub.2 Cl.sub.2 reflux temp 27 83 2-fluoro-4,1- 68 139.1 butylphenol p-fluorophenol 7 123.5 88 2 naphthol 2 CH.sub.2 Cl.sub.2 room temp 26 80 1-fluoro-2- 84 155.2 naphthol ##STR150## 11 101.6 89 benzene 3 benzene reflux temp 24 -- fluorobenzene 56 111.4 (in benzene solvent)
TABLE 8 N-Fluoropyridinium Fluorine .sup.19 F-NMR (ppm) Example salt (indicated by Temperature Hours Containing Yield (CFCl.sub.3 internal No. Enol Compound compound number) Solvent (°C.) (h) compound (%) standard in CDCl.sub.3) 90 ##STR151## 1 CH.sub.2 Cl.sub.2 room temp 7 ##STR152## 87 188(d, J=50Hz) 91 ##STR153## 7 CH.sub.2 Cl.sub.2 room temp 4 ##STR154## 57 188(d, J=50Hz) 92 ##STR155## 8 CH.sub.2 CH.sub.2 room temp 3 ##STR156## 65 188(d, J=50Hz) 93 ##STR157## 2 CH.sub.2 Cl.sub.2 room temp 2 ##STR158## 62 188(d, J=50Hz) 94 ##STR159## 6 CH.sub.2 Cl.sub.2 reflux temp 6 ##STR160## 41 188(d, J=50Hz) 95 ##STR161## 9 CH.sub.2 CH.sub.2 reflux temp 8 ##STR162## 23 188(d, J=50Hz) 96 ##STR163## 5 CH.sub.2 Cl.sub.2 room temp 5 ##STR164## 69 188(d, J=50Hz) 97 ##STR165## 10 CH.sub.2 Cl.sub.2 reflux temp 24 ##STR166## 40 188(d, J=50Hz) 98 ##STR167## 3 CH.sub.2 Cl.sub.2 reflux temp 3 ##STR168## 24 188(d, J=50Hz) 99 ##STR169## 1 CH.sub.2 Cl.sub.2 room temp 2 PhCHFCOOEt 65 180(d, J=48Hz) 100 ##STR170## 7 CH.sub.2 Cl.sub.2 room temp 2 PhCHFCOOEt 71 180(d, J=48Hz) 101 ##STR171## 7 CH.sub.2 Cl.sub.2 room temp 2 PhCHFCOOH 68 181(d, J=48Hz) 102 ##STR172## 11 CH.sub.2 Cl.sub.2 room temp 2 PhCHFCOOH 70 181(d, J=48Hz) 103 ##STR173## 1 CH.sub.2 Cl.sub.2 reflux temp 3 ##STR174## 58 188(m) 104 ##STR175## 1 CH.sub.2 Cl.sub.2 room temp 3 ##STR176## 31 168(t, J=51Hz) ##STR177## 21 184(d, J=50Hz) ##STR178## 10 206(d, J=50Hz) 105 ##STR179## 1 CH.sub.2 Cl.sub.2 room temp 1 ##STR180## 31 166(t, J=50Hz) ##STR181## 11 183(d, J=50Hz) ##STR182## 18 206(d, J=50Hz) 106 ##STR183## 1 CH.sub.2 Cl.sub.2 reflux temp 10 ##STR184## 48 166(t, J=48Hz) ##STR185## 24 184(d, J=48Hz) 107 ##STR186## 1 CH.sub.2 Cl.sub.2 reflux temp 14 ##STR187## 31 166(t, J=49.5Hz) ##STR188## 20 183(d, J=50Hz) 108 ##STR189## 1 CH.sub.2 Cl.sub.2 reflux temp 2 ##STR190## 59 192(m) 109 ##STR191## 15 CH.sub.2 CH.sub.2 CH.sub.3 CN(4/1) 15 1 ##STR192## 63 138(s) 110 ##STR193## 2 CH.sub.2 Cl.sub.2 reflux temp 24 ##STR194## 72 163(t, J=20Hz) 111 ##STR195## 7 CH.sub.2 Cl.sub.2 reflux temp 48 ##STR196## 83 163(t, J=20Hz) 112 ##STR197## 12 CH.sub.2 Cl.sub.2 reflux temp 48 ##STR198## 68 163(t, J=20Hz) 113 ##STR199## 2 CH.sub.2 Cl.sub.2 reflux temp. 15 ##STR200## 48 171(q, J=28Hz) 114 ##STR201## 1 CH.sub.2 Cl.sub.2 reflux temp 0.4 ##STR202## 59 177(m) *the reaction product was hydrorized in a DMFconc. HCl aqueous soln (R1)
TABLE 9__________________________________________________________________________Ex-am- N-Fluoropyndinium Temper- .sup.19 F-NMR(ppm)ple salt (indicated by Sol- ature Hours Fluorine containing Yield (CFCl.sub.3 internalNo. Carbon anion compound number) vent (°C.) (h) compound (%) standard in CDCl.sub.3)__________________________________________________________________________115 ##STR203## 7 THF room temp. 0.17 ##STR204## 78 162.8(t, J=20.3Hz)116 ##STR205## 7 THF room temp. 1 ##STR206## 44 172.5(q, J=22.5Hz)117 ##STR207## 7 THF 0 0.17 ##STR208## 78 158.0(q, J=21.9Hz)118 ##STR209## 7 THF 0 ##STR210## 42 144.6(q, J=48.6Hz) ##STR211## 6 111.0(s)119 ##STR212## 7 THF 0- room temp. 0.17 ##STR213## 71 118.9(s)120 n-C.sub.12 H.sub.25 MgCl 7 Et.sub.2 O 0 0.5 n-C.sub.12 H.sub.25 F 75 210.8(tt, J=51.3, 17Hz)121 PhMgCl 7 THF 0 0.17 PhF 58 --122 ##STR214## 7 THF 0 1 ##STR215## 50 179.6(d,__________________________________________________________________________ J=49.6Hz)
TABLE 10 N-Fluoropyridinium F-NMR (ppm) Example salt (indicated by Temperature Hours Yield (CFCl.sub.3 internal standard) No. Sulfide compound number) Solvent (°C.) (h) α fluorosulfide (%) Solvent 182.8(t, 52.5Hz) 123 ##STR216## 7 CH.sub.2 Cl.sub.2 room temp. 8 ##STR217## 87 CDCl.sub.3 182.8(t, 52.5Hz) 124 ##STR218## 1 CH.sub.2 Cl.sub.2 room temp. 75 ##STR219## 48 CDCl.sub.3 182.8(t, 52.5Hz) 125 PhSCH.sub.3 7 CH.sub.2 Cl.sub.2 room temp. 4 PhSCH.sub.2 F 85 CDCl.sub.3 180.3(t, 54Hz) 126 PhSCH.sub.3 1 CH.sub.2 Cl.sub.2 room temp. 6 PhSCH.sub.2 F 56 CDCl.sub.3 180.3(t, 54Hz) 127 PhCH.sub.2 SCH.sub.3 7 CH.sub.2 Cl.sub.2 room temp. 1 ##STR220## 76 CH.sub.2 Cl.sub.2 CH.sub.2 Cl.sub.2 152.0(d, 56Hz)187.2(t, 51Hz) 128 PhCH.sub.2 SCH.sub.3 7 CH.sub.2 Cl.sub.2 0 3 ##STR221## 48 CH.sub.2 Cl.sub.2 CH.sub.2 Cl.sub.2 152.0(d, 56Hz)187.2(t, 51Hz) 129 n-C.sub.12 H.sub.25 SCH.sub.3 7 CH.sub.2 Cl.sub.2 room temp. 175 n-C.sub.12 H.sub.25 SCH.sub.2 F 41 CH.sub.2 Cl.sub.2 184.2(t, 52Hz) 130 CH.sub.3 SCH.sub.2 COOEt 7 CH.sub.2 Cl.sub.2 room temp. 10 CH.sub.1 SCHFCOOEt 48 CH.sub.2 Cl.sub.2 167.3(d, 54Hz) 131 ##STR222## 7 CH.sub.2 Cl.sub.2 room temp. 75 ##STR223## 40 CDCl.sub.2 183.8(t, 51Hz) 132 ##STR224## 13 CH.sub.2 Cl.sub.2 40 4.5 ##STR225## 75 CDCl.sub.3 182.8(t, 52.5Hz) 133 PhSC.sub.2 COOMe 7 CH.sub.2 Cl.sub.2 room temp. 23 PhSCHFCOOMe 45 CDCl.sub.3 158.4(d, 52Hz) | A pyridine-compound is reacted with fluorine together with a .[.Bronsted.]. .Iadd.Bronsted .Iaddend.acid-compound or Lewis acid to form a N-fluoropyridinium salt which is very active to other compounds but is very selective for the preparation of a desired product and this product is very useful for a fluorine-introducing agent which makes it useful for the preparation of fluoro-compounds such as thyroid inhibitor. | 2 |
BACKGROUND
In 2003, the Check Clearing for the 21st Century Act was passed, requiring every bank to accept substitute checks, or image replacement documents (IRDs), which are electronic digital copies of paper checks. Accordingly, banks and other financial institutions are increasingly handling electronic financial items such as substitute checks. Standards for storing, sending, and receiving these electronic financial items have been developed and are presently being used throughout the financial industry.
For instance, the well-known Image Exchange Send standard defines requirements for electronic financial item information format, content, and transfer protocol. One of these requirements is that the sending financial institution must include an electronic endorsement record for each electronic financial item. When the sending financial institution is the true bank of first deposit (BOFD) the sending financial institution is supposed to include in the endorsement record a 26 Record (BOFD Endorsement Record). Where the sending financial institution is not the BOFD, such as for correspondent cash letter items, the sending financial institution is supposed include in the endorsement record a 28 Record (Subsequent Endorsement Record). Thus, financial institutions are required to include either a BOFD Endorsement Record or a Subsequent Endorsement Record for transmit items captured as paper and distributed under Image Exchange Send.
However, in practice it has been difficult to track BOFD items versus non-BOFD items and to apply the appropriate endorsement records. Due to the complexity of multi-tiered correspondent cash letter relationships, there has so far been no clear and consistent systematic or automated solution for accurately determining the true BOFD on correspondent paper capture items. Accordingly, some financial institutions have opted to initially include a BOFD Endorsement Record on all Image Exchange Send eligible items, regardless of BOFD status, and to take on or pass through non-BOFD return items. While the impact of this stop-gap measure has not yet been excessive, it is not expected to be feasible as electronic financial items become the norm. There has thus been a growing need by banks and other institutions that handle electronic financial items for a way to address these difficulties.
SUMMARY
It has been determined that a safe and efficient way to address this issue may be to recognize non-BOFD paper items and include only Subsequent Endorsement Records on Image Exchange Send eligible non-BOFD transit items. There are bank standard processes for capturing both BOFD and non-BOFD paper resulting in item level data set records that can systematically be interrogated, ultimately providing a solution for flagging non-BOFD items so that the appropriate Subsequent Endorsement Record can be applied to those items that are eligible for Image Exchange Send.
Accordingly, aspects of the present disclosure are directed to methods, systems, and computer-executable instructions that may provide a way to at least semi-automate Endorsement Records for Image Exchange Send. For example, some aspects are directed to a method that includes receiving a plurality of paper financial items, scanning each of the paper financial items, and for each paper financial item, generating a plurality of data sets based on the scanning For each data set, it may be determined whether the associated paper financial item is a bank of first deposit (BOFD) item or a non-BOFD item. Also, for each data set, the data set may be modified depending upon whether the associated paper financial item is determined to be a BOFD item or a non-BOFD item.
These and other aspects of the disclosure will be apparent upon consideration of the following detailed description of illustrative aspects.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present disclosure may be acquired by referring to the following description in consideration of the accompanying drawings, in which like reference numbers indicate like features, and wherein:
FIG. 1 is an illustrative functional block diagram of a system for handling and sending electronic financial items.
FIG. 2 is an illustrative flow chart showing steps that may be performed by the system of FIG. 1 .
FIG. 3 is an illustrative representation of the structure of microdata associated with an electronic financial item.
It is noted that the various drawings are not necessarily to scale.
DETAILED DESCRIPTION
The various aspects summarized previously may be embodied in various forms. The following description shows by way of illustration various examples in which the aspects may be practiced. It is understood that other examples may be utilized, and that structural and functional modifications may be made, without departing from the scope of the present disclosure.
Except where explicitly stated otherwise, all references herein to two or more elements being “coupled” to each other is intended to broadly include both (a) the elements being directly connected to each other, or otherwise in direct communication with each other, without any intervening elements, as well as (b) the elements being indirectly connected to each other, or otherwise in indirect communication with each other, with one or more intervening elements.
As previously discussed, it may be desirable to recognize non-BOFD paper items and include Subsequent Endorsement Record with Image Exchange Send eligible non-BOFD transit items. There are bank standard processes for capturing both BOFD and non-BOFD paper resulting in item-level data set records that may be systematically interrogated, ultimately providing a solution for flagging non-BOFD items so that the appropriate endorsement records may be applied to those items that are eligible for Image Exchange Send.
An illustrative overview for properly identifying and endorsing both BOFD and non-BOFD paper capture items is generally as follows. First, non-BOFD versus BOFD paper financial items may be identified at the point of capture into electronic form, such as substitute checks. Next, the capture data records for endorsement position and/or BOFD arrows may be interrogated at the item level. Non-BOFD items may be distinguished from BOFD items. For instance, non-BOFD items may be flagged. Later in the process, the previously identified non-BOFD items may be recognized at the item level and be associated with a Subsequent Endorsement Record for those non-BOFD items that are to be transmitted per Image Exchange Send. By default, a BOFD Endorsement Record may be applied to all items not identified as non-BOFD items. This process will be described in greater detail with reference to FIGS. 1-3 .
Referring to FIG. 1 , an illustrative system 100 is shown in functional block diagram form. System 100 may be physically located at a single location, such as within a single building of a bank or other financial institution, or distributed among multiple locations. System 100 as shown includes a controller 101 coupled to a scanner 102 and mass storage 103 .
Although controller 101 is shown in FIG. 1 as a personal computer, controller 101 may be embodied as any one or more computers directly or indirectly coupled together, such as one or more personal computers, mainframes, and/or servers. Controller 101 may be programmable to execute computer-executable instructions (e.g., software). These computer-executable instructions may be stored and accessible to controller 101 on one or more computer-readable media, such as mass storage 103 and/or another computer-readable medium such as a magnetic and/or optical disk 106 (e.g., a CD or hard drive). By executing the computer-executable instructions, controller 101 may perform the various functions described herein.
Scanner 102 may include one or more units of equipment. For instance, scanner 102 may include one or more units of scanning equipment that physically handles, sorts, and/or scans paper financial items (e.g., paper financial items 105 , 106 , 107 ), as well as one or more computers for controlling the scanning equipment and/or for processing data generated from the scanning equipment. An example of scanning equipment that may be included as part of scanner 102 is an IBM model 3890 series high speed document processor. Depending upon the document processor used, the scanning equipment may optically and/or magnetically scan, or read, information printed on each paper financial item provided to it. For instance, the scanning equipment may use magnetic ink character recognition (MICR) to recognize characters printed in special fonts with magnetic ink on paper checks, such as the popular E-13B MICR font. The scanning equipment may further optically scan the entire paper document to obtain an optical image of one or both sides of the paper document.
Scanner 102 may further generate data representing the results of scanning the paper documents. For instance, scanner 102 may generate data representing the MICR characters and/or data representing the images of the paper documents. This data may be stored locally by scanner 102 and/or sent to mass storage 103 for storage.
Mass storage 103 may include any one or more computer-readable media for storing data and/or computer-executable instructions. Such computer-readable media may include, for example, one or more magnetic disk drives, optical disk drives, and/or tape drives, and may be configured to store a large amount of data, on the order of gigabytes, terabytes, or more. Mass storage 103 may be used to store, for instance, data received from scanner 102 and/or controller 101 representing or otherwise associated with the scanning of the paper financial items. In addition, mass storage 103 may include one or more computers for implementing a database that relates various portions of the data stored in mass storage 103 with other portions of the data stored in mass storage 103 . Alternatively, the database may be implemented by controller 101 . In either case, controller 101 may generate and/or receive a query that is processed by the database to selectively return data from mass storage 103 responsive to the query. This data may include one or more data sets associated with financial items.
System 100 as shown is coupled to one or more other financial institutions 108 via a network 107 . This allows system 100 to send and/or receive information regarding electronic financial items to and/or from the other financial institutions 108 . Network 107 may consist of only a single network or may include a plurality of inter-operating networks. For example, network 107 may include, but is not limited to, one or more of the following types of networks: a wired network, a wireless network, the Internet, an intranet, a telephone network, a satellite network, a wide area network (WAN), and/or a local area network (LAN).
FIG. 2 is an illustrative flow chart showing steps that may be performed by system 100 for processing and transmitting information regarding financial items. Although various steps are shown as separate steps in FIG. 2 , these steps may be combined and/or further sub-divided in any manner desired. Also, the order of the steps may be rearranged as desired, and steps may even be skipped altogether.
In step 201 , scanner 102 receives and/or sorts through a plurality of paper financial items 105 - 107 , such as paper checks, paper cash letters, paper drafts, and the like. Next, in step 202 , the paper financial items are electronically captured, or scanned, to generate data representing each paper financial item. For each paper financial item, a data set may be generated that includes, for instance, MICR codeline data read from the magnetic ink printed on the paper financial item, one or more optical images of the paper financial item (e.g., one or both sides of the piece of paper), and/or other information regarding the paper financial item.
For example, for each paper financial item, the generated data set may be formatted as shown in FIG. 3 . The data set may have a plurality of fields (in this example, fifteen fields). The MICR codeline data may be stored in a subset of the fields. In this example, the MICR codeline data is stored in the first seven of the fields (i.e., fields one through seven as shown in FIG. 3 ). In addition, one or more of the fields may be set aside for use by a software application, such as the commonly-used IBM Check Processing Control System (CPCS), which operates in a mainframe computer operating system environment. In this example, field 8 is used for CPCS match processing. The various data sets may be generated at, for example, scanner 102 and/or controller 101 and stored together at, for instance, a database in mass storage 103 .
Also, referring again to FIG. 2 , in step 203 , a flag may be applied to the data sets of those financial items that are non-BOFD items, but not to the data sets of those financial items that are BOFD items, or vice-versa. To accomplish this, each paper financial item may be manually or automatically identified as either a BOFD item or a non-BOFD item before, during, or after capture. For instance, prior to providing the paper financial items to scanner 201 , the BOFD and non-BOFD items may already be pre-separated. Thus, a set of BOFD paper financial items may be easily captured separately from a set of non-BOFD paper financial items. The user of system 100 may thus inform scanner 102 and/or controller 101 of the BOFD status of various paper financial items being scanned. In response to being informed of the BOFD status of a given paper financial item being scanned, scanner 102 and/or controller 101 may either add a flag to the data set for that item or not add the flag, depending upon whether that item is a BOFD item or a non-BOFD item.
For example, where a flag is set, the flag may be included in any of the fields of the data set as shown in FIG. 3 , such as any one or more of fields nine, ten, eleven, twelve, thirteen, fourteen, or fifteen. It may alternatively be desirable to add the flag to one of fields one through eight, however these fields may be used to store MICR codeline data and CPCS match processing data, as previously described. The flag may be a single bit (e.g., the highest or lowest order bit of the field) or a plurality of bits. The flag may be set, as shown in FIG. 3 , where the associated financial item is a non-BOFD item but not when the associated financial item is a BOFD item. However, the opposite may be implemented.
Although the present example is discussed with regard to adding a flag to the data set, this is just one possibility. In general, a data set may be modified in step 203 in any manner desired depending upon whether the associated financial item is a BOFD item or a non-BOFD item. Alternatively, a data set may be modified in a first manner (e.g., a first flag) where the associated financial item is a BOFD item, and in a second manner (e.g., a different second flag) where the associated financial item is a non-BOFD item. The point is that the data set may include an indication as to whether the associated financial item is a BOFD item or not.
Next, in steps 204 and 205 , various standard processing techniques may be performed, such as repairing and/or re-scanning any rejected paper financial items (step 204 ) and/or performing documents review (step 205 ). For example, a paper financial item may have been mis-scanned, or may be ripped, etc. Steps 204 and 205 may be performed by controller 101 .
Next, in step 206 , the various financial items may be reconciled. In this step, the dollar amounts stored in the data sets for a batch of financial items are totaled and compared with the expected total dollar amount for the batch. Step 206 may be performed by controller 101 .
Next, in step 207 , controller 101 may select and pull one or more of the data sets from mass storage 103 for sending to one or more of the other financial institutions 108 via Image Exchange Send.
Upon pulling the selected data sets, controller 101 may check each data set to see whether it relates to a BOFD financial item or a non-BOFD financial item. For instance, controller 101 may recognize whether or not there is a non-BOFD flag at field nine. If the non-BOFD flag exists, then controller 101 may, in step 209 , prepare data for that item for sending via Image Exchange Send including a Subsequent Endorsement Record (i.e., a 28 Record). If the non-BOFD flag does not exist, then by default controller 101 may, in step 209 , prepare data for that financial item for sending via Image Exchange Send including a BOFD Endorsement Record (i.e., a 26 Record). Of course, if the flag is instead a BOFD flag (as opposed to a non-BOFD flag), then the opposite may be performed: the existence of the BOFD flag causes controller 101 to create a BOFD Endorsement Record, whereas the non-existence of the BOFD flag causes controller 101 to create a Subsequent Endorsement Record. In either case, controller 101 may provide the correct type of endorsement record for Image Exchange Send.
Thus, illustrative embodiments have been described that allow financial institutions to efficiently include the appropriate BOFD Endorsement Record or Subsequent Endorsement Record for items sent via Image Exchange Send. These embodiments may prove more and more valuable as the handling of substitute checks and other electronic financial items becomes widespread. | Aspects of the present disclosure are directed to a method that includes receiving a plurality of paper financial items, scanning each of the paper financial items, and for each paper financial item, generating a plurality of data sets based on the scanning. For each data set, it may be determined whether the associated paper financial item is a bank of first deposit (BOFD) item or a non-BOFD item. Also, for each data set, the data set may be modified depending upon whether the associated paper financial item is determined to be a BOFD item or a non-BOFD item. Further aspects are directed to systems that perform the above method. | 6 |
FIELD OF THE INVENTION
The current invention relates to tablets of low hardness but good physical stability, in particular fast dissolving tablets that can be made at very low compression force, yet have acceptable stability, and methods for preparing such tablets.
BACKGROUND OF THE INVENTION
Several processes are presently available by which a tablet, which dissolves quickly in the mouth, may be formulated. However, various disadvantages are associated with these currently available methods for producing fast dissolving tablets. For example the addition of high levels of disintegrants is disclosed by Cousin et al. (U.S. Pat. No. 5,464,632). Cousin et al. add two disintegrants to the disclosed tablet formulations, for example 16% starch 1500 and 13.3% crosspovidone. The oral-disintegration time of these tablets is 35 seconds to 45 seconds. However, tablets including high levels of disintegrants have a chalky or dry feel when placed in the mouth.
Another process for producing fast dissolving tablets involves freeze drying or lyophilizing solutions or suspensions of an active ingredient and matrix forming excipients. Pebley et al. (U.S. Pat. No. 5,298,261) disclose freeze-drying a slurry or paste comprising an active ingredient and excipients placed in blister packets. Humbert-Droz et al. (WO 97/36879) disclose vacuum drying, at room temperature or a slightly elevated temperature, a suspension including the active drug, a sugar alcohol, PEG 6000, talc, sweeteners and flavors in preformed blisters. The disadvantages of the freeze drying or vacuum drying methods are time (very slow process), cost of the equipment (not done on conventional tablet manufacturing equipment), and that it is limited to low dose actives.
Fast-dissolving tablets may also be formulated by the inclusion of effervescent coupled compounds. Wehling et al. (U.S. Pat. No. 5,178,878 and WO 91/04757) disclose the addition of an effervescent couple (such as sodium bicarbonate and citric acid) to a tablet. Exposure of the tablet to moisture results in contact and chemical reaction between the effervescent couple which leads to gas production and tablet disintegration. For this reason, tablets which include effervescent pairs are highly sensitive to moisture and have an unpleasant mouthfeel.
Tablets formed by compression under low compression force also dissolve more rapidly than tablets formed by high compression force. However, tablets produced by these processes have a high degree of friability. Crumbling and breakage of tablets prior to ingestion may lead to uncertainty as to the dosage of active ingredient per tablet. Furthermore, high friability also causes tablet breakage leading to waste during factory handling.
The present invention addresses these and other problems associated with the prior art. The invention provides fast-dissolving tablets of low hardness, low friability and high stability which have the added advantage of cost-effective methods of manufacture. In particular, the fast-dissolving tablets of the invention melt rapidly in the mouth and provide an excellent mouth feel.
SUMMARY OF THE INVENTION
The present invention advantageously provides compositions and methods for preparing a fast dissolving tablet of low hardness but good physical stability that can be made at very low compression force.
Thus, the invention provides a tablet comprising a low melting point compound that melts or softens at or below 37° C., a water soluble excipient, and an active ingredient. Preferably, the low melting point compound comprises from about 2.5% to about 20% (wt/wt) of the composition (e.g., 2.5, 5, 7.5, 10, 12, 14, 16, 18, or 20% (wt/wt)). Preferably the tablet has a hardness of about 3 kP or less, more preferably about 2 kP or less, and still more preferably about 1 kP or less. Preferably, the minimum hardness of the tablet is about 0.1 kP, although lower values, including 0.05 kP, are possible.
The invention further provides a method of producing a tablet composition. The method comprises combining an active agent (also termed “active ingredient” or “active”) with a fast dissolving granulation. The fast dissolving granulation comprises a low melting point compound and a water soluble excipient. Preferably, the low melting compound is present in an amount that will yield values of about 2.5% to about 20% (wt/wt) in a final tablet composition (e.g., 2.5, 5, 7.5, 10, 12, 14, 16, 18, or 20% (wt/wt)).
The accompanying Detailed Description, Examples and Drawings further elaborate the invention and its advantages.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a graph of tablet hardness as a function of compression force for tablets of the invention prepared by a melt granulation process (diamonds), and tablets prepared by direct compression (squares).
FIG. 2 shows a graph of friability as a function of tablet hardness; “Number of Rotations” indicates a number of rotations in a Friabilator which occur before a tablet breaks. Tablets prepared by melt granulation (diamonds) or by direct compression (squares) were evaluated.
FIG. 3 shows a graph of time of onset of disintegration (T1) as a function of compression force for tablets of the invention (diamonds) and for tablets formed by direct compression (squares).
FIG. 4 shows a graph of disintegration time (T2) as a function of compression force for tablets of the invention (diamonds) and for tablets formed by direct compression (squares).
FIG. 5 shows a graph of disintegration time as a function of the friability (as measured by the number of rotations in a Friabilator before a first tablet breaks) for tablets of the invention (diamonds) and for tablets formed by direct compression (squares).
FIG. 6 shows a graph of time to dissolve (mean of disintegration time in seconds for 34 samples of a tablet of the invention (MG), two types of tablets formed by direct compression (DC1 and DC2), and a commercial fast dissolving tablet (KIDTAB®).
FIG. 7 shows a graph of grittiness score (adjusted mean determined by least squares from ANOVA). Subjects scored this sensory attribute on a scale of 1 (low grittiness) to a 9 (high grittiness). Tablets were as described for FIG. 6 .
FIG. 8 shows a graph of chalkiness score (adjusted mean determined by least squares from ANOVA). Subjects scored this sensory attribute on a scale of 1 (low chalkiness) to a 9 (high chalkiness). Tablets were described for FIG. 6 .
FIG. 9 shows a graph of overall preference ranking for each product (as described in FIG. 6 ), represented by the percentage of subjects ranking each product 1 st , 2 nd , 3 rd , or 4 th .
DETAILED DESCRIPTION
The current invention provides fast dissolving tablet formulations that can be formed by compression into a conventional tablet. Tablet friability is lower than conventional fast dissolving tablets prepared by low compression. The fast dissolving tablet has at least one compound which partially or fully melts or softens at or below body temperature and a water soluble excipient. The low melting point excipient may be hydrophilic or hydrophobic. The tablets of the invention may also include an active ingredient and may also include one or more disintegrants, flavors, colorants, sweeteners, souring agents, glidants or lubricants.
The hardness of the tablets is low (less than or equal to about 3 kP), preferably less than or equal to about 2 kP, and more preferably less than or equal to about 1 kP, with a minimum hardness of greater than or equal to about 0.1 kP (e.g., 0.05, 0.07, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.3, 1.6, 1.9, 2.0, 2.1, 2.3, 2.5, 2.7, 2.8 or 3.0 kP). In a specific embodiment, hardness ranges from about 0.2 to about 1 kP. Attributes such as (1) fast tablet dissolution; (2) good tablet mouth feel; and (3) good tablet physical stability are of greater importance than minimum and maximum values of tablet hardness. Nevertheless, the tablets are somewhat pliable, and are less fragile than conventional tablets that have the same crushing strength. The tablets have an excellent mouthfeel resulting from the low melting point component which melts or softens in the mouth to produce a smooth feel and masks the grittiness of insoluble ingredients. Unlike other fast dissolving tablets, the disintegration of this fast dissolving tablet occurs by a combination of melting, disintegration of the tablet matrix, and dissolution of the water soluble excipient. Therefore, a dry feel does not occur. Disintegration time is 10 to 30 seconds (e.g., 10, 12, 14, 16, 18, 20, 22, 24, 26, 28 or 30 seconds), depending on the tablet size and amount of insoluble ingredients, e.g., coated active. Even though the tablet contains a low melting point ingredient, it is relatively stable to high temperatures. Heating the tablet above the melting point of its low melting point component will not significantly reduce its physical stability.
The friability of conventional tablets is measured by the percentage weight loss after atypical friability test (rotating 10 tablets in a friability apparatus for 100 rotations). This test is very harsh for conventional fast dissolving tablets and so cannot be used to measure their friability. Fast dissolving tablets made by direct compression at low force crumble after a few rotations in the friability apparatus. Fast dissolving tablets manufactured by the method in the current invention can withstand 20-50 rotations in the friability apparatus before any tablet breaks. After 20 rotations, the friability (% weight lost) is typically less than 1%.
The term “low melting point compound” may include any edible compound which melts or softens at or below 37° C. which is suitable for inclusion in the tablets of the invention. Materials commonly used for manufacturing suppositories usually have a melting point at or just below body temperature and can be used in the invention. The low melting point compound can be hydrophilic or hydrophobic.
Examples of hydrophilic low-melting point compounds include, but are not limited to, polyethylene glycol; the preferred mean molecular weight range of polyethylene glycol for use in the tablets of the invention is from about 900 to about 1000. Mixtures of polyethylene glycol with different molecular weights (200, 300, 400, 550, 600, 1450, 3350, 8000 or 10,000) are within the scope of the invention if the mixture melts or softens at or below 37 degrees celcius.
Examples of hydrophobic low-melting point compounds include, but are not limited to, low melting point triglycerides, monoglycerides and diglycerides, semisynthetic glyceride (e.g., EUTECOL®, GELUCIRE® (gatteffosse)), hydrogenated oils, hydrogenated oil derivatives or partially hydrogenated oils (e.g., partially hydrogenated palm kernel oil and partially hydrogenated cottonseed oil), fatty acid esters such as myristyl lactate, stearic acid and palmitic acid esters, cocoa butter or its artificial substitutes, palm oil/palm oil butter, and waxes or mixtures of waxes, which melt at 37° C. or below. In preferred embodiments, the hydrogenated oil is Wecobee M. To be effective in the tablet compositions, the low melting point compound must be edible.
Mono- di- and triglycerides are rarely used as pure components. Hydrogenated vegetable oils, and solid or semisolid fats are usually mixtures of mono- di- and triglycerides. The melting point of the fat or hydrogenated vegetable oil is characteristic of the mixture and not due to a single component. Witepsol (brand name by Condea), Supocire (brand name by Gattefosse), and Novata (brand name by Henkel) are commonly used in manufacturing suppositories, because they melt at body temperature. All are mixtures of triglycerides, monoglycerides and diglycerides.
In preferred embodiments, the low melting point compound comprises from about 2.5% to about 20%, by weight, of a tablet composition (e.g., about 2.5, 5, 7.5, 10, 12, 14, 15, 16, 18, or 20% (wt/wt)).
The tablets of the present invention also include a water soluble excipient. As used herein, the term “water soluble excipient” refers to a solid material or mixture of materials that is orally ingestible and readily dissolves in water. Examples of water soluble excipients include but are not limited to saccharides, amino acids, and the like. Saccharides are preferred water soluble excipients. Preferably, the saccharide is a mono-, di- or oligosaccharide. Examples of saccharides which may be added to the tablets of the invention may include sorbitol, glucose, dextrose, fructose, maltose and xylitol (all monosaccharides); sucrose, lactose, glucose, galactose and mannitol (all disaccharides). In a specific embodiment, exemplified below, the saccharide is lactose. Preferably, the saccharide is mannitol. Other suitable saccharides are oligosaccharides. Examples of oligosaccharides are dextrates and maltodextrins. Other water soluble excipients may include amino acids such as alanine, arginine, aspartic acid, asparagine, cysteine, glutamic acid, glutamine, glycine, histidine, isoleucine, leucine, lysine, methionine, phenylalanine, proline, serine, threonine, tryptophan, tyrosine and valine; glycine and lysine are preferred amino acids.
In preferred embodiments, the water soluble excipient comprises from about 25% to about 97.5%, by weight, of a tablet composition. The preferred range is about 40% to about 80%. For example, tablet compositions comprising about 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or 97.5%, by weight, saccharide are within the scope of the invention.
As used herein, the term “about” (or “approximately”) means a particular value can have a range acceptable to those of skill in the art given the nature of the value and method by which it is determined. In a specific embodiment, the term means within 50% of a given value, preferably with 20%, more preferably within 10%, and more preferably still within 5%.
Active Ingredients
As used herein, the term “active ingredient” or “active agent” refers to one or more compounds that have some pharmacological property. Accordingly, more than one type of active ingredient compound may be added to the tablets of the invention. The tablets of the invention may comprise any active ingredient which may be orally administered to a subject. Tablets including active ingredients in amounts appropriate for the desired pharmacological properties at the dosage administration can be formulated. Any amount of active ingredient that does not significantly affect beneficial tablet features, such as hardness, friability and mouthfeel are within the scope of the invention. Placebo tablets, which lack an “active ingredient” having a known pharmacologic activity, are also within the scope of the invention. An “active ingredient” of a placebo can be the water soluble excipient (i.e., lacking any identifiable “active”), a different water soluble compound, or any non-active compound.
A non-limiting list of acceptable active ingredients may include but is by no means limited to: 1) antipyretic analgesic anti-inflammatory agents such as indomethacin, aspirin, diclofenac sodium, ketoprofen, ibuprofen, mefenamic acid, dexamethasone, dexamethasone sodium sulfate, hydrocortisone, prednisolone, azulene, phenacetin, isopropylantipyrin, acetaminophen, benzydamine hydrochloride, phenylbutazone, flufenamic acid, mefenamic acid, sodium salicylate, choline salicylate, sasapyrine, clofezone or etodolac; 2) antiulcer agents such as ranitidine, sulpiride, cetraxate hydrochloride, gefarnate, irsogladine maleate, cimetidine, lanitidine hydrochloride, famotidine, nizatidine or roxatidine acetate hydrochloride; 3) coronary vasodilators such as Nifedipine, isosorbide dinitrate, diltiazem hydrochloride, trapidil, dipyridamole, dilazep dihydrochloride, methyl 2,6-dimethyl-4-(2-nitrophenyl)-5-(2-oxo-1,3,2-dioxaphosphorinan-2-yl)-1,4-dihydropyridine-3-carboxylate, verapamil, nicardipine, nicardipine hydrochloride or verapamil hydrochloride; 4) peripheral vasodialtors such as ifenprodil tartrate, cinepazide maleate, cyclandelate, cinnarizine or pentoxyfyline; 5) oral antibacterial and antifungal agents such as penicillin, ampicillin, amoxicillin, cefalexin, erythromycin ethylsuccinate, bacampicillin hydrochloride, minocycline hydrochloride, chloramphenicol, tetracycline, erythromycin, fluconazole, itraconazole, ketoconazole, miconazole or terbinafine; 6) synthetic antibacterial agents such as nlidixic acid, piromidic acid, pipemidic acid trihydrate, enoxacin, cinoxacin, ofloxacin, norfloxacin, ciprofloxacin hydrochloride, or sulfamethoxazole trimethoprim; 7) antipasmodics such as popantheline bromide, atropine sulfate, oxapium bromide, timepidium bromide, butylscopolamine bromide, rospium chloride, butropium bromide, N-methylscopolamine methylsulfate, or methyloctatropine bromidebutropium bromide; 8) antitussive, anti-asthmatic agents such as theophylline, aminophylline, methylephedrine hydrochloride, procaterol hydrochloride, trimetoquinol hydrochloride, codeine phosphate, sodium cromoglicate, tranilast, dextromethorphane hydrobromide, dimemorfan phosphate, clobutinol hydrochloride, fominoben hydrochloride, benproperine phosphate, tipepidine hibenzate, eprazinone hydrochloride, clofedanol hydrochloride, ephedrine hydrochloride, noscapine, calbetapentane citrate, oxeladin tannate, or isoaminile citrate; 9) broncyodilators such as diprophylline, salbutamol sulfate, clorprenaline hydrochloride, formoterol fumarate, orciprenalin sulfate, pirbuterol hydrochloride, hexoprenaline sulfate, bitolterol mesylate, clenbuterol hydrochloride, terbutaline sulfate, mabuterol hydrochloride, fenoterol hydrobromide, or methoxyphenamine hydrochloride; 10) diuretics such as furosemide, acetazolarmide, trichlormethiazide, methyclothiazide, hydrochlorothiazide, hydroflumethiazide, ethiazide, cyclopenthiazide, spironolactone, triamterene, fluorothiazide, piretanide, metruside, ethacrynic acid, azosemide, or clofenamide; 11) muscle relaxants such as chlorphenesin carbamate, tolperisone hydrochloride, eperisone hydrochloride, tizanidine hydrochloride, mephenesin, chlorozoxazone, phenprobamate, methocarbamol, chlormezanone, pridinol mesylate, afloqualone, baclofen, or dantrolene sodium; 12) brain metabolism altering drugs such as meclofenoxate hydrochloride; 13) minor tranquilizers such as oxazolam, diazepam, clotiazepam, medazepam, temazepam, fludiazepam, meprobamate, nitrazepam, or chlordiazepoxide; 14) major tranquilizers such as Sulpirid, clocapramine hydrochloride, zotepine, chlorpromazinon, or haloperidol; 15) β-blockers such as pindolol, propranolol hydrochloride, carteolol hydrochloride, metoprolol tartrate, labetalol hydrochloride, acebutolol hydrochloride, butetolol hydrochloride, alprenolol hydrochloride, arotinolol hydrochloride, oxprenolol hydrochloride, nadolol, bucumolol hydrochloride, indenolol hydrochloride, timolol maleate, befunolol hydrochloride, or bupranolol hydrochloride; 16) antiarrhythmic agents such as procainamide hydrochloride, disopyramide, ajimaline, quinidine sulfate, aprindine hydrochloride, propafenone hydrochloride, or mexiletine hydrochloride; 17) gout suppressants allopurinol, probenecid, colchicine, sulfinpyrazone, benzbromarone, or bucolome; 18) anticoagulants such as ticlopidine hydrochloride, dicumarol, or warfarin potassium; 19) antiepileptic agents such as phenytoin, sodium valproate, metharbital, or carbamazepine; 20) antihistaminics such as chlorpheniramine maleate, cremastin fumarate, mequitazine, alimemazine tartrate, or cycloheptazine hydrochloride; 21) antiemetics such as Difenidol hydrochloride, metoclopramide, domperidone, betahistine mesylate, or trimebutine maleate; 22) hypotensives such as dimethylaminoethyl reserpilinate dihydrochloride, rescinnamine, methyldopa, prazosin hydrochloride, bunazosin hydrochloride, clonidine hydrochloride, budralazine, or urapidin; 23) sympathomimetic agents such as dihydroergotamine mesylate, isoproterenol hydrochloride, or etilefrine hydrochloride; 24) expectorants such as bromhexine hydrochloride, carbocysteine, ethyl cysteine hydrochloride, or methyl cysteine hydrochloride; 25) oral antidiabetic agents such as glibenclamide, tolbutamide, or glymidine sodium; 26) circulatory agents such as ubidecarenone or ATP-2Na; 27) iron preparations such as ferrous sulfate or dried ferrous sulfate; 28) vitamins such as vitamin B1, vitamin B2, vitamin B6, vitamin B12, vitamin C, vitamin A, vitamin D, vitamin E, vitamin K or folic acid; 29) pollakiuria remedies such as flavoxate hydrochloride, oxybutynin hydrochloride, terodiline hydrochloride, or 4-diethylamino-1,1-dimethyl-2-butynyl (I)-α-cyclohexyl-α-phenylglycolate hydrochloride monohydrate; 30) angiotensin-converting enzyme inhibitors such as enalapril maleate, alacepril, or delapril hydrochloride; 31) anti-viral agents such as trisodium phosphonoformate, didanosine, dideoxycytidine, azido-deoxythymidine, didehydro-deoxythymidine, adefovir dipivoxil, abacavir, amprenavir, delavirdine, efavirenz, indinavir, lamivudine, nelfinavir, nevirapine, ritonavir, saquinavir or stavudine; 32) high potency analgesics such as codeine, dihydrocodeine, hydrocodone, morphine, dilandid, demoral, fentanyl, pentazocine, oxycodone, pentazocine orpropoxyphene; 33) antihistamines such as Brompheniramine maleate and 34) nasal decongestants such as Phenylpropanolamine HCl. Active ingredients in the foregoing list may also have beneficial pharmaceutical effects in addition to the one mentioned.
Other Tablet Ingredients
The term “tablet” refers to a pharmacological composition in the form of a small, essentially solid pellet of any shape. Tablet shapes maybe cylindrical, spherical, rectangular, capsular or irregular. The term “tablet composition” refers to the substances included in a tablet. A “tablet composition constituent” or “tablet constituent” refers to a compound or substance which is included in a tablet composition. These can include, but are not limited to, the active and any excipients in addition to the low melting compound and the water soluble excipient. An excipient is any ingredient in the tablet except the active, and includes binders, disintegrants, flavorants, colorants, glidants, souring agents and sweeteners.
For the purposes of the present application, “binder” refers to one or more ingredients added before or during granulation to form granules and/or promote cohesive compacts during compression. A “binder compound” or “binder constituent” is a compound or substance which is included in the binder. Binders of the present invention include, at least, the low melting compound.
Additionally, and optionally, other substances commonly used in pharmaceutical formulations can be included such as flavors (e.g., strawberry aroma, raspberry aroma, cherry flavor, magnasweet 135, key lime flavor, grape flavor trusil art 5-11815, fruit extracts and prosweet), flavor enhancers and sweeteners (e.g., aspartame, sodium saccharine, sorbitol, glucose, sucrose), souring agents (e.g. citric acid), dyes or colorants.
The tablet may also contain one or more glidant materials which improve the flow of the powder blend and minimize tablet weight variation. Glidants such as silicone dioxide may be used in the present invention.
Additionally, the tablets of the invention may include lubricants (e.g magnesium stearate) to facilitate ejection of the finished tablet from dies after compression and to prevent tablets from sticking to punch faces and each other.
Any method of forming a tablet of the invention into a desired shape which preserves the essential features thereof are within the scope of the invention.
Tablet Formation
A preferred method of forming the tablet compositions of the invention includes mixing a fast dissolving granulation, which includes a low-melting point compound and a water soluble excipient, preferably a saccharide. The term “fast dissolving granulation” refers to a composition of the low melting point compound and the water soluble excipient prepared for use in manufacture of tablets of the invention. A portion of the fast dissolving granulation may then be added to the remaining ingredients. However, methods of forming the tablets of the invention wherein all tablet constituents are combined simultaneously or wherein any combination of tablet constituents are combined separate from the other constituents are within the scope of the invention.
Granulation end point can be determined visually (visual inspection). It can also be determined using a load cell that measures power consumption. Tablet manufacturing and granulation routinely employ both techniques.
The tablet compositions of the invention can be formed by melt granulation which is a preferred method. In particular, the melt granulation can be performed in a high shear mixer, low shear mixer or fluid bed granulator. An example of high shear mixer is Diosna (this is a brand name by Diosna Dierks & Söhne GmbH). Examples of low shear mixers are various tumbling mixers (e.g., twin shell blenders or V-blender). Examples of fluid bed granulators are Glatt and Aeromatic fluid bed granulators.
There are three ways of manufacturing the granulation:
Melting the low melting point ingredient, then combining it with the water soluble ingredient(s) in the granulator and mixing until granules form.
Loading the water soluble excipient in the granulator and spraying the molten low melting point compound on it while mixing.
Combining the two (water soluble component and low melting point component) and possibly other ingredients and mixing while heating to a temperature around or higher than the melting point of the low melting point component until the granules form.
After the granulation congeals, it may be milled and/or screened. Examples of mills that can be used are CoMill, Stokes Oscillator (these are brand names). Any mills that are commonly used for milling tablet granulations may be used.
Melt extrusion can be used to form the fast dissolving granulation. An example of an extruder that can be used is Nica (a brand name by Niro-Aeromatic). The low melting point compound and the water soluble saccharide are mixed and heated in a planetary mixer bowl (low shear mixer) that is usually part of the extruder. The soft mass is then fed to the extrusion chamber and forced through small holes or orifices to shape it into thin rods or cylinders. After the extruded material congeals it can be milled or spheronized using standard equipment. In the spheronization step, the extrudate is dumped onto the spinning plate of the spheronizer and broken up into small cylinders with a length equal to their diameter, then rounded by frictional forces (See, International Journal of Pharmaceutics 1995, 116:131-146, especially p. 136.).
Spray congealing or prilling can also be used to form the tablet compositions of the invention. Spray congealing includes atomizing molten droplets of compositions which include a low melting point compound onto a surface or, preferably, other tablet constituents. Equipment that can be used for spray congealing includes spray driers (e.g., Nero spray drier) and a fluid bed coater/granulation with top spray (e.g., Glatt fluid bed coater/granulator). In preferred embodiments, a fast-dissolve granulation is formed wherein, preferably a water soluble excipient, more preferably a saccharide, is suspended in a molten low melting point ingredient and spray congealed. After spray congealing, the resulting composition is allowed to cool and congeal. Following congealing of the mixture, it is screened or sieved and mixed with remaining tablet constituents. Spray congealing processes wherein fast-dissolve granulations comprising any combination of low melting point compound and other tablet constituents are melted and spray congealed onto other tablet constituents are within the scope of the present invention. Spray congealing processes wherein all tablet constituents, including the low-melting point compound, are mixed, the low melting point compound is melted and the mixture is spray congealed onto a surface are also within the scope of the invention.
After spray congealing, the mixture may be milled and then combined with other tablet constituents. Following formation of the final tablet composition, the composition may be further processed to form a tablet shape.
Mixing and milling of tablet constituents during the preparation of a tablet composition may be accomplished by any method which causes the composition to become mixed to be essentially homogeneous. In preferred embodiments the mixers are high-shear mixers such as the Diosna, CoMill or V-Blender.
Once tablet compositions are prepared, they may be formed into various shapes. In preferred embodiments, the tablet compositions are pressed into a shape. This process may comprise placing the tablet composition into a form and applying pressure to the composition so as to cause the composition to assume the shape of the surface of the form with which the composition is in contact. In preferred embodiments, the tablet is compressed into the form at a pressure which will not exceed about 10 kN, preferably less than 5 kN. For example, pressing the tablets at less than 1, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 6, 7, 8, 9, or 10 kN is within the scope of the invention. The tablets of the invention generally have a hardness of about 3 kP or less; preferably the tablets have a hardness of about 2 kP or less and more preferably about 1 kP or less. For example, tablets of about 0.05, 0.07, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.3, 1.6, 1.9, 2.0, 2.1, 2.3, 2.5, 2.7, 2.8 or 3.0 or less than 0.1 kP are within the scope of the invention. Hydraulic presses such as a Carver Press or rotary tablet presses such as the Stokes Versa Press are suitable means by which to compress the tablet compositions of the invention.
Tablets may also be formed by tumbling melt granulation (TMG) essentially as described in Maejima et al, Chemical Pharmacology Bulletin.(1997) 45(3): 518-524; which is incorporated herein by reference. Tumbling melt granulation can be used for preparing the melt granulation. It can be done in a tumbling mixer. The molten low melting point compound is sprayed on the crystalline saccharide and powdered saccharide in the blender and are mixed until granules form. In this case, the low melting ingredient is the binder and the crystalline saccharide is the seed. An alternative method is to combine the unmelted low melting point ingredient, crystalline sugar (e.g. sucrose or maltose), and water-soluble ingredient in the powder form (e.g., mannitol or lactose) in the tumbling mixer and mix while heating to the melting point of the low melting point binder or higher. The seed should be crystalline or granular water soluble ingredient (saccharide), e.g., granular mannitol, crystalline maltose, crystalline sucrose, or any other sugar. An example of tumbling mixers is the twin-shell blender (V-blender), or any other shape of tumbling mixers. Heating can be achieved by circulating heated air through the chamber of the granulator and by heating the bottom surface of the chamber. As the seed material and the powdered tablet constituents circulate in the heated chamber, the low-melting point compound melts and adheres to the seeds. The unmelted, powdered material adheres to the seed-bound, molten low-melting point material. The spherical beads which are formed by this process are then cooled and screen sifted to remove nonadhered powder.
EXAMPLES
Example 1
Fast Dissolving Granulations
Compositions of Fast Dissolving Granulations. In these compositions, the water soluble excipient is a saccharide. As described above, the tablets of the invention may be formulated by a method wherein a fast dissolving granulation, comprising a low melting point compound and a water soluble excipient, is mixed separately from other tablet constituents. A portion of the fast dissolving granulation may then be combined with the other tablet constituents. In this example, several specific examples of fast dissolving granulations are set forth.
TABLE 1
Fast dissolving granulation formulations.
Fast Dissolving
Granulation
Low Melting Point
Saccharide
Composition
Compound (amount)
(amount)
1
Wecobee M hydrogenated
mannitol powder (5 Kg)
vegetable oil (1 Kg)
2
Gelucire 33/01
mannitol powder (1 Kg)
semisynthetic
glycerides (200 g)
3
Wecobee M (150 g)
crystalline maltose (100 g)
mannitol powder (750 g)
4
polyethylene glycol 900
fructose powder (400 g)
(100 g)
Fast dissolving granulations 1 and 2 were prepared by heating the low melting compound to 50° C. At 50° C., Wecobee M and Gelucire 33/01 become molten. The molten material was gradually added to the mannitol powder in a high shear granulator (Diosna). The granulation was mixed at high speed. When the granulation end point was reached as determined by visual inspection, the granulation was allowed to congeal. The congealed granulation was then milled using a CoMill.
Granulation 3 was granulated by combining melted Wecobee M with the mannitol in a high shear mixer (Robot Coupe) and blending until the granules formed. Granulation 4 was made by combining the melted PEG with fructose powder in a planetary mixer (low shear mixer) and mixing until the granules formed. The granulations were allowed to cool, then were screened.
Example 2
Fast Dissolving Ibuprofen Tablets
The following is an example of a fast dissolving tablet wherein the active ingredient is ibuprofen.
Ingredient
Amount (mg tablet)
Coated ibuprofen (active ingredient)
121.9
(equivalent to 100 mg ibuprofen)
Citric acid (souring agent)
11.0
Magnasweet 135 (sweetening agent)
3.9
Aspartame (sweetening agent)
6.5
Cherry flavor (flavoring agent)
7.8
Crosscarmellose sodium (disintegrant)
39.0
Silicone dioxide (glidant flow aid)
1.95
Magnesium stearate (lubricant)
3.25
Fast dissolving granulation 4
457.9
Total
653.2
Ingredients were screened, then mixed in a V-blender. Tablets were compressed using a hydraulic press (Carver Press) at 600 lb (about 2.7 kN). The tablets had a hardness of 0.2-0.5 kP and disintegrated in less than 15 seconds.
Example 3
Fast Dissolving Antihistamine/Decongestant Tablets
The following is an example of a fast dissolving tablet comprising the active ingredients of many common allergy medications, Phenylpropanolamine HCl and Brompheniramine maleate.
Ingredient
Amount (mg/tablet)
Phenylpropanolamine HCl (active ingredient)
6.25
Brompheniramine maleate (active ingredient)
1.0
Citric acid (souring agent)
6.0
Magnasweet 135 (sweetening agent)
1.80
Aspartame (sweetening agent)
4.5
Cherry flavor (flavoring agent)
3.60
Crosscarmellose sodium (disintegrant)
21.0
Lecithin (creamy mouthfeel)
3.0
Corn Starch (anti-adherent)
30.0
Silicone dioxide (glidant flow aid)
3.0
Fast dissolving granulation 4
219.25
Magnesium stearate (lubricant)
2.1
Total
301.5
Tablets were compressed on a hydraulic press (Carver Press) at approximately 3 kN. Tablet hardness was 0.2-0.5 kP and disintegration time 10 seconds.
Example 4
Fast Dissolving Ibuprofen Tablets
The following is an example of a fast dissolving tablet wherein the active ingredient is ibuprofen.
Ingredient
Amount (mg/tablet)
Coated ibuprofen (active agent)
119.0
Citric Acid (souring agent)
20.0
Magnasweet 135 (sweetening agent)
7.5
Aspartame (sweetening agent)
7.5
Grape flavor Trusil Art 5-11815 (flavoring agent)
5.00
Prosweet (flavor and sweetness enhancer)
5.00
Crosscarmellose sodium (enhancer)
20.0
Corn Starch, NF (anti-adherent)
40.0
Silicone dioxide (Syloid 244) (glidant flow aid)
5.00
Fast dissolving granulation 1
271
Total
500
Tablets were compressed using a rotary tablet press (Stokes Versa Press) at 3.3.-3.5 kN, resulting in a hardness of 0.2-0.9 kP. In vivo disintegration time was 19 seconds (average of 34 subjects).
Sensory Study: The melt granulation tablets of Example 4 were evaluated for in vivo disintegration time and mouthfeel in an in-house sensory study. The comparator was Kidtab®, an 80 mg acetaminophen fast dissolving tablet prepared by direct compression. Two other ibuprofen fast dissolving tablets prepared by direct compression were also included in the study. The study included 34 subjects. The subjects were asked to record the time for the tablet to completely dissolve in the mouth and give scores for mouthfeel attributes and overall liking of the product. The melt granulation prototype (based on this invention) performed best on disintegration time (FIG. 6) and mouthfeel attributes (least grittiness (FIG. 7) and least chalkiness (FIG. 8 )) and were ranked best on the overall performance by the panelists.
The following table shows the ranking results of the sensory study on disintegration time and mouthfeel attributes: MG is the melt granulation tablet of the invention. DC1 and DC2 are the two direct compression prototypes.
Ranking (1 = best, 4 = worst)
Prototype/Product
Sensory Attribute
DC1
MG
Kidtab
DC2
Time to dissolve (seconds)
2
1
4
3
Grittiness
4
1
2
3
Chalkiness
3
1
4
2
Overall Preference
4
1
2
3
The tablets of the invention were ranked the highest (1, best) in all four categories tested (dissolution time, grittiness, chalkiness and overall performance) against DC1, DC2 and KIDTAB.
As illustrated in FIG. 6, the tablets of the invention exhibited superior fast dissolving characteristics as compared to the direct compression tablets which were also evaluated (DC1, DC2 and KIDTAB); the average time for the tablet of the invention (MG) to dissolve was 19 seconds wherein the time for DC1, DC2 and KIDTAB to dissolve were about 20, 22 and 25 seconds, respectively. The tablets of the invention also exhibited a mouthfeel which was superior to the DC1, DC2 and KIDTAB tablets. FIGS. 7 and 8 indicate the 34 individuals who participated in the study perceived a lower level of grittiness and chalkiness associated with the tablets of the invention as compared to the direct compression tablets (DC1, DC2 and KIDTAB).
Overall preference was also scored (least squares mean from ANOVA) on a scale from 1 (most preferred) to 9 (least preferred). As indicated in FIG. 9, the tablet of the invention scored highest (2.11), followed by the KIDTAB® (2.29), and the two direct compression tablets (DC2-2.52, DC1-3.05)
Example 5
Fast Dissolving Ibuprofen Tablets
The following is an example of a fast dissolving tablet wherein the active ingredient is ibuprofen
Ingredient
mg/tablet
Coated ibuprofen (active agent)
238.0
Citric Acid (souring agent)
17.5
Magnasweet 135 (sweetening agent)
9.75
Aspartame (sweetening agent)
9.75
Key Lime flavor (flavoring agent)
6.50
Vanilla powder (flavoring agent)
0.650
Corn Starch, NF (anti-adherent)
52.0
Silicone dioxide (Syloid 244) (glidant/flow aid)
6.50
Sodium stearyl fumarate (Pruv) (lubricant)
4.88
Fast dissolving granulation 1
304
Total
650
Tablets were compressed using a rotary tablet press (Stokes Versa Press) at 3 kN, resulting in a hardness of 0.35-0.60 kP. In vivo disintegration time was 16 seconds.
Example 6
Compressibility and In Vitro Evaluation of Tablets
To compare fast dissolving tablets of the invention with fast dissolving tablets prepared by direct compression, the following two examples were prepared.
Melt Granulation Fast Dissolving Tablet:
Ingredient
mg/tablet
Ibuprofen microcaps
119.0
Citric Acid, anhydrous, fine granular
20.0
Magnasweet 135
7.5
Aspartame (Nutrasweet)
7.5
Cherry Berry flavor
4.25
Sweet AM
2.50
Crosscarmellose sodium
20.0
Corn Starch, NF
40.0
Silicone dioxide (Syloid 244)
5.00
Fast dissolve granulation
274.25
TOTAL
500
* The granulation is 85.0% Mannitol powder, USP and 15.0% Wecobee M (hydrogenated vegetable oil).
Direct Compression Fast Dissolving Tablet:
Ingredient
mg/tablet
Ibuprofen microcaps
119.0
Citric Acid, anhydrous, fine granular
20.0
Magnasweet 135
7.5
Aspartame (Nutrasweet)
7.5
Sweet AM
2.50
Fruit Punch flavor
3.50
Crosscarmellose sodium
20.0
Corn Starch, NF
40.0
Silicone dioxide (Syloid 244)
5.00
Mg Stearate
3.50
Granular mannitol
271.5
TOTAL
500
Melt granulation tablets and direct compression tablets were prepared based on the same formula, except that granular mannitol was used instead of the fast dissolve melt granulation. The compressibility of the two tablet formulations (melt granulation and direct compression) were compared. The two blends were compressed at different compression forces and the resulting tablets were evaluated for hardness and in vitro disintegration time. Tablet hardness (crushing strength) was measured using a high resolution texture analyzer (Stable Microsystems) with an acrylic cylindrical probe.
In vitro disintegration was performed in a texture analyzer. A tablet was held on a net that was then attached to a ¼″ stainless steal ball probe. The disintegration medium was 5 ml of water in a 50 ml beaker. The height of water was barely enough to submerge the tablet, and the water temperature was kept at 37±1° C. The texture analyzer was instructed to apply a small force (20 g) when the tablet hit the bottom of the beaker. The time for disintegration onset and total disintegration time were recorded.
Compressibility: Fast dissolving tablets in general are soft and need to be blister-packaged directly off the tablet press. The tablets manufactured according to the invention can be compressed at very low compression forces, which cannot be used with tablets prepared by direct compression or wet granulation. For fast dissolving tablets containing a coated active, it is important to compress at the lowest force possible so that the coating will not be ruptured under compression. With the melt granulation approach, tablets that are robust enough to withstand packaging right off the tablet press were obtained using a compression force as low as 2 kN, whereas for a similar direct compression formulation, acceptable tablets could not be obtained at compression forces below 5 kN (FIG. 1 ).
Hardness and Friability: Although the melt granulation tablets had a lower hardness compared to direct compression tablets that are compressed at the same force (FIG. 1 ), the melt granulation tablets were somewhat pliable and less fragile. As illustrated in FIG. 2, the softest melt granulation prototype, with a hardness of about 0.2 kP, was able to withstand at least 9 rotations in the friabilator (friability apparatus) before any tablet breaks. At 0.5 kP, these tablets survived 20-30 rotations. Direct compression tablets at about 0.45 kP started breaking after 4 rotations, while the hardest direct compression prototype with about 0.9 kP hardness only survived 12 rotations. In the same friability test, Kidtab® tablets (marketed fast dissolving tablets prepared by direct compression) started breaking after 5-10 rotations. The average hardness of Kidtab tablets was 1.8 kP. Moreover, at the end of the test, the direct compression tablets showed more chipping around the edges than melt granulation prototypes. Direct compression tablets with hardness greater than 1 kP were not fast dissolving (took 1 minute or more to dissolve in the mouth of a subject).
In vitro Disintegration: The onset of disintegration was faster for the melt granulation prototypes compared to direct compression prototypes prepared at the same compression force (FIG. 3 ). Furthermore, the total time for in vitro disintegration was dependent on compression force regardless of the formulation (FIG. 4 ). We obtained acceptable tablets from the melt granulation processing low compression force. Direct compression tablets could not be obtained at the same compression force. Therefore, for tablets with similar friability, the melt granulation approach produced faster disintegration time (FIG. 5 ).
The melt granulation formulation was less sensitive to small changes in compression force, whereas for the direct compression formulation, both hardness and onset of disintegration increased sharply with increasing the compression force (FIGS. 1 and 3 ).
Example 7
Example of Melt Granulation Tablets with Higher Hardness:
Ingredient
mg/tablet
Ibuprofen microcaps (encapsulated ibuprofen)
121.9
Citric Acid, anhydrous, fine granular
11.0
Magnasweet 135
4.0
Aspartame (Nutrasweet)
6.0
Cherry flavor
6.0
Sweet AM
0.5
Crosscarmellose sodium
45.0
Corn Starch, NF
40.0
Silicone dioxide (Syloid 244)
2.50
Fast dissolve granulation
263.1
TOTAL
500
* The granulation is 85.0% Mannitol powder, USP and 15.0% Wecobee M (hydrogenated vegetable oil).
The granulation is 85.0% Mannitol powder, USP and 15.0% Wecobee M (hydrogenated vegetable oil)
Tablets were compressed on Stokes Versapress. Compression force was not recorded. Tablet hardness was 1.5 kP. The tablets had a friability of less than 1.0% after 50 rotations in the friabilator, i.e, lost less than 1% of their initial weight and no tablet broke. Mean in vivo disintegration time was 25.8 seconds (12 subjects were asked to take the tablets and record the time it takes for the tablet to completely dissolve without chewing).
The present invention is not to be limited in scope by the specific embodiments described herein. Indeed, various modifications of the invention in addition to those described herein will become apparent to those skilled in the art from the foregoing description and the accompanying figures. Such modifications are intended to fall within the scope of the appended claims.
It is further to be understood that all values are approximate, and are provided for description.
Patents, patent applications, publications, product descriptions, and protocols are cited throughout this application, the disclosures of which are incorporated herein by reference in their entireties for all purposes. | The present invention relates to processes for the preparation of tablets which dissolve rapidly in the mouth and provide an excellent mouthfeel. The tablets of the invention comprise a compound which melts at about 37° C. or lower, have a low hardness, high stability and generally comprise few insoluble disintegrants which may cause a gritty or chalky sensation in the mouth. Convenient and economically feasible processes by which the tablets of the invention may be produced are also provided. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C. §119 of German Patent Application No. 10 2011 109 450.8, filed Aug. 4, 2011, the disclosure of which is hereby incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to a milling rotor for processing ground material, having a plurality of milling tools which are arranged in a distributed manner over the jacket surface spaced at predetermined distances and according to a predetermined pattern.
BACKGROUND OF THE INVENTION
[0003] In the road construction industry, ground milling machines in form of road milling machines, stabilizers and recyclers are used which comprise a milling rotor. The milling rotor consists of a cylindrical tube, on the jacket surface of which the milling tools are arranged. Chisels or chisel-like apparatuses which are either welded directly onto the rotor or held in quick-change tool holders are used as milling tools.
[0004] Ground milling machines of the generic kind are used for tearing open the respective surfaces over a wide area and in a continuous fashion, such as during the reconstruction of roads and paths, and for re-using the milling material subsequently for the production of a new base course. In the case of stabilizers and recyclers, stabilizing agents and so-called secondary raw materials and further building materials such as sand and the like are optionally mixed into the milling material within the rotor box in a continuous manner. They will be mixed with the detached milling material by a rotation of the milling drum in the rotor box. The mixture will remain locally as a relatively flat layer for further processing. The detached milling material and the mixture of detached milling material and aggregates will be referred to below simply as milling material.
[0005] In known milling rotors, the milling tools are distributed on the rotor jacket in the manner that—as seen in the circumferential direction—a pattern with a V-like or W-like progression is produced which is symmetrical to the central line. It has been found, however, that depending on the milling depth, the rotor speed and the travelling speed of the ground milling machine, the milling material will be conveyed towards the center of the rotor or on both sides to the outside, and will be deposited in an inhomogeneous manner. Coarse fractions in particular form undesirable accumulations in the center of the milling track.
SUMMARY OF THE INVENTION
[0006] The present invention is therefore based on the object of providing a milling rotor of the kind described above and a ground milling machine having such a rotor with which the distribution of the milling material is improved.
[0007] This object is achieved in such a way that the milling tools are arranged in the circumferential direction of the milling rotor along imaginary lines which extend in parallel and are composed of at least one respective, equally long section of a left-handed and a right-handed helical line.
[0008] The present invention offers the advantage that, as a result of the arrangement of the milling tools, there will not be any scooping effect and therefore no undesirable displacement and accumulation of the milling material by the milling tools. The arrangement of the milling tools in accordance with the present invention does not form any pattern causing a division within the jacket surface along the circumference, and no division towards the center of the rotor. The milling material rather remains approximately on the milling line when the rotor has turned once and forms a flat surface with homogeneous distribution.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention will be explained below in closer detail by reference to an embodiment shown in the schematic drawings, wherein:
[0010] FIG. 1 shows a perspective view of a milling rotor;
[0011] FIG. 2 shows a top developed view of the cylinder jacket of the milling rotor according to FIG. 1 ;
[0012] FIG. 3 shows a side view of the milling rotor of FIG. 1 ; and
[0013] FIG. 4 shows a top developed view of the cylinder jacket according to FIG. 2 with auxiliary lines.
DETAILED DESCRIPTION OF THE INVENTION
[0014] In accordance with FIGS. 1 and 2 , a circular-cylindrical milling rotor 10 of a ground milling machine (not shown) comprises a jacket surface 11 , on which a plurality of milling tools 12 are attached. The rotor axis is designated with reference numeral 8 . A component is designated here as a milling tool which consists of a chisel holder 13 with a chisel receptacle 14 , a clod breaker 15 and a chisel 16 which is only shown on a single milling tool 12 a . The milling tools 12 are arranged in lines 9 which extend along parallel dot-dash lines 17 , 18 and which extend over the entire width of the milling rotor 10 . The lines 9 are disposed at the same angular distance a from one another and the milling tools 12 have the same lateral distance from one another within one line. From a spatial point of view, the lines 17 , 18 concern sections of helical lines with a first, relatively large ascending gradient. The direction of rotation of the milling rotor 10 is illustrated with arrow 19 .
[0015] As is shown in FIG. 2 in conjunction with FIG. 3 , the milling tools 12 are further arranged in the circumferential direction along imaginary further lines 20 which in a developed view of the jacket surface 11 in accordance with FIG. 2 are shown as a zigzag line with four equally long, alternating sections A, B and A′, B′ and four direction changes C. In order to ensure clarity of the illustration, only one of these lines 20 is shown. The number n of the direction changes C along the further lines 20 therefore has an even number. From a spatial point of view, this concerns four alternating sections of left-hand and right-hand second and third helical lines with a second ascending gradient. The second ascending gradient is identical in the second and third helical line. It is much shorter in comparison with the first helical line. The arrangement of the milling tools 12 is repeated after half a jacket length, i.e., it is similar on each half of the milling rotor 10 . FIG. 3 shows the first section A of a right-hand helical line and the first section B of a left-hand helical line, as shown in a view on one side of the milling rotor 10 . Each section A, B and A′, B′ has the same number of milling tools 12 . As an example, three milling tools 12 are respectively disposed along the line 20 in each of sections A, B and A′, B′.
[0016] In order to provide more clarity as to the arrangement of the milling tools 12 on the jacket surface 11 , the developed view of the jacket surface 11 according to FIG. 4 shows auxiliary lines in the form of a rectangular grid. Furthermore, the left-hand helical lines of the sections B and B′ are additionally labeled with an (*) for visually illustrating the arrangement in the figure. In all other respects, FIG. 4 corresponds to the illustration of FIG. 2 . The grid of the auxiliary lines shows that the milling tools 12 which are arranged in one line 9 are arranged with a first lateral offset a to each other within the line 9 . Furthermore, the milling tools which are arranged on further imaginary lines 20 in the circumferential direction are arranged in interstices, i.e., in the circumferential direction at least one other milling tool 12 is arranged at least in a partly lateral overlapping manner between two adjacent milling tools 12 or in a gap that is formed by two adjacent milling tools 12 . In the illustrated example, the milling tools 12 are arranged along the lines 20 within each section A, B and A′, B′ with the predetermined second lateral offset b. The milling tools 12 in sections of the line 20 with opposing helical lines, i.e., sections A, A′ on the one hand and sections B, B′ on the other hand, are further arranged in sections by the second lateral offset b in the manner that the milling tools 12 of the sections with opposing helical lines A, B and A′, B′ overlap partly by the second lateral offset b, as seen in the circumferential direction. Two further milling tools 12 are therefore disposed along the line 20 in connection with each milling tool 12 , which further milling tools are arranged in a partly overlapping manner by the second lateral offset b. The second lateral offset b is smaller than the first lateral offset a. In the illustrated example, the first offset a corresponds approximately to the width of three milling tools 12 and the second offset b approximately to half the width of the milling tool 12 .
[0017] A respective channel 21 on either side of the lines 20 is obtained between the milling tools 12 of two adjacent lines 20 by the first lateral offset a, which channel has the same width as the first offset a. These channels 21 are free from milling tools 12 and extend along the entire circumference of the milling rotor 10 . Their progression corresponds to the progression of the lines 20 . Material detached by the milling tools 12 and optionally admixed material therefore reaches the adjacent channels 21 on both sides of the milling tools 12 on the lines 20 . The material is therefore merely provided with a lateral deflection which is not larger than the channel width or the first lateral offset a. The material processed by the milling tools 12 on two adjacent lines 20 reaches the channels 21 in the described manner.
[0018] Milling tools 12 are provided having two different angular positions relative to the rotor axis 8 . One part of the milling tools is arranged with an angular orientation directed to the left with an angle γ on the one rotor edge and an equally large part is arranged with an angular orientation directed to the right with an angle γ′ on the other rotor edge. The angles γ and γ′ are equally large and mirrored on a circumferential line. They are disposed in the range of approximately 2° to 3°. The milling tools 12 with the one angular position are disposed on the sections A, A′ of the lines 20 , which corresponds to the one helical line. The milling tools 12 with the other angular position are disposed on the sections B, B′; the milling tools 12 on the sections with the left-hand helical line all have the same angular position and the milling tools 12 with the mirrored angular position are all disposed on the sections with the right-hand helical line. Furthermore, all milling tools on a line 9 respectively have the same angular position.
[0019] The milling tools 12 are subdivided into equally large groups. Each group comprises the milling tools 12 which are arranged within one of the sections A, B, A′ and B′. It is therefore determined by a number m of the associated lines 9 . All milling tools 12 within one group further respectively have the same angular position of the milling tools 12 . The number of such groups is even. A total of four groups are provided in the illustrated example, with groups with milling tools 12 with opposing angular positions alternating along the jacket surface 11 in the direction of rotation.
[0020] As a result of the angular position of the milling tools 12 , a wedge surface acting against the direction of rotation of the milling rotor 10 will be produced in each milling tool 12 especially by the chisel holders 13 and the clod breakers 15 , because the milling tools 12 form a body by the chisel holders 13 and the clod breakers 15 , which body is aligned with its longitudinal axis in an oblique manner in relation to the direction of rotation. The wedge surfaces produce a lateral deflection of detached or admixed material, which is also supported by the chisel tips because the chisels 16 , together with the chisel holders 13 , are likewise aligned in an angular fashion.
[0021] While the present invention has been illustrated by description of various embodiments and while those embodiments have been described in considerable detail, it is not the intention of Applicants to restrict or in any way limit the scope of the appended claims to such details. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of Applicants' invention. | The present invention relates to a milling rotor for processing ground material, comprising a plurality of milling tools which are arranged in a distributed manner over the jacket surface spaced at predetermined distances and according to a predetermined pattern. In order to improve the distribution of the milling material, the milling tools are arranged in the circumferential direction of the milling rotor along parallel imaginary lines which are composed of at least one respective, equally long section of a left-hand and a right-hand helical line. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an oven to be used mainly in the home.
2. Description of Related Art
Conventionally, an oven having a plurality of heat sources for cooking a material inside an oven chamber is known in, for example, JP-B-34426/1988.
SUMMARY OF THE INVENTION
In this kind of oven, when part of the heat sources is not operated or operated at a reduced capacity depending on the kind of cooking in order to perform various kinds of cooking, oils and the like scattering from the object of cooking during cooking are caused to adhere to the heat sources not operated or operated at a reduced capacity, resulting in a disadvantage in that a smell is generated by the burning of the oils when the oven is used next time.
This invention has an object of providing an oven without this kind of disadvantage.
In order to attain this object an oven in accordance with this invention is of the type that it has a plurality of heat sources for cooking by heating a material inside an oven chamber, the capacities of the heat sources being arranged to be capable of independent control, the operating time thereof being arranged to be set by a timer, wherein heat sources not operated or operated at a reduced capacity are operated substantially at their full capacities for a predetermined period of time after a cooking time set by the timer has elapsed.
An oven in accordance with this invention is of the type that it has a plurality of heat sources for cooking by heating a material inside a grill chamber, the capacities of the heat sources being arranged to be capable of independent control, the operating time thereof being arranged to be set by a timer, wherein heat sources not operated or operated at a reduced capacity are operated substantially at their full capacities for a predetermined period of time before a cooking time set by the timer elapses.
An oven in accordance with this invention is characterised in that the heating sources are halogen lamps.
In the oven having the abovementioned construction, since the heat sources not operated or operated at a reduced capacity are made to operate substantially at their fully capacities for a predetermined period of time after or before the cooking time set by the timer expires, the oils and the like adhered to the heating sources can be burned off during this period of time.
When the halogen lamps are used as the heating sources, the surface temperatures of the heat sources are particularly high and the burning off can be performed in a short period of time.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of this invention is described, by way of example, with reference to the drawings in which:
FIG. 1 is a perspective view of one embodying example of this invention;
FIG. 2 is a sectional side view thereof;
FIG. 3 is a diagram showing a control circuit thereof; and
FIGS 4 and 5 are flow charts.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, there are shown an oven main body 1, an oven chamber 2 provided in the oven main body 1, a door 3 which is provided at the front side of the oven chamber 2 and which can be opened and closed, and heat sources 4 provided in the grill chamber 3. These heat sources 4 comprise halogen lamps 4a with a far infrared coating which are disposed on both sides of, and in the front and the rear portions of the ceiling of, the oven chamber 2, respectively, a halogen lamp 4b without the coating which is disposed between the halogen lamps 4a, 4a on the ceiling, and a sheath heater 4c which is disposed in the rear of the oven chamber 2 to enclose a fan 5 inside the chamber. For each of the heat sources 4 there is an operating time respectively set by a timer and also the capacity respectively controlled. This invention is so arranged that the heat sources 4 which are operated or operated at a reduced capacity are operated at their full capacities for a predetermined period of time after or before the expiration of cooking time which is set in the timer. Its control is made by a control circuit shown in FIG. 3 which is explained below. The halogen lamp 4b without the far infrared coating is controlled by a CPU which is connected to a power source via a main switch Ms. The halogen lamps 4a with the far infrared coating and the sheath heater 4c are controlled by the CPU which is connected to the power source via the main switch Ms as well as by relay contacts r1, r2 and r3 of a relay R which is connected to the power source via the main switch Ms, a door switch Ds1 and a normally closed switch Ohs which is opened in an interlocking relationship with an overheating protection device. In FIG. 3 reference numerals 4a-1 and 4a-2 denote halogen lamps disposed on the sides of the oven chamber and 4a-3 and 4a-4 denote halogen lamps disposed on the ceiling thereof. The CPU is provided with a phase control function, a timer function and a detection function for detecting the opening of the door switch Ds2.
Next, an explanation is given regarding oven cooking and grill cooking in both of which the adhesion of the oils to the heat sources 4 becomes a problem. In oven cooking, as shown in the flow chart of FIG. 4, the capacities of the halogen lamps 4a-3, 4a-4 with the far infrared coating are set at 1/2 of a total output of 700W and, at the same time, the output of the halogen lamp 4b without the coating is also lowered to 50W which corresponds to 1/14 of the total output of 700W. The other heat sources 4 are operated at their maximum capacities to maintain the temperature inside the oven chamber at 160° to 250° C. At this time the fan 5 inside the oven chamber is also operated. It is therefore so arranged that the halogen lamps 4a-3, 4a-4 and 4b are operated at their maximum capacities for a predetermined period of time, e.g., for 10 seconds, after the lapse of the cooking time set by the timer, i.e., t-10 seconds as shown in FIG. 4 to maintain the surface temperatures of the lamps 4a-3, 4a-4, 4b at 500° C. or above, thereby burning off the oils and the like which are generated out by the material being cooked and which are adhered to the surfaces of the heat sources. In other words, the oils and the like which are adhered to the surface of the heat sources are made to burn off in a predetermined period of time after the lapse of the cooking time. This burning off can, however, be performed in a predetermined period of time, e.g., in 10 seconds, before the lapse of the cooking time t. Int his case, the heat sources 4 which are operating at their full capacities may be stopped before the start of the above mentioned 10 seconds.
In grill cooking only the sheath heater 4c is stopped and the other heat sources 4 are operated at their full capacities, and by stopping the operation of the fan 5 inside the oven chamber the temperature inside the oven chamber is maintained at about 300° C. for performing cooking. Therefore, it is so arranged that the sheath heater 4c which is not operated is made to operate at its maximum capacity for a predetermined period of time after the lapse of the cooking time set by the timer, thereby burning off the oils or the like adhered to the surfaces of the heat sources during cooking. However, this burning off can also be performed in a predetermined period of time immediately before the lapse of the cooking time, in the same manner as in the oven cooking.
Although the above-mentioned heat sources 4 are explained as halogen lamps and a sheath heater, it is needless to say that the heat sources 4 may also be gas burners.
As regards the cooking time to be set by the timer, the cooking time itself may also be set, or else the setting may be made inclusive of the time for burning off the adhered oils and the like. A reduction in the cooking capacity is attained, when the heat sources 4 are lamps, either by reducing the wattage or by repeatedly switching on and off the lamps. The reduction of the cooking capacity by switching on and off the lamps is especially effective in the case where the heat sources 4 are in a switched off condition at the end of cooking operation.
The oven of this invention has the following effects.
In the oven of the invention, by operating the heat sources which are not operated or operated at reduced capacities substantially at their maximum capacities for a predetermined period of time after or before the lapse of the cooking time set by the timer, the oils and the like adhered to the heat sources can be burned off during this period of time. If the heat sources are halogen lamps, the surface temperatures thereof are high and, therefore, the oils and the like can be burned off in a short time. | In an oven having a plurality of heat sources for cooking by heating an object of cooking inside an oven chamber, the capacities of said heat sources are arranged to be capable of independent control. The operating time of the heat sources is arranged to be set by a timer, wherein heat sources not operated or operated at a reduced capacity are operated substantially at their full capacities for a predetermined period of time after a cooking time set by the timer has elapsed. | 5 |
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 61/524,516, the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
This disclosure relates to the mining arts and, more particularly, to a drill guide for a drilling apparatus, such as for use in connection with a drill for forming a borehole in a face of a mine passage.
BACKGROUND OF THE INVENTION
Drill guides may be provided for use in connection with guiding a drilling element in the course of forming a borehole in a face of a mine passage. Typically, the drill guide includes a pair of pivotally mounted clamping jaws that close to support the drilling element as the result of the application of hydraulic force. One approach may be found in U.S. Pat. No. 7,428,935 to Hinshaw et al. the disclosure of which is incorporated herein by reference.
The need to provide a manual holding force for the drilling element while these jaws are closed using hydraulic power can require considerable skill, and often leads to suboptimal results. Also, the drill guide hoses for supplying the working fluid to an associated actuator are usually poorly positioned, and prone to failure as a result. Accordingly, a need is identified for an improved drill guide that meets and overcomes one or more of the foregoing limitations and others.
SUMMARY
One aspect of the invention relates to an apparatus for use in connection using a drill having a drilling element for forming a borehole in a face of a mine passage. The apparatus comprises a drill guide for engaging the drilling element while permitting the drilling element to move toward the face for forming the borehole, the drill guide including a keeper for holding the drilling element. The keeper is biased for pivoting movement upon the application of a manual force between an active position for capturing the drilling element and a retracted position for releasing the drilling element.
In one embodiment, the keeper includes a first notch aligning with a second notch of an associated support in the active position of the drill guide. The first and second notches together form a passage in the drill guide for receiving the drilling element.
The apparatus may further include a retainer for retaining the keeper in the active position. The retainer may comprise a hydraulic cylinder having a rod pivotally connected to the keeper. The retainer may also or alternatively comprise a biasing element for urging the keeper toward either the retracted position or active position.
The apparatus may further including a controller for actuating the retainer when a predetermined condition is met. The predetermined condition may be, for example, receiving a feed signal for feeding the drill from an operator input device, receiving a rotation signal for causing the drill to rotate the drilling element from an operator input device, or both. The controller may also deactivate the retainer to allow for manual movement of the drill guide to the retracted position when both the feed signal and the rotation signal are removed.
The apparatus may also include a first stop for engaging the keeper in the active position of the drill guide and a second stop for engaging the keeper in the retracted position of the drill guide.
Another aspect of this disclosure relates to an apparatus for use in connection using a drill having a drilling element for forming a borehole in a face of a mine passage. The apparatus comprises a drill guide for engaging the drilling element while permitting the drilling element to move toward the face for forming the borehole. The drill guide is adapted for pivoting movement between a retracted position for releasing the drilling element from the drill guide and an active position for associating the drilling element with the drill guide. A retainer is provided for retaining the drill guide in at least the active position. A controller is also provided for actuating the retainer on receiving at least one signal corresponding to the movement of the drill relative to the drill guide.
The controller may actuate the retainer on detecting the presence of one of a feed signal or a rotation signal, or both. The controller may deactivate the retainer to allow for manual movement of the drill guide to the retracted position when both the feed signal and the rotation signal are removed.
A further aspect of this disclosure pertains to a drill guide having a first jaw for engaging a drilling element in a first plane and a second jaw for engaging the drilling element in a second, adjacent plane. The first jaw may be mounted for pivoting movement relative to the stationary second jaw.
Still another aspect of this disclosure relates to a drill guide having a support, the support including a notch forming a first jaw for receiving the drilling element and supporting a second jaw pivotally mounted to the support and having a second notch for receiving the drilling element.
Yet a further aspect of the disclosure pertains to an apparatus for use in connection using a drill having a drilling element for forming a borehole in a face of a mine passage in connection with a mast. The apparatus comprises a drill guide for engaging the drilling element while permitting the drilling element to move toward the face for forming the borehole, the drill guide including at least one movable jaw. The apparatus further comprises an elongated shaft extending along the mast and connected at one end to the at least one movable jaw. An actuator is adapted for rotating the elongated shaft for moving the at least one jaw of the drill guide.
In one embodiment, the actuator comprises a cylinder including an extendable rod connected to the elongated shaft. The apparatus may further include a delivery line for delivering a working fluid to or from the cylinder. The delivery line may extend extending along the mast.
Still another aspect of this disclosure pertains to an apparatus for use in connection using a drill having a drilling element for forming a borehole in a face of a mine passage. The apparatus comprises a drill guide having one or more movable jaws for engaging the drilling element while permitting the drilling element to move toward the face for forming the borehole. The drill guide includes a guard having a guide for guiding the drilling element to a position for being engaged by the one or more jaws.
In one embodiment, the guard comprises a pair of spaced plates, and the guide is non-linear. The guide may include an open end and a closed end. The closed end may align with the opening in the drill guide for receiving the drilling element.
Another aspect of this disclosure relates to a method for guiding a drilling element for forming a borehole in a face of a mine passage. The method comprises providing a manually operable drill guide for engaging the drilling element while permitting the drilling element to move toward the face for forming the borehole, the drill guide adapted for pivoting movement to move between a retracted position for releasing the drilling element from the drill guide and an active position for associating the drilling element with the drill guide. The method further comprises preventing the drill guide from moving to the retracted position during the drilling of the borehole.
The method may further include the step of providing a biasing element for biasing the drill guide in at least the active position. Still further, the method may include the step of biasing the drill guide in at least the retracted position, and further including the step of manually moving the drill guide by overcoming the biasing.
A further aspect of this disclosure relates to a method of delivering a drilling element to a drill guide associated with a drill including a chuck for receiving the drilling element upon being inserted therein. The method comprises delivering the drilling element though a guard for guarding the drill guide before inserting the drilling element in the chuck. The delivering step may comprise passing a portion of the drilling element through a labyrinth guide.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIGS. 1-4 schematically illustrate a drill mast in various positions for use in forming boreholes in one or more faces of a mine passage;
FIG. 5 schematically illustrates a drill guide in a non-actuated condition;
FIG. 6 schematically illustrates the drill guide of FIG. 5 in an actuated condition;
FIG. 7 is a perspective view of a drill mast including a second embodiment of a drill guide;
FIG. 8 is a perspective view of the drill guide of FIG. 7 in an actuated condition;
FIG. 9 is a perspective view of the drill guide of FIG. 8 in a non-actuated condition;
FIG. 10 is a perspective view of a third embodiment of a drill guide including a guard; and
FIG. 11 is a top view of the drill guide of FIG. 10 .
DETAILED DESCRIPTION
Referring now to FIGS. 1-4 , this disclosure relates primarily to a drill guide 10 for use in a drilling or bolting machine, or “bolter.” This bolter is used in connection with the installation of support in a face of a mine passage. Specifically, such a bolter is adapted for forming a borehole in the face, and then subsequently installing an anchor (typically an elongated piece of rebar called a “roof bolt”) in the borehole. The drill guide 10 typically lends support to and provides guidance for a drilling element, or “drill steel,” prior to and during the process of forming the borehole, but must also allow for release when the operation is complete. Although reference will be primarily made herein to a drilling element, it should be appreciated that a drill guide may also lend support for the anchor prior to installation in the borehole.
As shown in FIG. 1 , the bolter typically includes a mechanism for advancing and retracting a drill D (which includes a chuck for receiving the drilling element) toward any away from the case. This mechanism may comprise a “two-stage” linear mast M having an extendable roof jack J with one or more rods R that are received in a base B. The rods R may support the drill guide 10 at the distal end adjacent the face in use. The drill guide 10 may alternatively or additionally be provided on the base B to lend intermediate support, or elsewhere in the drilling path, without limitation.
The base B supports an elongated bearing member G (such a beam), which in turn carries the drill D during movement toward and away from the mine face (compare FIGS. 2, 3, and 4 ) in response to the activation of an onboard feed mechanism E, which may comprise a chain drive, linear cylinder, or the like. The bearing member G may also be adapted for moving toward and away from the face (compare FIG. 1 and FIG. 4 ), and thus may be mounted to the base B so as to permit movement in a linear path in the desired direction.
Turning to the plan views of FIGS. 5 and 6 , the details of one possible embodiment of a drill guide 10 are shown. The drill guide 10 may comprise a support 12 in the form of a plate having a major surface generally parallel to the plane of the face to be worked. This plate 12 includes a peripheral notch 12 a arranged for receiving the drilling element. Positioned adjacent to the notch 12 a is a keeper for keeping the drilling element in the space provided. In one embodiment, this keeper may comprise a holder 14 serving as a first jaw for temporarily holding the drilling element in place before and during the time it is advanced toward and into the face to form the borehole.
In the active position, the holder 14 includes a first end having a notch 14 a adapted for receiving the drilling element and retaining it within the corresponding notch 12 a of the plate 12 , which may be considered to form a second jaw. As should be appreciated, these jaws lie in different, but adjacent, horizontal planes, thus forming a scissor-like arrangement. The notches 12 a , 14 a are shown as being generally V-shaped, but of course could be round, square, or have other shapes while achieving the desired holding function for the drilling element.
As should be appreciated, it is desirable to arrange the drill guide 10 for ready retraction to admit the drilling element, and then activation to hold the drilling element in place. To achieve this, the holder 14 in the illustrated embodiment is mounted for pivoting movement relative to the plate 12 between an open position for allowing notch 14 a , which is generally U-shaped, to receive the drilling element ( FIG. 5 ) and a closed position ( FIG. 6 ) for confining the drilling element within notch 12 a . The primary pivot point for the holder 14 is designated as P 1 .
To provide the movement between these positions, the holder 14 connects with a retainer, which in the illustrated embodiment includes a linear actuator in the form of a hydraulic cylinder 16 . This may involve connecting the holder 14 to the rod 16 a of the cylinder 16 in a manner that allows for relative pivoting movement (designated as P 2 ). The case 16 b may also be connected to a support, such as plate 12 , in a manner that allows for pivoting movement in the same general plane as the holder 14 . The pivot point for the cylinder 16 is designated as P 3 .
Depending on the arrangement, it may be desirable to define the boundaries of relative lateral movement of the holder 14 . This may be achieved using stops 18 , 20 , with the first stop 18 corresponding to the open condition and the second stop 20 corresponding to the closed condition. The stops 18 , 20 may comprise extendable, threaded bolts journaled in a support structure, which thus can be adjusted as necessary to provide an engagement surface for the corresponding portion of the holder 14 in the illustrated embodiment. However, it should be appreciated that the stops could also engage the cylinder 16 or other associated structures to achieve a similar result.
The retainer may include a biasing element for urging the holder 14 toward the retracted or active condition, depending on the mode of use. In the illustrated embodiment, the biasing element comprises a coil spring 16 c contained within the case 16 b of the cylinder 16 that normally urges the rod 16 a in a direction along the longitudinal axis L. As will be understood upon reviewing the description that follows, the biasing or spring force along the axis L is selected so that it retains the holder 14 in the active or retracted position, but can be overcome with the application of only manual effort to extend or retract the rod 16 a when the cylinder 16 is not pressurized. In use, the holder 14 may be considered initially in the open position, as shown in FIG. 5 . As should be appreciated, the biasing force aligned with axis L is offset from pivot point P 1 . Thus, it creates a moment that keeps the holder 14 in the open condition, with stop 18 engaged.
Once associated with the drilling element (shown in cross-section as element T in the plan view FIG. 6 ), the holder 14 may be rotated toward the closed position, at which point the biasing force aligned with axis L is overcome and the linkage moves past the over center or equilibrium position until engagement with stop 20 is made. The moment about pivot point P 2 created by the spring force keeps the holder 14 in the closed condition. In this position, the drilling element is captured in the substantially aligned notches 12 a , 14 a , and the drilling operation may proceed.
Once the holder 14 is closed, the keeper or retainer is used to maintain the linkage in the corresponding position. This may be achieved by using a controller for controlling the supply of pressurized fluid from a remote source. In its most basic form, the controller may comprise a valve V (which may include a two position, three way spring return valve). The valve V may be actuated when a corresponding pilot signal is received, which may be activated by a push button or the like.
Alternatively, the pilot signal may automatically issue. For example, the signal may be generated once corresponding signals for feeding and for rotating the drill are provided to a feed and rotation controller C associated with the valve V. The feed and rotation signals may be generated by one or more input devices I (e.g., one or more joysticks, buttons, or the like, positioned at a control panel or elsewhere on an associated mine vehicle, generally away from the location on the face where the borehole is being formed).
This optional requirement for feed and rotation signals before activation of the cylinder 16 helps to assure that the operator is clear of the drill guide 10 after the manual closing operation is completed. Likewise, the pressure may be maintained on the cylinder 16 until both signals for causing feed and rotation of the drill D are removed. This prevents the operator from manually opening the drill guide 10 by moving the holder 14 while either feed or rotation is occurring.
Once feed and rotation signals are removed (usually meaning the borehole is complete and the drill D has been retracted fully from the face), the holder 14 may be manually moved to the open position. The drilling element L may then be withdrawn from the guide 10 , such as by removing it from the notch 14 a of holder 14 . If desired, the operation may then be repeated with an anchor element, such as a roof bolt.
Another embodiment of an improved drill guide 100 is shown in FIGS. 7-9 . The drill guide of this embodiment includes a pair of jaws 102 a , 102 b mounted for movement toward and away from each other in a plane generally transverse to the direction of feed of the drill D. The jaws 102 a , 102 b may be sandwiched between a pair of spaced plates 104 a , 104 b , and mounted for relative pivoting movement about pivot points P and in a common plane.
An actuator 106 is provided for actuating the jaws 102 a , 102 b to move between a first, closed position ( FIG. 8 ) for gripping an object and a second, open position ( FIG. 9 ). The actuator 106 in the illustrated embodiment comprises a linear actuator, such as a hydraulic cylinder, which is provided spaced apart from the jaws 102 a , 102 b and plates 104 a , 104 b . This advantageously allows for the fluid supply lines to be located away from the drill guide 100 , mast, and other moving components. Specifically, in the illustrated embodiment, one or more conduits (e.g., hoses H or telescoping cylinders providing internal fluid delivery and return passages) may be provided along a sidewall of the mast.
To convert the linear movement into rotational movement, the actuator 106 may connect with a rotary member, such as an elongated shaft or rod 108 , journaled between or adjacent the drill guide 100 , such as through plates 104 a , 104 b . A linkage 110 may connect the rod 108 to one of the jaws 102 a , 102 b , such as jaw 102 b , which in turn may be connected by a link 112 to the other jaw, such as jaw 102 a . In this manner, rotation of the rod 108 causes the jaws 102 a , 102 b to open and close, and shown in FIGS. 8 and 9 , respectively.
In accordance with a further aspect of the disclosure, it is also a desirable option to provide a drill guide 200 including a guard 204 having a guide 206 for guiding the drilling element into the proper position for being gripped, while assisting in preventing the operator's hands from being inadvertently positioned in the path of movement of the gripping jaws 202 a , 202 b . In the embodiment illustrated in FIG. 10 , the guard 204 comprises at least one, and preferably a pair of spaced, generally parallel plates 208 , 210 mounted to and forming an integral part of the guide 200 . The plates 208 , 210 may be spaced apart a distance slightly greater than the height of the jaws 202 a , 202 b in the same (vertical) direction. Each of these plates 208 , 210 includes a slot 212 having an open end for receiving the drilling element and a closed end adjacent to the location where the gripping jaws 202 a , 202 b close over the drilling element in the operative position. The slots 212 may be non-linear and, specifically, may be generally L-shaped, but could take other forms including for example C-shaped, U-shaped, serpentine, or the like. In any case, the slots 212 are dimensioned so as to only slightly exceed the diameter of the portion of the drilling element adapted to be gripped by the jaws 202 a , 202 b.
In use, the operator may manually insert the drilling element into the open end of the labyrinth path of guide 206 and along the slots 212 to the position for being gripped. As should be appreciated, the arrangement is such that the operator's hands may be positioned above or below the plates 208 , 210 , but generally not in the space between them (in which space the gripping ends of the jaws 202 a , 202 b are located). Consequently, the guard 204 helps to prevent contact between the jaws 202 a , 202 b and the operator, should inadvertent actuation occur. The path formed by the guard 204 also helps to position the drilling element properly for gripping by the jaws 202 a , 202 b , especially when the closed end of guide 206 corresponds to the location where gripping occurs.
The foregoing descriptions of various embodiments are provided for purposes of illustration, and are not intended to be exhaustive or limiting. Modifications or variations are also possible in light of the above teachings. The embodiments described above were chosen to provide the best application to thereby enable one of ordinary skill in the art to utilize the disclosed inventions in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations (including the combination of any or all of the embodiments disclosed into a single apparatus) are within the scope of the invention. | An apparatus for use in connection using a drill having a drilling element for forming a borehole in a face of a mine passage includes a drill guide for engaging the drilling element while permitting the drilling element to move toward the face for forming the borehole. The drill guide includes a keeper for keeping the drilling element in a desired position, which keeper is biased for pivoting movement upon the application of a manual force between an active position for capturing the drilling element and a retracted position for releasing the drilling element. A low profile drill guide is also disclosed, as is a guard for a drill guide, and also related methods. | 4 |
This is a continuation of application Ser. No. 660,353, filed on Feb. 22, 1991, for a CAMERA HAVING A DATA RECORDING FUNCTION, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a camera, more particularly to a camera which can record data other than image of object at the time of phototaking.
2. Description of the Related Art
Among conventional cameras capable of recording data other than image of object at the time of photo-taking, various cameras have been proposed in which date data and the number of frames are automatically set, and such data are imprinted onto the film.
In addition, a camera has been known, which can imprint data of exposure control mode onto the film by attaching a device to the camera body, such as in Canon's Technical Back E. Further, as to Canon's Technical Back E, an extra keyboard unit can be connected thereto, and by operating the keys of the keyboard unit, the operator can set any arbitrary combination of letters and numbers desired to be imprinted onto the film.
However, in these conventional cameras, if the operator tried to record data regarding the location of photo-taking, he/she had to go to the trouble of manually setting each letter to be recorded in the camera one by one prior to every photo-taking operation.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a camera capable of recording data other than image of object at the time of photo-taking, which can automatically record data relating to the place where photo-taking operation is carried out.
It is also an object of this invention to provide a camera which can record data relating to place together with image of object without having the operator do any special manual operation for that purpose.
It is still another object of this invention to provide a camera which can record data relating to place together with image of object without installing a special manually operable member.
It is yet another object of this invention to provide a camera capable of recording data other than image of object at the time of photo-taking, which can record the data in accordance with wireless electric waves transmitted from an external device.
It is another object of this invention to provide a camera system capable of searching for picture images recorded by the camera, which can conduct such search by data relating to place.
It is further another object of this invention to provide a camera system capable of searching for picture images recorded by the camera, which can easily record data, as search data corresponding to every picture image, which is easy for the operator to remember.
In order to attain the above-described object, a camera according to the present invention includes: first means for recording an image of an object on a recording medium at every photographic shot, means for receiving an electric wave transmitted from an external device in a wireless manner and second means for recording data corresponding to every photographic shot in accordance with the electric wave received by said receiving means.
Since the camera system according to the present invention includes the above-described elements, the camera records data in accordance with wireless electric waves from outside equipment, and therefore, it is not necessary for the operator to manually set data corresponding to every shot, to be recorded. Furthermore, it is not necessary to provide a manually operable unit for that purpose on the camera.
In order to attain the above-described object, a camera according to the present invention includes: first means for recording an image of an object on a recording medium at every shot, means for automatically detecting a place where the shot is carried out and second means for recording data relating to the place detected by said detecting means with respect to every shot.
Since the camera system according to the present invention includes the above-described elements, the camera automatically detects the place where a photo-taking operation is carried out and records the data in accordance with the detection. The operator, therefore, can record data relating to place together with the image of object without any special manual operation for that purpose.
According to a further aspect of the present invention, a camera system according to the present invention includes: first means for recording an image of an object on a recording medium at every shot, means for receiving an electric wave transmitted from an external device in a wireless manner, second means for recording data corresponding to every shot in accordance with the electric wave received by said receiving means, means for designating data relating to a desired image and means for searching, among data recorded by said recording means, for data identical with the data designated by said designating means to detect the desired image.
Since the camera system according to the present invention includes the above-described elements, the camera records data corresponding to the picture image in accordance with wireless electric waves transmitted from outside equipment, and a search for the recorded picture images may be carried out using said data. The operator, therefore, does not need to manually set search data corresponding to each picture image prior to every photo-taking operation.
According to a still further aspect of the present invention, a camera system according to the present invention includes: first means for recording an image of an object on a recording medium at every recording event, e.g., shot, means for storing in advance a plurality of data relating to various places, respectively, means for selecting one of the plurality of data stored by said storing means, second means for recording the data selected by said selecting means with respect to every shot, means for designating a data relating to a desired image and means for searching, among data recorded by said second recording means, for a data identical with the data designated by said designating means to detect the desired image.
Since the camera system according to the present invention includes the above-described elements, the camera can easily record data relating to place as search data corresponding to every picture image. Further, place is often more vividly remembered by the operator than date and time, it is likely that searches will be easier than conventional searches using date data.
The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the inside structure of the still video camera in Embodiment 1.
FIG. 1A shows a variant of the inside structure in Embodiment 1.
FIG. 2 shows one example of data relating to place stored in the camera in Embodiment 1.
FIG. 3 is a block diagram of the inside structure of the still video camera of Embodiment 2.
FIG. 4 is a detailed block diagram of 10, 11 and 12 of FIG. 3.
FIG. 5 shows a segmental block diagram of modified Embodiment 2.
FIG. 6 is a block diagram of the inside structure of the SLR camera of Embodiment 3.
FIG. 7 is a block diagram of one example of a structure for search by recorded data.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the invention will be explained below with reference to drawings.
Embodiment 1
Embodiment 1 will be explained referring to FIG. 1 and FIG. 2. FIG. 1 is a block diagram of the circuit structure inside a still video camera housing 30. The image of an object taken by means of lens 1 is converted to electrical image signals by an image sensing device 2, such as a CCD, which are then converted to recording signals by the modulation circuit 3. Then the image can be recorded on a recording medium in FIG. 1 such as an IC card, magnetic disk or optical disk through a record amplifier 4. Meanwhile the output from modulation circuit 3 is output to the monitor 8, which is equipped with a display element such as an LCD, enabling the operator to monitor the image while taking it.
On the other hand, as shown in FIG. 2, data relating to places is stored in categories such as area, state and city in the built-in ROM (read-only memory) chip 5. Each category contains a trigger to move to another category (the arrows in the figure). The switches 1 to 4 in data selection circuit 6 in FIG. 1 are the selection switches for each category. The operator can select any place data by using the switches.
Specifically, the operator selects one area among the available area names (Western, for example) by pressing switch 1 as many times as he chooses. He then selects one state among the available state names (California, for example) by pressing switch 2 and then one city among the city names (Los Angeles, for example) by pressing switch 3. He can also select one tourist spot among the available tourist spot names by pressing the switch 4. If the operator wants to go back to the first category above, he can do so by selecting the arrow.
The place data selected above are output to both monitor 8 and record amplifier 4 by data output unit 7 in the form of electric signals. Record amplifier 4 inputs date and time data from a known circuit not indicated in the figure, adds the place data and date/time data onto the recording signals, and records them according to the operation of a shutter release button, which is also not shown in the figure. The monitor 8 displays the selected place data on a display element provided beside display element for the picture.
The place data to be recorded on the recording medium through record amplifier 4 can be imposed on the pictures as letter-image signals; however, in this embodiment, they are recorded as codes apart from the pictures.
In addition to place-names, it is also possible to store various other data relating to place, such as origins of city names and special products of the region, in ROM chip 5.
Further, as in FIG. 1A, it is also possible to provide ROM chip 5 in the form of an easily exchangeable CD-ROM or IC card so that a ROM chip containing specific data can be used for each different location.
Embodiment 2
Embodiment 2, which is a still video camera, will be explained referring to FIG. 3. Elements which function in the same manner as those in FIG. 1 or FIG. 2 have the same numbers as those in said figures.
The picture taken by lens 1 is converted to electronic signals by an image sensing device 2 and can be recorded on a recording medium via a modulation circuit 3 and record amplifier 4 in accordance with the operation of a shutter release button. This still video camera contains a built-in receiving circuit 10 which can receive electric wave from transmitting stations (satellites) using such methods as loran, Decca, Omega or GPS, Demodulation unit 11 demodulates the electric wave which is received when the still video camera starts its operation. The present location is determined by means of data determination unit 12 based on the demodulated signals in accordance with the respective method.
FIG. 4 is a detailed block diagram of receiving circuit 10, demodulation unit 11, determination unit 12 and their peripherals when, for example, current location is determined from the electric waves from a transmitting satellite.
Antenna 10a is, for example, of the quadrifilar helix type, which receives transmitted electric waves from a Navastar satellite not drawn in the figure. The RF signals received by this antenna 10a are transmitted to mixer 16a. On the other hand, modulator 16b defuses the local oscillation signals CK 1 from local oscillator 19a by the PN code signals from PN code generator 17, and the diffused modulation signals are input to said mixer 16a. In this way, said RF signals are converted into IF signals, as an intermediate frequency, and input to data demodulation circuit 11a. The data demodulation circuit 11a demodulates from the input signals a data concerning time of data transmission from the satellite. The demodulated data is input to data determination circuit 12a and delay measuring circuit 18.
When demodulated data is input to delay measuring circuit 18, said delay measuring means first transmits timing signals to PN code generator 17. PN code generator 17 is generating PN codes at all times by clock pulse CK 2 from PN code clock generator 19b, and is so designed to transmit the generated PN codes to delay measuring circuit 18 when it receives said timing signals. Then the PN code from data demodulation circuit 11a and the PN code from PN code generator 17 are transmitted to delay measuring circuit 18, and the delay time necessary for obtaining the correlation of the two PN codes is measured. The delay time between the two PN codes is measured by counting the high frequency clock pulse CK 3 from measuring clock generator 19c. The count is transmitted to data determination circuit 12a from delay measuring circuit 18 as delay data needed for the correlation of the two PN codes.
The data determination circuit 12a is composed of microprocessors and is driven by clock pulse CK 4 from data processing clock generation circuit 19d. It calculates the time taken for the transmission of the electric waves from the satellite to the GPS receiver (or the camera) in accordance with the transmission time data included in the demodulated data from data demodulation circuit 11a and the receiving time data obtained from a cesium or rubidium-vapor atomic clock, not shown in the figure, and in response to the calculated time it calculates the distance from the satellite to the GPS receiver (or the camera). Then the data determination circuit 12a calculates information regarding latitude, longitude and altitude of the camera (or the operator) on the basis of the information regarding distance from the respective satellite and information regarding the location of the satellite included in the demodulated data.
The determination is made by first calculating the absolute location in terms of longitude, latitude and altitude as explained above, and then selecting a place data corresponding to the absolute location through checking the place names and their respective area data stored in the determination unit 12, as in the case of Embodiment 1. Place data obtained by the data determination unit 12 is output to data latch 13. In addition, data determination unit 12 contains a switch, not indicated in the figure, and unless this switch is operated, the place data in data latch 13 cannot be rewritten. Therefore, the same place data may be continuously selected when the operator does not want to change the place data to be recorded or when the conditions for transmission of electric wave have deteriorated.
Though the above data determination unit 12 transmits a specific place name, it is possible to simply transmit the longitude and latitude.
Furthermore, the still video camera contains a built-in sensor 14 which can detect the temperature and humidity at the time of picture-taking. The detected results are transmitted to data latch 13 after being matched with the place data in data type by signal processing unit 15. While place data and temperature/humidity data are always output to monitor 8 from data latch 13, the data are output to the record amplifier 4 only when the shutter release button, not indicated in the figure, is operated. These data are added to the image data by the record amplifier 4 and recorded in a recording medium.
In this embodiment, receiving unit 10, demodulation unit 11, data determination unit 12 and data latch 13, employed in producing place data, are provided in the camera in built-in form; it is also possible to provide them as modular components detachable from the camera body.
Further, since it is usually not necessary to precisely determine the location by the loran method, for example, it is also acceptable to determine location by receiving electric waves from existing AM or FM radio stations with receiving circuit 10, demodulating them with demodulation unit 11 and detecting the frequency and field intensity of the electric wave with data determination unit 12 (referring to FIG. 5). It would be useful as well, too, to install a local transmitting station, which transmits codes relating to place directly, in tourist areas or tourist facilities (e.g., major JR or private railway stations, service area, parking area or interchange of expressways, bays, ships, etc.) for the camera to receive the code from these stations and determine the location through decoding said code.
Embodiment 3
Embodiment 3, which is an SLR camera, will be explained with reference to FIG. 6. Elements having the same functions as those in FIG. 1, FIG. 2 or FIG. 3 have the same numbers as in said drawings.
The image of object obtained through lens 1 is recorded on a film in accordance with the operation of a shutter release button, not indicated in the diagram. When the switch A is ON, place data and temperature/humidity data from data latch 13 are recorded on the film simultaneously by data record module 20.
The position of the recording of the data can be either inside or outside a frame of the film. It is also possible to record a portion of the data inside the frame and the rest outside the frame.
Searching
Searching of image of object recorded by the above-described cameras will be explained referring to FIG. 7.
When a recording medium which has already recorded is set in the filing device, in accordance to selection of recorded place data or date/time data, the image can be selectively reproduced by the signal reproduction unit 21 of the filing device, which has a built-in magnetic reproducer or photoelectric converter. The recorded data corresponding to the place and date/time inputted by operation board 21 is searched in response to the output of data comparison unit 23, and when the recorded data corresponding to the inputted data is found, they are sent to an outer monitor 24, such as a television receiver, together with their corresponding recorded image. The data and image are then displayed on an outer monitor 24.
If, when searching by place name, the filing device is set to search all place data in lower categories (e.g., Disneyland, Rose Parade) of the place data inputted by the operation board 22 (e.g., California), it will be more convenient to search records regarding travel.
As explained above, if data relating to place can be recorded, searching of records will be easier than conventional data-based searching, because people generally remember places easier than dates. Further, more search methods are available because the search can be done by such other data relating to the place as weather and event, in addition to the place name itself. | A camera is disclosed which has means for receiving an electric wave which is transmitted from an external device in a wireless manner (e.g., equipment for radio navigation systems, satellites and radio stations). When an image of an object is recorded at every shot on a recording medium loaded in said camera, a data corresponding to every shot is recorded in accordance with the electric wave received by said receiving means. Preferably said camera further has means for detecting a place where the photo-taking operation is carried out and in accordance with the detection of said detecting means, the data corresponding to every shot is recorded. Thus, records of the object image together with data relating to place can be obtained without any manual operation prior to every photo-taking operation. | 7 |
BACKGROUND OF THE INVENTION
This invention relates to wellheads and to apparatus providing capability for removal and insertion of wellhead stripper rubbers through a blowout preventer, such apparatus being more particularly useful as a workover tool for conversion of existing wellheads to units having enhanced reworking capabilities.
Superatmospheric pressures exist, or may be suddenly encountered, in many wells, such as oil and gas wells, and accordingly drilling and producing operations must be carried out while the pressure in the well bore is confined. Blowout preventers are used on many wells which include devices being capable of sealing the annular space between an inner and an outer pipe or casing. Such blowout preventers are not a permanent portion of a wellhead and if wells are under pressure, then blowout preventers are positioned on a wellhead prior to reworking of the well, which blowout preventers are subsequently removed and used on another well to be reworked.
When reworking is required on a well, for example of the type requiring removal of a tubing string, wells with pressure not having an effectual stripper rubber must either be provided with a stripper rubber or killed. If a well with pressure or having the possibility of being with pressure is to be reworked, a blow out preventer is also utilized during the reworking operation. Installation of a stripper rubber in a wellhead requires killing of the well unless the stripper rubber can be installed through an in place blowout preventer. Killing a well, that is, the process of feeding a fluid such as water down into the well bore to provide a pressure head, is undesirable as a result of the time and expense involved in the operation. Additionally, there is an ever present possibility that a well which has been killed cannot be revived, ending its useful production life.
Even when blowout preventers are used, if a stripper rubber is unavailable the operation can be undesirably time consuming and cause wear on the components involved. Proper pulling of a tubing string through a blowout preventer on a live well requires having a stripper type apparatus. Without a stripper apparatus such pulling involves, for example, opening of a bottom one of a pair of rams, movement of the tubing collar passed the open bottom ram, closing of the open ram and opening of an upper of the pair of rams, and further upward movement of the tubing coupling through the upper ram which is subsequently closed. This operation must be continuously repeated.
Pulling of tubing is preferable with a stripper rubber in place, as the stripper rubber functions to retain pressure by sealing against the tubing, and it also performs a cleaning function, stripping deposits from against the tubing. Only when the last joint of tubing is pulled uwpardly through the blowout preventer must the sequential opening and closing of the pair of rams be utilized. During pulling of the balance of the tubing string, contact between the stripper rubber and tubing, including the coupling, retains the pressure below the stripper rubber. In this operation, however, the stripper rubber is subjected to high wear as each coupling is pulled through the stripper rubber, continually flexing the stripper rubber. Because of this wear, the stripper rubber needs to be removed and replaced as part of the reworking operation.
In most producing wells removal of the stripper rubber is difficult, requiring killing of the well. Although some wellheads, and particularly many so called flange type wellheads, allow removal of a stripper rubber through an in place blowout preventer so that killing of the well is not required, a large number of commercially producing wellheads do not provide such removal and replacement capabilities. In particular, the most common of the so called threaded or screwed type wellheads have included a design whereby a stripper rubber is seated in a casing or tubing body or head and a stripper attachment threadedly attached to the head includes an interior shoulder overlapping the top surface of the stripper rubber. Thus, the stripper rubber can only be removed from the head subsequent to removal of the attachment from the head, which cannot be performed with a blowout preventer in place due to the configuration of the attachment. Accordingly, wells of this type must be killed for proper repair or other reworking activities. Prior to the instant invention, the capability for a relatively simple manner in which to convert the large number of field operating production screwed type wellheads to units allowing stripper rubber insertion or removal though a blowout preventer has not existed.
It is thus desirable to provide wellhead apparatus which allows reworking of the wellhead without requiring killing of the well. It is also desirable to provide such structure which allows removal and insertion of a stripper rubber into the wellhead through an in place blowout preventer. It is further desirable to provide a method whereby existing production wells not having the capability for stripper rubber replacement through an in place blowout preventer can be readily modified to have such capability. As flanged wellheads, compared to screwed wellheads, are particularly expensive, generally heavier and more massive then screwed wellheads, it is particularly desirable that such method and apparatus be available with screwed, as opposed to flanged, wellhead apparatus.
SUMMARY OF THE INVENTION
This invention provides apparatus for facilitating wellhead opertions including method and structure for the modification of existing screwed type production wellheads which do not have the capability for removal of a stripper rubber through a blowout preventer readily into wellheads having such capability. Thus, instead of having to kill a well each time reworking is performed, a well need only be killed one time to make the modification, and subsequent operations will not require detrimental killing of the well.
In preferred form a wellhead body portion, such as a tubing head, includes a male threaded top to which is sealingly secured a female threaded adapter. The interior bore of the adapter includes, from top to bottom, three sections of progressively decreasing diameter, such that an upper shoulder and lower shoulder are formed within the adapter. A stripper rubber seats on the lower shoulder and is maintained in position against the upwardly directed well pressure by a plurality of radial hold down screws. The screws are housed in barrels which removably or fixedly extend laterally from the adapter wall. Removable barrels allow for relative ease of replacement in the event that the threads attaching the barrels to the adapter wall or the threads about the hold down screw become worn or corroded in the operating environment. Removal of the barrels can also facilitate reworking operations and attachment of chains or other tooling. Additional discussion of the removable barrels is provided in the below cross-referenced application.
A slip assembly is positioned within the adapter above the stripper rubber, and is seated on the upper shoulder. Threadedly secured to the top of the adapter is a top piece such as a top nut which restrains against upward pressure within the wellhead and which seats packing rings or other sealing means positioned atop the slip assembly.
Thus, upon removal of the top piece and packing, the slip assembly, and particularly the stripper rubber upon retraction of the hold down screws, can be removed upwardly from the adapter and passed through a blowout preventer. Moreover, existing wellheads not having such capabilities can be readily modified with a relatively minimal amount of new structure while reutilizing much of the structure existing prior to the modification.
CROSS REFERENCE TO RELATED APPLICATION
This disclosure is closely related to U.S. patent application Ser. No. 529,306 in the name of Bigbie et al entitled Wellhead System with Removable Self Sealing Stripper Rubber, filed concurrently herewith and hereby incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages, nature and additional features of the invention will become more apparent from the following description, taking in connection with the accompanying drawings, in which:
FIGS. 1 and 2 are elevation views, in cross section, of common prior art wellheads known respectively in the industry as a type R and a type SR wellhead;
FIG. 3 is an elevation view, in cross section, of a wellhead structure in accordance with the invention; and
FIG. 4 is an elevation view, in cross section, of a wellhead structure in accordance with the invention including a blow out preventer.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring initially to FIGS. 1 and 2 there are shown two screwed type wellheads commonly in use in production wells. The wellhead shown in FIG. 1 includes a bottom body or head 10 extending upwardly at the top of a well bore. It will be recognized that such heads 10 are commonly made with one of three types of bottom configurations 12, a female threaded connection as shown, a male threaded connection, or a slip joint welded connection. A conduit such as a string of production tubing 14 extends through the wellhead and into the well bore, which can, for example, convey a fluid petroleum product to an outlet. The tubing string generally includes couplings 16 joining thirty-foot tubing 14 sections. An annulus 17 is formed between the head 10 and the tubing 14. A connection is made between the bottom configuration 12 of the head 10 and other wellhead structures eventually transferring the load of the tubing string and wellhead components to the ground, such as a surface casing. The head 10 includes apertures 18 which can, for example, be used as outlets for gas production or inlets for brine water used to kill the well during a reworking operation.
Seated on a ledge 20 of the head 10 is a slip assembly 22 including a slip bowl 24 supporting hinged slips 26. The head 10 includes a male threaded top portion 28 to which matingly attaches a female threaded top nut 30. Disposed between the slip assembly 22 and the top nut 30 are packing means such as a packing 32 including a metallic top packing ring 34, an intermediate rubber packing ring 36, and a metallic bottom packing ring 38. The top nut 30 provides a downwardly acting force on the packing 32 and the packing 32 annularly seals the upper area of the head 10. The wedging interaction of the bowl 24 and slips effects gripping of the tubing 14 and maintains the elevation of the tubing 14.
The prior art wellhead shown in FIG. 2 includes in common with the wellhead of FIG. 1 certain components including the head 10, a slip assembly 22, the packing 32 and the top nut 30. It will be recognized that in field use the top nut 30 of both wellhead types is oftentimes replaced with additional components for attachment of further mechanisms such as blowout preventers, production valves, spools, siamese and frac adapters, and additional production heads.
The wellhead of FIG. 2 additionally includes an attachment 40, a stripper rubber 42, and a sealing O-ring 44. The attachemnt 40 includes a female threaded bottom portion 46 matingly sized to the top portion 28 of the head 10 so that the attachment 40 is threadedly secured to the head 10 and is sealed heretofore by O-ring 44. The slip assembly 22 seats on a ledge 47 of the attachment 40.
The stripper rubber 42 seats on the ledge 20 of the head 10, and is retained in position against upward movement by a rib 48 of the attachment 40. Pressure in the annulus 17 tends to force the stripper rubber against the periphery of the tubing 14, thereby creating a seal. Pressure forces also act to push the stripper rubber upwardly. The configuration of the rib 48, overlapping the stripper rubber 42, requires that the attachment 40 to removed from the head 10 in order to allow removal of the stripper rubber from the body.
Referring now to FIG. 3, there is shown an improved wellhead 50 in accordance with this invention. The wellhead 50 includes a generally cylindrical hollow body 52 extending upwardly at the top of a well bore. The body 52 in many instances will be an existing wellhead such as the head 10. As with the head 10, the body 52 includes a bottom configuration 12' of either a female threaded connection as shown, a male threaded connection, or a slip joint welded connection. Tubing 14 extends through the body 52, forming an annulus 17' in fluid communication with apertures 18'. The body 52 also includes a male threaded top portion 28'. Alternate thread arrangements can also be utilized.
Threadedly attached to the body 52 is an adapter 54. The adapter 54 is preferably of a generally cylindrical configuration having a wall 53 and interior bore 64. The adapter includes a bottom portion 56 having female threads for connection to the male threaded top portion 28' of the body 52. Also included are means for sealing the adapter 54 and the body 52, such as a groove 60 in a seating surface 58 which receives an O-ring 62. The adapter differs from, for example, a tubing head in that the adapter 54 does not have a production outlet port which is a part of a tubing head.
The interior bore 64 of the adapter includes three interior cross sectional dimensions or inside diameters. The inside diameters of the bore 64 decrease from the top to the bottom of the adapter. Accordingly, an upper diameter 66 is larger than an intermediate diameter 68 which is larger than a lower diameter 70. This configuration forms upper means for seating a slip assembly 22', such as an upper shoulder 72, and lower means for seating a stripper rubber 86, such as a lower shoulder 74, within the interior bore 64 of the adapter. The peripheral dimensiion or diameter of the upper shoulder 72 is greater than that of the lower shoulder 74.
The preferred adapter 54 includes means for attaching a plurality of barrels 76 through the wall 53, such as threaded apertures 78. The interconnection of each barrel 76, which extends radially or laterally at an angle from the adapter, and the adapter 54, is sealed by an O-ring 80. The barrels 76, preferably four in number spaced at ninety degree intervals about the adapter 54, each contain an adjustable hold down screw 82 selectively extendable into the adapter bore 64. The hold down screws 82 are sealed to the barrels 76 through a packing 84. Additional advantages and structure associated with the removable barrels 76 are discussed in the cross-referenced application.
Seated on the lower shoulder 74 is the stripper rubber 86. The stripper rubber 86 is inserted into the adapter with the hold down screws 82 in a retracted position. Subsequently the hold down screws 82 are extended into the bore 64 and provide a means for restraining the stripper rubber 86 against upward motion from the influence of pressure in the annulus 17'. It will be noted that when the hold down screws are retracted from the bore, there is no structure obstructing insertion or removal of the stripper rubber 86 through an upper end 88 of the adapter 54.
Seated on the upper shoulder 72 is the slip assembly 22'. Preferably the upper interior diameter 66 and the configuration of the upper shoulder 72 is identical to that of the ledges 20, 46, (FIGS. 1 and 2) such that the slip assembly 22' can be identical with slip assembly 22. Affixed to the male threaded upper end 88 of the adapter is a female threaded top piece such a a top nut 30' which can be identical to the top nut 30. It will be recognized that such interconnections among component parts of the inventive structure, such as the body 52, adapter 54 and top nut 30', can be alternatively male threaded, female threaded or otherwise configured for interconnection. As with the interchangeability of the top nut 30, 30', a packing 32' including a top packing ring 34', an intermediate packing ring 36' and a bottom packing ring 38' can be identical to the packing 32. It will be recognized that for attachment of other structures, such as a blowout preventer, the top nut 30', packing elements 34', 36', 38' and slip assembly are removed and a top piece adaptably threaded to mate with the upper end 88 of the adapter is attached.
It will now be apparent that with a wellhead 50 configuration of the type disclosed, the stripper rubber 86 can be removed from the wellhead through a blowout preventer affixed above the adapter 54, merely by withdrawing the hold down screws. FIG. 4 shows in simplified fashion a blowout preventer 90 affixed atop the adapter 54 by bolts 92. The blowout preventer is shown with lower rams 94 being retracted on the left hand side of the Figure and being inserted on the right hand side of the Figure.
It will also be apparent that existing production or other wells can readily be modified to structures having the benefits of the inventive wellhead 50. To modify an operational wellhead of the type shown in FIG. 1, the well will be killed once, and the top nut 30 or other top structure will be removed along with the packing 32, the slip assembly 22 and preferably the tubing 14. The adapter 54 is then affixed to the top portion 28 of the head 10. A new stripper rubber 86 is seated on the lower shoulder 74, the hold down screws are extended, and the original slip assembly 22 or a replacement is replaced onto the upper shoulder 72. The packing 32, if in functional condition, can also be re-used. A top piece, such as the original top nut 30, is affixed to the adapter 54. Modification of the type of wellhead of FIG. 2 is similar. The top nut 30, attachment 40, packing 32, slip assembly 22 and a stripper rubber 42 are removed and an adapter 54 is affixed to the head 10. If in good condition the slip assembly 22, packing 32, and top nut can be reused. The original stripper rubber 42 will require replacement. Extension of the hold down screws 82 restrains upward motion of the replacement stripper rubber.
Modifications and additions of the specific structures and methods disclosed are possible. For example, while it is necessary that the new stripper rubber be freely insertable in the bottom shoulder of the adapter and that an upper shoulder exist to support the slip assembly, such structures can be achieved with arrangements other than that of a three diameter interior bore. For example, fabricated shoulders or ridges can be welded or otherwise formed on the interior of the adapter. Additionally, it may be desirable in the field to prepare or rethread the top surface of the body, or even cut the surface to reduce the height, prior to affixing the adapter. Other modifications and additions can be contemplated without departing from the spirit of the invention. It therefore is intended that the foregoing description and Figures be taken as illustrative, and not in a limiting sense. | Improved wellhead structure and method for modification of commercially operating wellheads. Screwed type wellheads include an adapter attached to a body extending upwardly from a well bore. The adapter supports a stripper rubber and a slip assembly on internal shoulders. An upper shoulder supporting the slip assembly and a lower shoulder supporting the stripper rubber extend radially into the central bore of the adapter a selected distance allowing unencumbered removal and reinsertion of the stripper rubber through the top portion of the adapter while the adapter is affixed to the body. Barrels radially extending from the adapter wall contain hold down screws extendable into the bore to selectively restrict upward motion of the stripper rubber. | 4 |
BACKGROUND OF THE INVENTION
Hydrocephalus is a brain condition in which cerebrospinal fluid accumulates at abnormally high pressure in ventricles or chambers within the brain. The ventricles expand in response to the pressure exerted by the fluid, and surrounding brain tissue is compressed between the ventricles and the skull. Hydrocephalus usually occurs in babies or young children, and, if unchecked, results in brain damage, enlargement and deformation of the head, and eventual death.
Modern medical methods are effective in arresting many cases of hydrocephalus, but it is often desirable to monitor pressure of the cerebrospinal fluid over an extended period to detect relapse and to determine long-range effectiveness of treatment. In the past, this measurement has been made by surgically implanting a miniature but generally conventional transducer such as a strain-gage-bridge pressure pickup. This technique requires that wiring be conducted from the implanted transducer to external instrumentation which provides excitation voltage to the bridge and detects bridge-unbalance voltage signals indicative of pressure. Alternatively, non-electrical manometric measurement methods may be used, but these techniques require installation of a conduit extending from the interior of the brain ventricle through the skull and scalp to external measurement equipment.
The primary disadvantage of these known techniques is that they involve conducting an electrical cable or fluid tube through the skull and scalp to enable direct electrical or mechanical connection between the interior of the brain ventricle and external equipment. This connection is disturbing and uncomfortable for the patient, and the danger of infection of tissue surrounding the cable or tube (and the risk of infection spread resulting in meningitis, ventriculitis, brain abscess or septicemia) requires constant supervision and usually full-time hospitalization of the patient. There is accordingly a need for a measuring device which does not require direct electrical or mechanical connection from the brain to external equipment, and which permits the patient to be ambulatory after the device is installed. pg,3
Connection-free implantable transducers have been previously proposed, and they typically function by external detection of the resonant frequency of a resonant circuit in the implanted device. For example, the prior art includes a biological pressure transducer for sensing pressure in the gastrointestinal tract and having a resonant circuit with a pressure-controlled inductor. Wireless systems are also used for sensing EEG or ECG voltages, the implantable part of the system using an electrically variable capacitor in a resonant circuit. A wireless resonantcircuit transducer has also been used for measuring intraocular pressure, the transducer using a pair of variably spaced Archimedean-spiral coils mounted on pressure-sensitive diaphragms.
The transducer of this invention operates in wireless fashion similar to the instruments described above, but provides improved performance and lower drift in implantation applications involving placement in body cavities such as brain ventricles or heart chambers where only a very small transducer can be tolerated. The transducer and is disclosed below in a specific form suitable for intracranial implantation to monitor pressure of cerebrospinal fluid in a brain ventricle. This form is also suitable for mounting on hydrocephalus shunt apparatus as often used in treating and controlling this disease.
Our transducer is, however, also suitable for implantation elsewhere in the body, and is believed to be useful in any application where a very small, implantable and wireless device is needed to measure fluid or tissue pressure. For example, the transducer is believed useful for either short- or long-term monitoring of abnormal intracranial pressure in head-injury patients, or for post-surgical monitoring of brain-tumor victims to detect possible recurrence of the tumor. When such monitoring is no longer needed, the implanted transducer is removed by a simple re-opening and closure of the overlying scalp tissue.
SUMMARY OF THE INVENTION
Briefly stated, the transducer of this invention is a sealed housing having an outer surface formed of a biologically compatible material, the housing having a pressure-sensing means such as a bellows extending therefrom. Preferably, the bellows is isolated from direct contact with the biological fluid to be monitored by a flexible balloon-like enclosure which extends from the housing around the bellows, a space between the enclosure and bellows being filled with a buffer fluid such as distilled water.
An inductor assembly is mounted within the housing, and in one form is a hollow ferrite core having a conductive coil wound on its outer surface. A variable capacitor assembly, preferably a coaxial piston-cylinder type, is fitted within the core and includes a movable element connected to the pressure-sensing means to vary capacitance of the capacitor in response to changes in pressure of the fluid being monitored and in which the transducer is immersed. The capacitor is electrically connected across the inductor to form a resonant L-C circuit, the resonant frequency of which is varied by changes in the fluid pressure applied to the bellows or similar means which in turn drives the capacitor movable element. In another form of the invention, a coaxially variable inductor is mechanically coupled to the pressure-sensing means and electrically connected across a capacitor to form a pressure-controlled, variable-resonant-frequency L-C circuit. The transducer is implanted in the body to measure pressure of surrounding fluid or tissue. In one important application, the transducer is positioned within a brain ventricle to sense pressure of cerebrospinal fluid or surrounding tissue in this body chamber. There is no direct electrical connection from the transducer to equipment external to the chamber. The resonant frequency of the L-C circuit is monitored by wireless transmission of electromagnetic energy from an external generator such as a grid-dip oscillator, thereby providing resonant-frequency data which is analogous to fluid or tissue pressure in the chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a portion of a pressure transducer according to the invention;
FIG. 2 is a side elevation, partly in section, of the assembled transducer;
FIG. 3 is a side elevation of the transducer mounted on a plug for intracranial installation;
FIG. 4 is a block diagram of external electronic equipment used with the transducer; and
FIG. 5 is a side sectional elevation of an alternative and presently preferred transducer according to the invention and using a variable inductor.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-2, a pressure transducer 10 according to the invention includes a housing 11 which is preferably a hollow cylindrical cup of cast plastic as sold under the trademark "Hysol." In a typical form, the housing is 0.550-inch long, and has outside and inside diameters of 0.275 and 0.260-inch respectively.
A hollow cylindrical ferromagnetic core 12 is sized to make a loose fit within housing 11, and the core is typically 0.500-inch long, with outside and inside diameters of 0.250 and 0.125-inch respectively. The core is preferably made from a sintered ferrite material such as sold by Indiana General Division of Electronic Memories Magnetics Corporation as "Q-2 Ferramic" material.
A coil 13 (FIG. 2) is formed by helically wrapping about 10 turns of a conductor such as 0.020-inch-diameter gold wire around the outside surface of core 12. Core 12 and coil 13 form an inductor 14 for the transducer as shown in the electrical schematic in FIG. 4.
A hollow cylindrical sleeve 17 (FIGS. 1-2) of a nonferrous material such as brass forms a fixed electrode of a coaxial variable capacitor 18 (FIG. 4) in transducer 10. The sleeve is sized to make a snug slip fit within core 12, and is typically 0.400-inch long with outside and inside diameters of 0.124 and 0.100-inch respectively.
A rod or piston 20, having a thin, integrally formed and radially extending flange 21 at one end, is also made from a non-ferrous material such as brass. A portion of the outside of the rod is covered with a thin dielectric coating 22 of a material such as tantalum pentoxide. The piston fits into sleeve 17 in piston-cylinder fashion, and forms a movable element or electrode of coaxial variable capacitor 18. The piston has an overall length of about 0.500-inch, and the piston and flange have diameters of about 0.095 and 0.020-inch respectively.
A generally cylindrical bellows 24 (FIG. 2) provides a force-summing surface for transducer 10, the bellows varying in length according to the pressure of fluid in which the transducer is immersed. A typical and suitable bellows is sold by Servometer Corporation as a Type SK4681. The bellows is made of an electrically conductive material which is preferably gold-plated nickel. The ends of the bellows are open, and each end defines an axially extending shell or flange 25.
To assemble the transducer, capacitor sleeve 17 is cemented within core 12, the left ends (as viewed in FIG. 2) of these components being flush. The left end of coil 13 is drawn around the end of core 12 and soldered into electrical contact with the sleeve. Flange 25 at the left end of bellows 24 is then slipped over the right end of core 12 and cemented in place. The right end of coil 13 is soldered or otherwise bonded into electrical contact with the bellows flange as shown in FIG. 2.
Capacitor piston 20 is then fitted through the bellows into sleeve 17, and flange 21 of the piston is secured within flange 25 at the right end of the bellows, the attachment being made with an electrically conductive cement such as a conductive silver-epoxy or gold-epoxy adhesive. The capacitor piston is thus electrically connected to the right end of coil 13 through bellows 24. Sealing of the transducer is completed by placing an annular body 27 of epoxy resin or a similar sealant between the right end of housing 11 and the bellows.
The transducer interior is hermetically sealed from the outside environment so fluid cannot seep into the bellows or variable coaxial capacitor. Preferably, the transducer is evacuated prior to final sealing, and is back-filled with dry nitrogen. Back-filling is normally done at one atmosphere of pressure to provide a transducer which functions as a "sealed gage pressure" measuring device, but other pressures may be used if a reference pressure other than one atmosphere is preferred.
Preferably, housing 11 is sheathed in a covering 29 of a biologically compatible material such as plastic sold under the trademark "Silastic." In a preferred embodiment, covering 29 is extended to form a loose balloon-like enclosure 30 around bellows 24, and enclosure 30 is filled with distilled water 31, or preferably with a fluid which approximates the composition of the fluid being monitored (such as Elliot's `B` solution when cerebrospinal fluid is being monitored) to provide a correct ionic balance on both sides of the enclosure. Pressure of the fluid being monitored is transmitted through enclosure 30 and water 31 to actuate bellows 24, but the enclosure and water form a chemical and mechanical buffer preventing tissue encroachment which could interfere with free compression and extension of the bellows.
When used as an intracranial implant in a brain ventricle or in brain tissue, transducer 10 is preferably mounted on a flanged plug 33 of a material such as Silastic plastic. Surgical installation of this equipment involves generally the same procedures used in installing hydrocephalus shunts or pressure absorbers, these procedures being briefly discussed in U.S. Pat. No. 3,583,387--Garner and Bullara titled "Pressure Absorbing Appliance for Treating Hydrocephalus."
The values of inductance and capacitance of the parallelconnected inductor and capacitor of transducer 10 can be computed and pre-determined using known engineering formulae. Circuits having nominal resonant frequencies in the range of about 30 to perhaps 100 megaHertz are believed best suited for biological applications. Higher frequencies (e.g., 200 mHz) have some advantages, but low "Q's" typically experienced in tissue at these frequencies tend to obscure the accurate external detection of resonance of the transducer L-C circuit.
Pressure range of the transducer is determined primarily by the mechanical performance of bellows 24, and these displacement-versus-pressure characteristics can also be calculated by known engineering formulae. Typical units we have tested have had an operating pressure range of 0 to 1000 millimeters of water (gage), and the transducer L-C circuit has been designed to have a zero-pressure resonant frequency of about 82 mHz. As the fluid pressure is increased, bellows 24 contracts to drive capacitor piston 20 into sleeve 17, thereby increasing the capacity of the coaxial capacitor and decreasing the resonant frequency of the circuit. A change in resonant frequency of about 20 mHz is typically obtained in driving the transducer from zero to full-scale pressure.
In use, the installed transducer is irradiated with electromagnetic energy transmitted through the body and generated by an external variable-frequency oscillator. Some of this radio-frequency energy is absorbed (and also reflected or retransmitted) by the resonant circuit, depending on how close the incident frequency is to the resonance frequency of the circuit. The frequency of the external oscillator is varied or swept until resonance of the transducer L-C circuit is externally detected. This resonant frequency is in turn indicative of the internal fluid pressure being sensed by the transducer.
A simple and accurate way to detect internal transducer resonance with an external circuit involves use of a grid-dip oscillator 35 (FIG. 4) which shows a sharp drop or "valley" in grid current when the resonant point of the "receiving" circuit is swept through by the "transmitting" oscillator. The oscillator is preferably used in conjunction with a conventional electronic frequency counter which provides a direct visual readout of frequency at the resonant point.
External phase-sensitive equipment can also be used to detect the characteristic and marked phase shift which occurs when the resonant circuit receives energy at its resonant frequency. Other external detection systems are discussed in the aforementioned article from IEEE Transactions on Bio-Medical Engineering and the references therein cited.
Prior to installation, the transducer is calibrated by immersing it in a fluid (e.g., Elliot's `B` solution) having characteristics similar to the biological fluid or tissue to be eventually monitored. The pressure of the test fluid is then varied under controlled conditions while the resonant frequency of the transducer is tracked as described above to develop a pressure-versus-frequency calibration curve.
The transducer of this invention can also be made with a variable-reactance element which is a coaxial variable inductor connected across a fixed capacitor, or both the capacitive and inductive components can be variable under control of the pressure-sensitive bellows. A presently preferred embodiment of the invention is shown as a transducer 40 in FIG. 5.
Transducer 40 includes a cup-shaped hollow cylindrical coil-supporting sleeve 41 which is preferably made of polytetrafluorethylene plastic or a medical-grade acrylic plastic. The sleeve has an annular recess 42 in which is wound an inductive coil 43 of say 12 turns of 0.005-inch-diameter copper or gold insulated wire. The ends of the coil are fed through a pair of longitudinal slots 44 at one end of sleeve 41 for connection to a miniature fixed capacitor 46 mounted on a wall 47 which closes one end of the sleeve. The coil and capacitor are preferably "potted" in a medical-grade paraffin (not shown).
A bellows 48 (generally corresponding to bellows 24 described above) is fitted over and secured to the open end of sleeve 41. A solid cylindrical ferrite core 49 is positioned within sleeve 41 to form an inductor with coil 43. A stiff metal shaft 50 (preferably a length of stainless-steel tubing of about 0.009-inch outside diameter as used in hypodermic needles) is secured to the core and extends therefrom through a central opening 51 in the closed end of bellows 48. During assembly of the transducer, the "zero" position of the core is adjusted to provide a desired inductance of the coil and core, and shaft 50 is then permanently secured to the bellows to support the core and seal opening 51.
A cup-shaped housing 53 made of medical-grade acrylic plastic is slipped over and secured to sleeve 41. An enclosure 54 is fitted over and sealed to the open end of housing 53, and this enclosure is preferably a membrane of Silastic plastic sheet. The space between the outer surface of the bellows and the inner surfaces of the membrane and housing is filled with distilled water or a fluid compatible with the characteristics of the fluid being monitored as described above.
The dimensions of housing 53 are about 0.165-inch diameter by 0.445-inch length, and a very compact assembly is provided which is suitable for implantation. A nominal resonant frequency of about 80 mHz is provided by using a capacitor of 5 picofarads and an inductance of about 0.8 microhenries. Installation and use of transducer 40 corresponds to the procedures discussed above with respect to transducer 10.
There has been described a compact variable-resonance-frequency pressure transducer using a coaxial variable capacitor or inductor controlled by pressure-sensing means such as a bellows. The use of coaxial variable-reactance components permits packaging of the transducer in a compact size and shape which enables wireless implantation in body chambers which heretofore were monitored effectively only with attached-wire measurement systems. | A wireless, surgically implantable pressure transducer for measuring pressure of fluid or tissue in a body chamber such as brain ventricle of a patient suffering hydrocephalus or a severe head injury. The transducer includes a coaxial variable capacitor electrically connected across an inductor to form a parallel resonant L-C circuit. Alternatively, a coaxially variable inductor may be connected across a capacitor to form the L-C circuit. A bellows is mechanically connected to the variable component to vary the value of capacitance or inductance and hence the resonant frequency of the L-C circuit in response to pressure changes of the fluid in which the bellows is immersed. The transducer is electromagnetically coupled to an external source of variable-frequency oscillatory energy such as a grid-dip oscillator which enables external detection of the transducer resonant frequency which is in turn indicative of the level of fluid pressure being sensed. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to optoelectronic circuits for simultaneous transmitting and receiving operation in a wavelength multiplex process, in a structure in which the relative position of active circuit components determines their operating mode. Single-stage as well as multi-stage circuits with a light waveguide arrangement and light signal detectors and light signal sources as active circuit elements for bidirectional and unidirectional transmitting and receiving operations will be disclosed. The circuits may be structured as integrated or hybrid circuits.
2. Discussion of the Prior Art
A bidirectional optical transmitting and receiving device is known from British patent specification GB-A-2,241,130 provided with an optical duplexer having a waveguide coupling device structured as a quadruple gate. Two gates of the quadruple gate at the same connection side are connected to the active circuit components for transmitting and receiving. The other two gates at the other connection side lead, on the one hand, to an external waveguide and, on the other hand, to a phase shifter. For the reduction of interfering effects between transmitting and receiving components, complementary signals are used which are guided through the actually unnecessary fourth gate and are made available by reflection at a reflecting surface and at the phase shifter.
The state of the art from which the invention is proceeding, is known from Ragdale, C. M., Reid, T. J., Reid D. C. J., Carter, A. C.: Integrated three channel laser and optical multiplexer for narrowband wavelength division multiplexing, Electronics Letters 1994, Vol. 30, No. 11. A wavelength multiplexer is described there which permits unidirectional multi-channel data transmission through a light waveguide. In this respect, the following details are set forth in greater detail:
The wavelength multiplexer is provided with three lasers each of which energizes a transmission channel. The separation between the wavelengths of the lasers, i.e. the channel spacing, amounts to about 5 nm.
The lasers are connected to a signal output by way of several 3 dB couplers, light waveguides and wavelength-selective grating reflectors, at which output the light signals emitted by the lasers are coupled to an external light waveguide. The multiplexer is structured as an optoelectronic integrated circuit, i.e. all structural components are integrated on a chip.
Each 3 dB coupler is connected with four branches of light waveguides, the branches being positioned in opposite pairs. Thus, the first branch and the second branch are arranged opposite the third and fourth branches, respectively.
The first laser of wavelength λ 1 is connected to the first branch of the 3 dB coupler. Hence, 50% of the light signals emitted by the first laser are coupled into each of the third and fourth branches of the 3 dB coupler. A wavelength-selective grating reflector reflecting light of wavelength λ 1 and being transparent to light of any other wavelength, is arranged in each of the third and fourth branches of the first 3 dB coupler. Thus, the light emitted by the first laser is reflected by the grating reflectors and passes through, or transverses, the coupler again in the opposite direction. The light emitted by the first laser is coupled almost entirely into the second branch to which the signal output of the multiplexer is connected. Since the first 3 dB coupler couples almost the entire light reflected at the grating reflectors into the second branch, not only is interference of the laser by light returning to the first branch prevented but the efficiency during transmission is also improved.
The first laser, the first 3 dB coupler and the first wavelength-selective grating reflector are part of a first stage which energizes the first channel with wavelength λ 1 . Following this first stage, there is arranged an analogously constructed second stage, the laser of the second stage transmitting light of wavelength λ 2 and the wavelength-selective grating reflector of the second stage reflecting light of wavelength λ 2 .
The second branch of the second stage is connected by a further 3 dB coupler to the third and fourth branches of the first 3 dB coupler of the first stage. The light emitted by the laser of the second stage is therefore coupled at 50% each into the third and fourth branch of the first 3 dB coupler of the second stage, by the 3 dB coupler of the second stage. It is there reflected at the wavelength-selective grating reflectors and coupled almost entirely into the second branch of the second stage. The 3 dB coupler arranged between the first and second stages couples 50% of the light emitted by the second stage into the third and fourth branches, respectively, of the first 3 dB coupler of the first stage. There, the light from the second stage passes through the wavelength-selective grating reflectors since these are tuned to the first wavelength λ 1 , and is coupled almost entirely into the second branch of the first stage by the first 3 dB coupler of the first stage. It is thus fed to the signal output of the multiplexer.
A fourth 3 dB coupler is arranged following the second stage, the third and fourth branches of this fourth 3 dB coupler being respectively connected to the third and fourth branch of the 3 dB coupler of the second stage. A third laser emitting light of wavelength λ 3 is connected to the first branch of the fourth 3 dB coupler. Hence, the light emitted by the third laser passes through the two wavelength-selective grating reflectors of the first and second stages, respectively, and is in the end coupled at the signal output into the external light waveguide.
Accordingly, the multiplexer is constructed of three stages, each stage energizing one channel with light signals. This described wavelength multiplexer allows unidirectional multi-channel date transmission by way of a light waveguide, that is to say it allows multi-channel transmission. The arrangement may also be constructed and operated as a wavelength demultiplexer. The arrangement does not, however, permit simultaneous operation as a transmitter and as a receiver, even, if necessary, by way of a single light waveguide.
TASK OF THE INVENTION
It is a task of the invention to provide optoelectronic circuit arrangements for transceivers as well as multiplexers or demultiplexers for data transmitted by wavelength multiplexing, which also satisfy an "add/" function, i.e. by being capable, for instance, of newly charging channels carrying data which may be deleted at the receiving location with data generated at the receiving location. These circuits are to be made available in large quantities, for instance as integrated circuits, as well as in small quantities, which may be assembled from individual modules, at economically feasible fabrication efforts.
SUMMARY OF THE INVENTION
In the ensuing description terminology may be used which will different in appearance but is of the same meaning as the terminology used in the independent claims. More particularly, this relates to the term "branch" which has the same meaning as "waveguide branch".
The invention includes the technical teaching of minimizing electric and optic cross-talk in the case of a laser, a photo-diode and a 3 dB coupler integrated on a chip as well as in the case of a hybrid construction from individual components, with the 3 dB coupler either blocking light signals at the signal input or feeding them to the photo-diode, the photo-diode and the laser being arranged at opposite sides of the circuit to reduce electric cross-talk between them.
As the light signal source is electrically operated with high-speed modulating constrained current, an electromagnetic field is formed in the vicinity of the light signal source when the circuit is operated as a transmitter, which may cause cross-talk with the light signal detector or its output conduit and thus interfere with its output signal. To minimize this electric cross-talk, the light signal source is therefore spaced from the light signal detector, the two components being positioned at opposite sides of the circuit. Moreover, the arrangement of wavelength-selective components also reduces optical cross-talk from the light signal source to the light signal detector.
Electrooptic circuits in accordance with the invention make possible simultaneous operation as transmitters and receivers by a wavelength multiplexing process. During such operation, such a circuit is transmitting and receiving at different wavelengths. Preferably, the transmission and receiving waves lie within optical windows at 1,500 nm or 1,300 nm, i.e., within the so-called third optical window of glass where light absorption and, therefore, attenuation of the light waveguide are relatively low. Using these wavelengths makes it possible, therefore, to transmit data at relatively low transmission power or without intermediate amplifiers (repeaters) over large distances.
A circuit which does not only detect received signals is provided with a light signal source for emitting light signals when operating in a transmission mode. In preferred embodiments of the invention a single-mode laser is used emitting light in one fundamental mode only.
Furthermore, a circuit which does not only generate data to be transmitted is provided with a light signal detector which converts the light signals received through the light waveguide into electrical signals and renders them accessible at contact connections at the exterior of the circuit housing.
For coupling to a bidirectionally operated transmission network, an optoelectric circuit in accordance with the invention is provided with a common interface for connection of the external light waveguide by means of which the data is transmitted. For coupling to a unidirectional transmission network as well as for cascading, there are provided separate interfaces at each component for connection of the external light waveguides which either conduct data streams to be received or to be internally transmitted or externally transmitted.
In a prefered embodiment of the invention of a light waveguide arrangement for bidirectional transmission the first branch is connected to the common interface, the second branch is connected to the light signal source, and the third and/or the fourth branch is connected to a light signal detector. This light waveguide arrangement makes it possible to transmit to the light signal detector the light signals received by way of the external light waveguide and entering at the common interface, or to transmit the light signals emitted by the light signal source to the common interface, as the case may be, and to couple it into the external light waveguide.
In accordance with the invention, the light signal source and the light signal detector are arranged on opposite sides of the circuit. Accordingly, the second branch is positioned opposite the third as well as the fourth branch of the light waveguide arrangement.
The four branches of the light circuit arrangement are connected to each other by an optical coupler. Two of the branches are connected to the coupler at one side thereof, and the other two branches are connected to the coupler at the opposite side thereof. A light signal entering the coupler from one branch is thus coupled to the branches connected to the opposite side, the coupler having a 1:1 division ratio, i.e. it couples the light signal from a given branch at a 50% intensity into the two opposite branches. Therefore, the coupler is a 3 dB coupler.
In a prefered embodiment of the invention the coupler is structured as a 3 dB MMI coupler (MMI=Multi-Mode-Interference). The 3 dB-MMI coupler is provided with a multi-mode section made from light-conducting material, the four branches of the light waveguide arrangement being connected thereto in pairs at two opposite side surfaces of the multi-mode section. Depending upon the length of the multi-mode section the coupler either operates in a so-called cross-state, a bar state or in an intermediate state.
In the bar state, the electromagnetic field at the input of the multi-mode section is imaged at, or transfered to, the output of the multi-mode section. Thus, a light signal present at a branch at the input of the coupler is coupled into the straight ("bar") opposite branch.
By contrast, in the cross state image of the electromagnetic field the input of the multi-mode section appears inverted at the output. A light signal present at a branch at the input of the coupler is therefore coupled into the oblique ("cross") opposite branch at the output.
The 3 dB state is an excellent intermediate state. In this state, a light signal present at one branch at the input of the coupler is coupled in equal shares into the two opposite branches, the two output signals having a phase difference of λ/4. If, therefore, the two output signals are reflected at the output, for instance by a waveguide grating or by a filter plate, the light signal will pass through the coupler again in the opposite direction and the light is coupled in equal shares into the two input branches. As a consequence of the phase difference this will result in an extinction in one input branch of the coupler. Such couplers are characterized in an advantageous manner by a relatively high fabrication tolerance.
In another embodiment of the invention the coupler which connects the different branches of the light waveguide arrangement to each other, is a 3 dB directional coupler. In a light waveguide the light is totally reflected at the interfaces to the ambient medium. However, the light does penetrate the ambient medium up to the so-called depth of penetration. If a second light waveguide is then moved towards the first light waveguide until the spacing between he light waveguides is less than the depth of penetration, the light may transfer between the two light waveguides without significant changes in the direction of the light rays.
In a variant of the invention, the monolithically integrated optoelectronic OEIC circuit (optoelectronic integrated circuit) serves as a bidirectional transmitter/receiver ("transceiver"). Here, too, the first and second branches of the light waveguide arrangement are positioned at the same side of the coupler; the third and fourth branches are positioned at the side opposite thereto. In this variant, the coupler couples a light signal entering a common interface in equal propositions into the third and fourth branches. In this variant, a wavelength-selective reflector is arranged in the third and fourth branches between the light signal detector and the coupler. Depending upon the wavelength of the light, the reflector either reflects substantially entirely or it is transparent. In this variant the reflector is designed so that light of the transmission wave length is almost entirely reflected, whereas light of the receiving wavelength passes almost entirely.
In the receiving mode of the circuit, a light signal of the receiving wavelength present at the interface is coupled from the first branch into the third and fourth branches where it passes the wavelength-selective reflector almost unattenuated and in this manner it arrives at the light signal detector.
By contrast, in the simultaneously possible transmission mode the light emitted by the light signal source is coupled in equal propositions from the second branch into the third and fourth branches where it is almost entirely reflected by the wavelength-selective reflector and thereafter it passes through the coupler in the opposite direction. The light signal is thus coupled from the third and fourth branches into the first branch and arrives at the common interface where the light signal is coupled into the external light waveguide and is thus transmitted.
In this connection, it is important that the coupler does not again couple the light reflected at the wavelength-selective reflectors in the third and fourth branches into the second branch connected to the light signal source. This is of particular importance when a single-mode laser is used as the light signal source, since the operation of the laser would be disturbed by returning light.
In the above-described variant of the invention structured as a bidirectional transmitter/receiver ("transceiver-OEIC"), the light signal source and the light signal detector are arranged in opposite relationship to the coupler coupling the light emitted by the light signal source into the branch of the light signal detector. For this reason, there is a possibility of cross-talk from the light signal source to the light signal detector. Such optical cross-talk is reduced by arranging a wavelength-selective reflector reflecting light of the transmission wavelength, in front of each light signal detector. However, even for light of the transmission wavelength the degree of reflection of the reflector is not one hundred percent exact, so that part of the light emitted by the light signal source will reach the light signal detector and will lead to optical cross-talk, albeit very little.
In one embodiment of the invention, for further reducing optical crosstalk, there is provided a band-pass filter stop in the third and/or fourth branch between the light signal detector and the wavelength-selective reflector, the filter passing light of a wave length other than the transmission wavelength substantially unattenuated. In this connection, it is important that the band width of the band-pass filter stop is smaller than the channel spacing between the transmission wavelength and the receiving wavelength so that the transmission wavelength may be selectively filtered out without detrimentally affecting the reception of the photo diode on the receiving wavelength.
In one embodiment of the invention optical cross-talk from the light signal source to the light signal detector is prevented by structuring the third and fourth branches of the light waveguide arrangement at the output of the band-pass filter stops such that light of the transmission wavelength cannot propagate in the third and fourth branches. Thus, in a light waveguide of limited cross-section only those waves can propagate the wavelength of which is less than the so-called cut-off wavelength of a given light waveguide, the cut-off wavelength being dependent on the cross-section of the ligh waveguide, among others. The gage of the light waveguide in the third and fourth branches of the light waveguide arrangement behind the band-pass filter stops is thus chosen so that the transmission wavelength is below the cut-off wavelength whereas the receiving wavelength is above the cut-off wavelength. In that case, although the light emitted by the light signal source is still coupled into the third and fourth branches by the coupler, yet it cannot there propagate behind the band-pass filter stops and, therefore, does not reach the light signal detector.
Complementary transceivers are part of complete systems equipped with such transceivers. If the previously described transceiver is transmitting at a wavelength of 1.5 μm and receiving at a wavelength of 1.3 μm, the complementary receiver has to operate at a wavelength of 1.3 μm for transmission and 1.5 μm for receiving. Embodiments of the invention also include such complementary transceivers. To this end, in a circuit having a light signal source at the second branch and light signal detectors at the third and/or fourth branch of the light waveguide arrangement, the third and the fourth branch are provided with an absorption element consisting of a semiconductor layer covering the waveguides in the areas abutting the light signal detectors. The semiconductor material is transparent for wavelengths of 1.5 μm; but it absorbs lightwaves having a wavelength of 1.3 μm. This may be, for instance, a quaternary layer having a band gap corresponding to 1.4 μm. With this arrangement too, two-stage filtering is achieved which ensures comparable values for optical cross-talk dampening.
In a preferred embodiment of the invention the light signal generator is a photo diode. A primary method of reducing optical cross-talk provides, for instance for a transceiver circuit of the kind heretofore described first, for fabricating the photo diode from a semiconductor material which is insensitive to light of the transmission wavelength. For instance, a certain composition of InGaAsP semiconductor compound displays an energy band gap corresponding to a wavelength of 1,400 nm. If the transmission wavelength is 1,500 nm, the quantum energy of the radiation will be insufficient to bridge the energy band gap of the photo diode and to cause the detector to react. The light emitted by the light signal source is therefore not detected by the photo diode. If, however, the receiving wavelength is 1,300 nm the quantum energy corresponding to this wavelength exceeds the energy band gap of the semiconductor material so that light of the receiving wavelength will be detected by the photo diode. Two conditions must be satisfied in respect of this possibility of reducing optical cross-talk. Firstly, the transmission wavelength has to exceed the receiving wavelength and, secondly, the wavelength corresponding to the energy band gap of the used semiconductor material has to be between the transmission and receiving wavelengths.
In one variant of inventive significance a light signal detector is divided into a first section of quarternary material and a second section of ternary material connected in series therewith. The second section detects light signals of a wavelength of 1,500 nm and thus assumes the functions of the receiver for bidirectional services. The first section detects additionally received light signals at 1,300 nm which may be heterodyned with the bidirectional services for purposes of distribution, signaling and the like.
Moreover, there is a strong possibility that the light emitted by the light signal source will be dispersed or scattered within the chip and thus reach the light detector and distort the output signal. For that reason, in one variant of the invention absorbers absorbing light of the transmission wavelength are arranged laterally of the light signal source and/or the light signal detectors, possibly formed as marginal structures at the chip border. The absorbers may, for instance, be made from a special semiconductor material which absorbs light of the transmission wavelength.
In another variant of the invention of inventive significance, the circuit in accordance with the invention is structured as an optoelectronic add/drop circuit (add/drop OEIC). This circuit set up as a Mach-Zehnder arrangement serves to decouple and detect ("drop function") light signals of a certain wavelength from a light waveguide and thereafter to couple a new signal of this wavelength into the light waveguide ("add function"). For this purpose, this circuit is provided with a receiving interface to which is connected a first light waveguide for receiving light signals, and a transmission interface to which a second light waveguide is connected for transmitting transmitted new light signals of the same wavelength or of light signals yet to be detected of another wavelength.
In common with the previously described variants of the invention this add/drop OEIC is provided with a light waveguide arrangement which is, however, constituted of several series-connected couplers each provided with branches arranged in oppositely positioned pairs. A light signal entering at the receiving interface is fed to the first optical coupler of the series connection connected to the receiving interface for coupling the light in equal shares into the opposite branches. There the light signal is reflected in the two branches at two successively arranged wavelength-selective reflectors tuned to the given receiving wave length, and again passes in the opposite direction through this coupler. The light signal is thus coupled into the other branch of that pair one branch of which is connected to the receiving interface. That is where the photo diode is positioned. Preferably, a TE light polarization grating and a TM light polarization grating are arranged in each branch to provide polarization-dependent operation.
If the wavelength of the light signal to be detected by the photo diode does not conform to the wavelength to which the wavelength-selective reflectors have been tuned, the light signal will traverse the two reflector almost unattenuated and is heterodyned to a sum signal by the second coupler of the series connection, and is also coupled into one of the two opposite branches at the other side of the second coupler. This branch is connected to a transmission interface to which a second "external" light waveguide is connected. A light signal the wavelength of which does not correspond to the wavelength of reflection of the wavelength-selective reflectors in an ideal case transverses the add/drop circuit unattenuated and is coupled into the second external light waveguide at the transmission interface.
The other branch of the previously mentioned pair is connected to a laser diode which in a state of transmission emits a light signal with the wavelength-selective reflectors being tuned to the wavelength of this laser diode. The light signal emitted by the laser diode thus initially traverses the second coupler of the series-connection and is there coupled in equal shares into the two opposite branches at another side. There the signal is almost totally reflected at the two wavelength-selective reflectors and traverses the second coupler again in the opposite direction. In an ideal case the total intensity of the light signal to be transmitted is coupled into that branch which is connected to the transmission interface.
In one variant of the invention of inventive significance several add/drop circuits are cascaded as stages, the receiving interface of each succeeding stage being connected to the transmission interface of the stage preceding it. In that arrangement the wavelength-selective reflectors of the individual stages are tuned to different wavelengths, so that a channel of a defined wavelength may be detected (drop) in each stage and charged (add) with a new signal in the corresponding following stage.
In a further variant of the invention of its inventive significance the wavelength-selective reflectors are structured as grating reflectors, the surface of the waveguide being formed as a Bragg grating. As has been described supra, the individual branches of the waveguide arrangement are integrated on a chip together with the light signal source and the light signal detector. The grating reflector is formed by a corrugated, i.e. wave-like interface between the light waveguide and the surrounding material.
In such an arrangement the optical behavior of such a grating reflector is dependent upon the wavelength of the incident light. If the wavelength equals twice the distance between two crests of the corrugated structure, also known as the corrugation period, the grating reflector will act as a Bragg reflector and reflect nearly one hundred percent of the incident radiation. If, however, the wavelength of the incident radiation differs from the double corrugation period the light will pass more or less unattenuated. By suitably structuring the interface between the light waveguide and the surrounding material the wavelength may thus be set at which the grating reflector will reflect the incident light. The reflection and transmission properties of the grating reflector may be set by the length of the grating and the depth of the troughs, i.e. by the ripple or corrugation of the interface.
As has been described supra, in one variant of the invention a bandpass filter stop is arranged in front of the light signal detector in order to reduce optical cross-talk from the light signal source to the light signal detector. In one embodiment of the invention this band-pass filter stop, too, is formed as a Bragg grating.
A special variant of the invention aims at the tuning properties of the wavelength-selective grating arrangements and of the mono-mode laser diodes. If in their immediate vicinity they are provided with heating elements, the filter characteristics or the emitted wavelengths may be shifted to greater wavelengths at increasing temperatures and vice versa. Such heating elements may be arranged to cover absorber layers of the kind previously mentioned. Such a measure makes it possible also to compensate for possible deviations in the component properties as a result of unavoidable fabrication tolerances and thus to optimize the overall performance. In respect of cascading components such an adjustability of wavelength-selective elements assumed particular significance. The heating elements may be fabricated in integrated circuits in separate fabrication steps, parallel to the appropriate waveguide structures. The effect of shifting of emission wavelengths of monomode lasers is about 0.1 mm/° C.
Whereas the previous explanations on the whole relate to integrated circuits in accordance with the invention, the major differences to be observed in respect of hybrid circuit structures will be described in greater detail hereinafter.
The above captioned embodiments of the invention relate to integrated optoelectronic circuits in which the wavelength-selective filters are structured as reflectors, e.g. grating or Bragg reflectors as well as band-pass filter stops. The above described alternative to an integrated circuit structure which will hereafter be described in greater detail, in a hybrid planar-optical structure provides for dielectric filter plates as wavelength-selective filters of a light waveguide arrangement. Of course, in such an arrangement the light signal detectors on the one hand and the light signal source on the other hand are arranged at opposite sides of the optical couplers to reduce electrical cross-talk.
The previously mentioned filter plates or reflector plates are common measures in interferometry and are known as "Etalon". It is known to use them in WDM (wavelength division multiplexing) transceivers (vide Y. Yamada et al., OFC '95, Post Deadline Paper 12).
This variant of the invention adds a further genus to the circuit structures in accordance with the previously described embodiments functioning as transmitter/receiver modules as well as as add/drop multiplexers/demultiplexers for transmitters and receivers. The architectures of the active and passive components in this further genus can no longer be applied as integrated circuit but rather as individual components of a hybrid planar lightwave circuit (PLC=planar lightwave circuit). In such PLC's, the planar-optical waveguide network circuits and the planar optoelectronic laser and photo detector circuits may each be constructed in integrated technology.
In this respect, the simplification of the architectures in respect of the wavelength-selective filters is of particular significance. All the planar-optical waveguide network circuits may be structured on the basis of like principles substantially independent of the range of intended wavelengths. Their assembly is carried out be adding given specific planar optoelectronic laser diode and/or photo diode circuitry.
In respect of the operation of the optoelectronic circuits and their components which operation is equally applicable to this variant of the invention, reference is made to the explanations set forth above. This is particularly true of MMI couplers (MMI: multi mode interference), photo diodes used as light signal detectors, as well as those which are transparent to a first wavelength and absorbent in respect of a second wavelength, and single-mode laser diodes used as light signal sources. Because the operation of the reflective plates independent of polarization and in contrast to the previously described embodiments, all those arrangements necessary for separately affecting the TE and TM polarization of light may be avoided.
An especially advantageous embodiment provides for fabrication of basic cells of planar-optical waveguide networks in silica-on-silicon technology and of basic cells of planar optoelectronic laser and photo diode switching circuits in InP technology and to arrange them on a carrier plate. Such basic cells are based upon proven technologies; they provide for an economically feasible effort of fabrication even at small production runs; and they are even suitable for polymer waveguide technologies which at present are still in their development stage.
The waveguides of third and fourth branches of two series-connected couplers of one stage of the light waveguide arrangement extend parallel to each other and each carry the same wavelength proportions of the optical signal. This results in the expedient possibility to structure the filters in the third and fourth branches of the light waveguide arrangement as a one-piece dielectric filter plate.
These narrow band thin optical filter plates reflecting may be arranged and affixed in a simple and effective way if the carrier plate is provided with a sawed slot for supporting the filter plate. The support substrate contains the planar waveguides and it is the support chip for the photo diode and for the laser diode switching circuit. It also receives external glass fibers in a V-notch. The sawed slot is to configured such that its cutting surfaces relative to the planar waveguides are of optical quality. The filter plates may be affixed by an optical adhesive which preferably is of the same refractive index as the material of the planar-optic waveguide network circuit and the filter plate. In that manner, no disturbing reflections and scattering will arise.
As in the previously described functions in respect of add/drop components a particularly advantageous modular construction also results in respect of the embodiments of the hybrid variant here under discussion, in which a Mach-Zehnder arrangement is assembled from at least three basic cells, i.e. two series-connected passive basic cells of planar-optic waveguide networks, as, for instance, MMI couplers each having four branches, as well as a filter plate arranged therebetween and at least one optoelectronic basic cell, i.e. a laser diode switching circuit or a photo diode switching circuit. In this respect, it is to be particularly noted that regardless of the desired number of stages the first of the cascading stages is provided with a photo diode switching circuit, the last stage is provided with a laser diode switching circuit, and all intermediate stages are provided with both kinds of such switching circuits.
DESCRIPTION OF THE SEVERAL DRAWING
Advantageous embodiments or will hereinafter be described in more detail, together with the description of the preferred embodiments of the invention, with reference to the drawings, in which:
FIG. 1 is a block circuit diagram of a preferred embodiment of an integrated optoelectronic bidirectional transceiver;
FIG. 2 is a perspective view of the transceiver of FIG. 1;
FIG. 3 is a block circuit diagram of an integrated optoelectronic multi-channel add/drop circuit in a cascading arrangement;
FIG. 4 is a receiver module;
FIG. 5 is a receiver/transmitter module;
FIG. 6 is a transmitter module;
FIG. 7 is a bidirectional receiver/transmitter module; and
FIG. 8 is a perspective view of the module of FIG. 7.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The transceiver depicted in FIG. 1 serves to transmit data by way of a common external light waveguide and permits simultaneous transmitting and receiving operations. To this end, a wavelength multiplexing process is used, i.e. data is received, for instance, at a wavelength of λ E =1,300 nm, whereas transmission is correspondingly carried out at a wavelength of λ S =1,500 nm. In that manner transmitted and received data may be separately processed at any time.
To generate the light signals to be transmitted the transceiver is provided with a laser diode 5, whereas for detection of light signals there are provided two photo diodes 6', 6". Instead, a large surface photo diode PD may be used to detect the light fed to it by way of two waveguide branches 3, 4 (hereinafter called "branch") of a coupler 11. The entire circuit may be monolithically integrated.
Furthermore, the transceiver is provided with an interface 7 to which the external light waveguide is connected and at which the light signals to be transmitted are coupled out or into which the light signals to be received are coupled. This interface 7 is provided with a mode transformer 12 (vide FIG. 3) ensures a light coupling with as low a loss as possible and with an adjustment tolerance.
The interface 7, the photo diodes 6', 6" as well as the laser diode 5 are connected to a light waveguide arrangement which enables transmission of the light signals emitted by the laser diode 5 to the interface 7 and, in reverse, a transmission of light signals entering at the interface 7 to the photo diodes 6', 6". The light waveguide arrangement consists of four branches 1, 2, 3, 4, the first branch 1 being connected to the interface 7, the second branch 2 being connected with the laser diode 5, and the third and fourth branches 3 and 4 being each connected to a photo diode 6' and 6".
The four branches 1, 2, 3, 4 of the light waveguide arrangement are connected by a 3 dB MMI coupler 11 (MMI--multi mode interference) which couples a light signal emanating from one of its branches in equal propositions into the two branches at the opposite side of the coupler 11. For instance, a light signal entering the coupler from the second branch 2 is coupled in equal proportions into the third branch 3 and fourth branch 4. The partial light signals in the third and fourth branches 3 and 4 have a phase difference of λ/4.
If a light signal of wavelength λ E is present at the interface 7, the light signal will first be coupled into the first branch 1 and then passes through the 3 dB MMI coupler 11 where 50% of its intensity are coupled into the third branch 3 and 50% of its intensity are coupled into the fourth branch 4.
In both the third branch 3 and the fourth branch 4 there is arranged a wavelength-selective grating reflector structured as a band-pass filter stop 10', 10". These grating reflectors 10', 10" are structured so that light of the transmission wavelength λ S is reflected, whilst light of another wavelength may pass almost unattenuated. The received light signal of wavelength λ E thus passes the grating reflectors 10', 10" substantially unattenuated and is detected by photo diodes 6', 6" arranged downstream. Moreover, in the area between the band-pass filter stops 10', 10" and the photo diodes 6', 6" the light waveguides of the third and forth branches 3 and 4 may have a reduced cross-sectional surface where only those light waves may be propagated the wavelength of which is less than the so-called cut-off wavelength.
The light signal of wavelength λ S emitted by the laser diode 5 initially enters the second branch 2 of the light waveguide arrangement and passes the wavelength-selective grating reflector 8 substantially unattenuated since the reflector is tuned to the receiving wavelength λ E . Thereafter, the light signal traverses the 3 dB MMI coupler 11 where 50% of the light signal is coupled into each of the third and fourth branches 3 and 4.
Within the third and fourth branches 3 and 4, the light signal emitted by the laser diode 5 is almost totally reflected by the wavelength-selective grating reflectors 10', 10" and passes for a second time through the 3 dB MMI coupler 11, in the opposite direction. At the same time, almost the entire intensity of the light signal reflected at the grating reflectors 10', 10" is coupled into the first branch 1, and finally it is coupled out into the external light waveguide at the interface 7. In this connection, it is important that the light reflected at the wavelength-selective grating reflectors 10', 10" is not coupled back into the second branch 2 connected with the laser diode 5 as it might lead to disturbance of the single-mode laser 5. The previously mentioned grating reflector 8 contributes additional safety in this respect.
Laterally of the second, the third and the fourth branches 2 and 3 and 4 there are provided absorbers 9.1, 9.2, 9.3, 9.4 and 9.5 which consist of a semiconductor compound of the kind absorbing light of wavelength λ S . This prevents scattered light from the laser diode 5 from reaching the photo diodes 6', 6" which would disturb the electric output signal of the photo diodes 6', 6". These absorbers may structurally be combined with heating elements for providing temperature-dependent tuning of wavelength-selective components.
In FIG. 2 the structure of the of the multiplex transceiver of FIG. 1 is shown in perspective. The transceiver is structured as an integrated circuit fabricated of several layers 13, 14, 15, 16 which are successively stacked during assembly. The integrated circuit is shown in schematic elevation to depict the extent of the layers in the interior of the circuit.
The photo diodes 6', 6" and the laser diode 5 form islands within the layer structure leading up to the surface thereof so that the laser diode 5 and the photo diodes 6', 6" may be electrically contacted directly at the upper surface.
The light waveguide arrangement in essence consists of the four branches 1, 2, 3, 4 of the coupler 11. The first branch 1 is leading to the exterior of the circuit where it forms the connection with the external light waveguide. The second branch 2 is connected to the laser diode 5, the third branch 3 and the fourth branch 4 are each connected to a photo diode 6', 6". In this manner, the light signals emitted by the laser diode 5 may on the one hand be transmitted to the interface 7 and, on the other hand, the light signals received at the interface 7 may be transmitted to the photo diodes 6', 6".
The 3 dB MMI coupler 11 arranged in the center of the circuit connects the four branches 1, 2, 3, 4 with each other and couples a light signal entering the coupler 11 from one of the branches, in equal proportions into the branches at the opposite side of the coupler 11. Thus, light entering the 3 dB coupler 11 from the first branch 1 is coupled into the third branch 3 as well as the fourth branch 4.
When it is operating as a receiver, a light signal of wavelength λ E enters the integrated circuit at the interface 7 and is fed to the 3 dB coupler 11 by the first branch of the light waveguide arrangement. The 3 dB coupler 11 then couples 50% of this light signal into the third branch 3 and 50% into the fourth branch 4. The light signal of wavelength λ E passes almost unattenuatedly through the wavelength-selective reflectors 10', 10" arranged in the third and fourth branches 3 and 4 as they are tuned to the transmission wave length λ S . Finally, the light signal reaches the two photo diodes 6', 6" and is reflected.
During a simultaneously possible transmitting operation the laser diode 5 emits a light signal of wavelength λ S , which is initially fed by the second branch 2 of the light waveguide arrangement to the 3 dB MMI coupler which couples the light signal in equal proportions into the third and fourth branches 3 and 4. There, the light signal of wavelength λ S is almost totally reflected at the wavelength-selective reflectors 10', 10" and passes through the coupler 11 for a second time in the opposite direction.
Almost the entire intensity of the light signal to be transmitted is coupled into the first branch 1 and is from there fed to the interface 7 for transmission.
The diameter of the external light waveguide is substantially larger than the width of the first branch 1 of the light waveguide arrangement. In the transmission operation, this results in a relatively low coupling factor without any special measures, i.e. a relatively low intensity only is fed into the external light waveguide. The first branch 1 is therefore structured as a mode transformer 12 immediately ahead of the interface. Such a mode transformer 12 is characterized by a changing width of the light waveguide in the direction of light propagation. In this manner the coupling factor between the external light waveguide and the first branch 1 of the light waveguide arrangement is increased.
The wavelength-selective reflectors 10', 10" are structured as Bragg reflectors. To this end, the interface in the vicinity of such a Bragg reflector between the light waveguide and the surrounding material is formed as a corrugated i.e. wave-like structure. Its wave crests and wave troughs are equidistant and extend substantially at a right angle to the direction in which the light waveguide is extending. The distance between two wave crests or between two wave troughs, the so-called corrugation period, is chosen in the Bragg reflectors 10', 10" so as to reflect the transmission wavelength λ S .
In connection with the previously described arrangement of waveguides in the third and fourth branches 3 and 4 of reduced cross-sectional surface area, the area of the waveguides in the immediate vicinity of the photo diodes 6', 6" is significant for another reason. If these areas of the waveguides 6', 6" are provided with an absorption element consisting, for instance, of a layer of quarternary semiconductor material having a band gap corresponding to 1.4 μm, a complementary transceiver may be realized which is substantially of the structure shown in FIG. 2 and which utilizes 1.3 μm wavelengths for transmitting and 1.5 μm wavelengths for receiving.
The monolithically integratable optoelectronic multi-channel add/drop circuitry (add/drop OEIC) makes it possible successively to detect (drop), for instance, three channels of a light waveguide having different wavelengths λ E1 , λ E2 , λ E3 and to couple into the light waveguide (add) a new signal of the wave-length λ S1 , or λ S2 detected immediately previously.
Such an add/drop OEIC consists of three stages 32.1, 32.2, 32.3, each stage detecting one channel. The three stages 32.1, 32.2 32.3 are connected in succession, so that in one stage one channel each is detected (drop) and in the following stage the channel with the same wavelength may be charged with new data (add).
Each stage 32.1, 32.2, 32.3 is provided with a light waveguide arrangement having six branches 18.1, . . . 18.6; 19.1 . . . 19.6 and 20.1 . . . 20.6. of light waveguides and two 3 dB MMI couplers 22.1 . . . 22.3 and 23.1 . . . 23.3.
The first branch 18.1 of the first stage 32.1 serves to connect the external light waveguide by which the incoming light signals are received, whilst the first branch 19.1, 20.1 of the following stages 32.2 and 32.3 serves for connection to the sixth branches 18.6 and 19.6 of the preceding stage 32.1 and 32.2.
The second branch 18.3, 19.3, 20.3 is in each stage 32.1, 32.2, 32.3 connected to a photo diode 17.1, 17.2, 17.3, each photo diode detecting one channel. (N.B.: In FIG. 3 the second branches have been shown with terminal digit "2" and third branches are shown with terminal digits 3 of the reference numerals.)
The first 3 dB MMI coupler 22.1, 22.2, 22.3 of each stage couples equal proportions of light signals entering the light waveguide arrangement by a first branch 18.1, 19.1, 20.1 or by a second branch 18.3, 19.3, 20.3 into the third branches 18.2, 19.2, 20.2 and into the fourth branches 18.4, 19.4, 20.4. In this manner a light signal coming from the first branch 18.1, for instance, is coupled at 50% intensity into the third branch 18.2 and at 50% intensity into the fourth branch 18.4.
In each of the third branches 18.2, 19.2, 20.2 and fourth branches 18.4, 19.4, 20.4 there is provided a wavelength-selective reflector 24.1, 24.2, 25.1, 25.2, 26.1, 26.2, 27.1, 27.2, 29.1, 29.2, 30.1, 30.2, these reflectors being tuned in the first stage to wavelength λ E1 of the first channel, in the second stage to wavelength λ E2 of the second channel, and in the third stage to wavelength λ E3 of the third channel. Each one of these reflectors consists of a wavelength-selective waveguide grating, whereby one grating is used for each of the TE mode and of the TM mode because of the polarization dependency of the gratings.
The third branch 18.2, 19.2, 20.2 and the fourth branch 18.4, 19.4, 20.4 of each stage are respectively connected to the fifth branch 18.5, 19.5, 20.5 and to the sixth branch 18.6, 19.6, 20.6 by way of a second 3 dB MMI coupler 23.1, 23.2, 23.3. The sixth branch 18.6, 19.6 of the two first stages is connected with the first branch 19.1, 20.1 of the successive stage, whereas the sixth branch 20.6 of the third stage 32.3 is connected to the external light waveguide by which the light signals are transmitted. It this position, a last stage may be provided instead (vide FIG. 6) where no light signal can be detected but where a light signal may be generated which is of the wavelength detected in the last stage but one.
The fifth branch 19.5, 20.5 of the light waveguide arrangement is connected at the second and third stages 32.2, 32.3 with a laser diode 21.1, 21.2, whereby the laser diode 21.1 of the second stage 32.2 emits light of wavelength λ S1 of the first channel, whilst laser diode 21.2 of the third stage emits light of wavelength λ S2 of the second channel.
In the third branch 19.2, 20.2 and in the fourth branch 19.4, 20.4 of the light waveguide arrangement there is provided a further wavelength-selective reflector 28.1, 28.2, 31.1, 31.2 in each of the second and third stages 32.2, 32.3, whereby the reflector 28.1, 28.2 of the second stage 32.2 is tuned to wavelength λ S1 of the first channel and reflector 31.1., 31.2 of the third stage 32.3 is tuned to wavelength λ S2 of the second channel.
At the input interface of this three-channel add/drop OEIC a light signal is received from the external light waveguide which includes components of wavelengths λ S1 , λ S2 , λ S3 of the three channels.
This signal is initially coupled into the first branch 18.1 of the first stage 32.1 and passes through the 3 dB MMI coupler 22.1 which couples this signal in equals proportions into the third branch 18.2 and fourth branch 18.4 of the light waveguide arrangement. There, the first channel of wavelength λ E1 is reflected at the wavelength-selective reflectors 24.1, 24.2, 25.1, 25.2 and passes through the 3 dB MMI coupler 22.1 for a second time, in the opposite direction. Almost the entire intensity of the first channel is then coupled into the second branch 18.3 and thus reaches the photo diode 17.1 of the first stage 32.1.
The channels of wavelengths λ E2 and λ E3 , however, pass through the wavelength-selective reflectors 24.1, 24.2, 25.1, 25.2 substantially unattenuated and are almost completely coupled into the sixth branch 18.6 by the second 3 dB MMI coupler 23.1. From there, the light signal which still contains the second and the third channel is coupled into the first branch 19.1 of the second stage 32.2.
The first stage 32.1 thus filters the first channel of wavelength λ E1 out of the input signal, and it also detects it. However, for light signals of another wavelength the first stage 32.1 is substantially transparent.
Analogously, the second channel is filtered out and detected in the second stage. Thus, in the second stage 32.2 the light signal is initially coupled into the third and fourth branches and 19.4. There, the light signal of the second channel is reflected at the wavelength-selective reflectors 26.1, 26.2, 27.1, 27.2 and passes through the 3 dB MMI coupler 22.2 for a second time, in the opposite direction. Substantially the entire intensity of the second channel is coupled into the second branch 19.3 and fed to the photo diode 17.2 of the second stage 32.2.
The other light signals pass through the wavelength-selective reflectors 26.1, 26.2, 27.1, 27.2 substantially unattenuatedly and are coupled almost entirely into the sixth branch 19.6 by the second 3 dB MMI coupler 23.2 of the second stage 32.2 and are thus fed to the third stage 32.3.
The fifth branch 19.5 of the second stage 32.2 is connected with a laser diode 21.1 which emits light of wavelength λ S1 of the first channel. This light is initially coupled into the fifth branch 19.5 and passes through the second 3 dB MMI coupler 23.2. Thus, 50% of the intensity of the emitted light is coupled into each of the third branch 19.2 and the fourth branch 19.4 of the light waveguide arrangement, and are there reflected by the wavelength-selective reflectors 28.1, 28.2. The light signal emitted by the laser diode 21.1 thus passes through the 3 dB MMI coupler 23.2 for a second time, in the opposite direction, almost the entire intensity being coupled into the sixth branch 19.6 and reaching the third stage 32.3.
Thus, the second stage 32.2 filters the second channel out of the light signal received from the first branch; it detects this channel with a photo diode 17.2 and charges the first channel with a new light signal from a laser diode 21.1.
The sixth branch 19.6 of the second stage is connected to the first branch 20.1 of the third stage 32.3 is structured similarly to the second stage 32.2.
The light signal entering the third stage 32.3 initially passes through the first 3 dB MMI coupler 22.3 whereby 50% of the intensity are coupled into each of the third branch 20.2 and fourth branch 20.4. Light of wavelength λ E3 of the third channel is reflected and passes through the 3 dB MMI coupler 22.3 for a second time, in the opposite direction. Almost the entire intensity of the reflected light is coupled into the second branch 20.3 and fed to the third photo diode 17.3.
Light of another wavelength passes through the wavelength-selective reflectors 29.1, 29.3, 30.1, 30.2 substantially unattenuatedly and passes through the second 3 dB MMI coupler 23.3 which couples substantially the entire intensity of the passed light into the sixth branch 20.6 and thus feeds it to the output interface where the light is coupled into the external light waveguide.
A further laser diode 21.2 is provided in the fifth branch 20.5 of the third stage 32.3. The laser diode 21.2 emits light of wavelength λ S2 of the second channel. This light traverses the second 3 dB MMI coupler 23.3 whereby the light signal emitted by the laser diode 21.2 is coupled in equal proportions into the third and fourth branches 20.2 and 20.4 of the light waveguide arrangement.
A further wavelength-selective reflector 31.1, 31.2 is arranged in each of the third and fourth branches 20.2 and 20.4 which is tuned to the wavelength λ S2 of the second channel. The light signal emitted by the laser diode 21.2 is thus reflected in the third and fourth branches 20.2 and 20.3 and passes through the second 3 dB MMI coupler 23.3 again in the opposite direction, whereby almost the entire intensity is coupled into the sixth branch 20.6 and fed to the transmission interface.
For reducing optic cross-talk from the laser diodes 21.1, 21.2 to the photo diodes 17.2, 17.3 a wavelength-selective reflector 33.1 and 33.2 is arranged in each of the second branches 19.3 and 20.3 in the second and third stages 32.2 and 32.3. In the second stage, the reflector is tuned to wavelength λ S1 of the first channel, and in the third stage 32.3 it is tuned to wavelength λ S2 of the second channel.
The multi-channel add/drop circuit is structured as an opto-electronic monolithically integrated circuit. The three optically series-stages 32.1, 32.2, 32.3 are assembled in side by side relationship such that the photo diodes 17.1, 17.2, 17.3 are positioned at one side of the chip and the laser diodes 21.1., 21.2 are positioned at the other side of the chip. The distance between the photo diodes 17.1, 17.2, 17.3 and the laser diodes 21.1, 21.2 is thus maximized, and electric cross-talk is reduced. In front of the photo diodes 17.2, 17.3 at the waveguide branches 19.3, 20.3 there are provided, for optical decoupling, wavelength-selective reflectors 33.1, 33.2 for each given wavelength of transmitting operation λ S1 , λ S2 as well as TE polarization. Furthermore, a compact structure of the circuit is achieved by the arrangement of the individual stages 32.1, 32.2, 32.3, as the spatial dimension of the individual stages 32.1, 32.2, 32.3 in the lateral direction is substantially smaller than in the longitudinal direction.
The figures described hereafter relate to embodiments of the invention of hybrid construction. With a view to avoiding repetition reference is made to the previous descriptions as regards explanations of functions of these embodiments which substantially conform to those of the previously described embodiments.
An optical WDM signal (WDM: wavelength division multiplex) signal is fed to the PLC receiver module 34.0 (PLC : planar lightwave circuit) fabricated in hybrid technology and depicted in FIG. 4, and transmitted by an input waveguide 34.1 to a first 3 dB coupler 34.2. From there, the signal reaches a narrow-band reflective thin optic filter plate 35 at the opposite side of the 3 dB coupler 34.2, in equal proportions, by way of two parallel connecting waveguides 34.5. The signal which is wavelength-selectively reflected at the filter plate 35 passes through the first 3 dB coupler 34.2 in the opposite direction and thereafter a feed waveguide 34.3 to which a photo diode switching circuit 36 is connected for processing the selected optic signal.
Structural details of the arrangement and affixing of the filter plate 35 will be set forth in greater detail in connection with the description of FIG. 8.
The wavelength proportions in the WDM signal which are transmitted by the filter plate 35 are fed into two parallel connector waveguides 34.6 and from there to a second 3 dB coupler 34.4. A Mach-Zehnder interferometer structure is thus created during transmission. The previously mentioned transmission portions are available for further processing at an output waveguide 34.7.
Similar to the description of the PLC receiver module 34.0, the PLC transmitter module 37.0 depicted in FIG. 6 will be initially described. The optic signal emitted by a laser diode switching circuit 38 is fed to a second 3 dB coupler 37.2 by a feed waveguide 37.1. From there it is fed in equal proportions by connector waveguides 37.5 to the filter plate 35 where it is wavelength-selectively reflected. The reflected laser signals pass in an opposite direction through the connector waveguide 37.5 and the second 3 dB coupler 37.2, and combined to a WDM signal they reach an output waveguide 37.3.
Wavelength portions of the optic WDM signal not reflected by the filter plate 35 may be fed to the PLC transmitter module 37.0 by way of an input waveguide 37.7. They will be fed into a first 3 dB coupler 37.4, from there they will be fed in equal proportions to a connector waveguide 37.6 and pass the filter plate 35. On their way through the connecter waveguides 37.5 the wavelength portions are combined in a in the second 3 dB coupler 37.2 (Mach-Zehnder interferometer principle) and in the output waveguide 37.3 they are heterodyned with the signal generated by the laser diode switching circuit 38, in wavelength multiplex.
The filter plates 35 of the modules 34.0 of FIG. 4 and 37.0 of FIG. 6 are each individually tuned to the working wavelength of the photo diode switching circuit 36 or of the laser diode switching circuit 38 and may be fabricated as one-piece structures. Both modules 34.0 and 37.0 are part of a unit, or the first and the last stage of a cascade, as the case may be. Intermediate stages of the cascade dimensioned to predetermined wavelengths to be selected, will be described hereafter.
Combining a PLC receiver module 34.0 of FIG. 3 and a PLC transmitter module 37.0 of FIG. 6 results in a so-called unidirectional transceiver. In this respect, FIG. 5 depicts a PLC receiver/transmitter module 39.0. There a provided an input waveguide 39.1, a first 3 dB coupler 39.2, two feed waveguides 39.3 one leading to the photo diode switching circuit 36 and the other leading to the laser diode switching circuit 38, A second 3 dB coupler 39.4, connector waveguides 39.5 and 39.6 as well as an output waveguide 39.7. The operating modes of the receiver and of the transmitter may each be taken by reference to the previous descriptions relating to FIG. 4 and FIG. 6.
With a view to attaining as little optic cross-talk as possible the operating wavelengths of the detecting photo diodes and of the emitting laser diodes within a receiver/transmitter module of the kind depicted in FIG. 5 should be different. Thus, having regard to the PLC receiver/transmitter module 39.0, there should either be provided two filter plates 35 for each one of the operating wavelengths or, in case of closely adjacent working wavelengths of photo diode and laser diode, about twice the bandwidth of the two wavelengths to be selected.
The modules 34.0, 37.0 and 39.0 depicted in FIG. 4, 5 and 6 each contain two series-connected passive basic cells of planar-optic waveguide networks, each with a 3 dB coupler having two branches at one side and two branches at the opposite side. Furthermore, these modules contain at least one opto-electronic basic cell. In a PLC receiver module 34.0 this basic cell is a photo diode switching circuit 36, and in a PLC transmitter module 37.0 it is a laser diode switching circuit 38. a PLC receiver/transmitter module 39.0 is provided with a photo diode switching circuit 36 as well as a laser diode switching circuit 38. Basic cells of planar-optic waveguide networks may be fabricated in silica on silicon technology, and basic cells of planar-optoelectronic laser diode and photo diode switching circuits may be fabricate in InP technology, and they may be arranged on a common carrier plate.
FIGS. 7 and 8 depict a bidirectional receiver/transmitter module (transceiver) 40.0 in hybrid structural technology. For transmission and reception, it operates on selected different wavelengths. The signals are transmitted in both directions by a common glass fiber 41. Together with the bidirectional receiver/transmitter module 40.0, the glass fiber 41 is mounted on a carrier plate 43. As regards complementary transceivers as well as additional transmission of distributer services, signalizing channels and the like, reference is made to the corresponding previous descriptions.
Signals received are carried in an input/output waveguide 40.5 structured by a mode transformer 40.6 for optical field expansion, are fed to a 3 dB coupler 40.3 and from there in equal proportions into two parallel connector waveguides 40.4. a filter plate 35 is provided there which lets this signal pass to a photo diode switching circuit 42. An optic signal to be transmitted is generated in a laser diode switching circuit 44 and is fed to the 3 dB coupler 40.3 by a feed waveguide 40.2. This signal is fed from there in equal proportions into the connector waveguides 40.4. The filter plate 35 selects, i.e., it reflects this wavelength so that the reflected laser signal returns to the 3 dB coupler 40.3 which heterodynes the two portions of the laser signal. The output signal is fed into the glass fiber 41 by way of the input/output waveguide 40.5 and the mode transformer 40.6.
Structural details and measures for supporting a fixing the filter plates 35 which are true for all embodiment of the invention fabricated in hybrid technology may be clearly derived from FIG. 8. The filter plate 35 may be supported an fixed in a slot sawed into the support plate 43 and which also contains the planar waveguides 40.2, 40.4, 40.5 and 40.6 as well as the coupler 40.3, and which functions as the support chip for the photo diode and laser diode switching circuits 42 and 44 and which received the glass fiber 41 in a V notch. The sawed slot is executed with optical quality at its interfaces with the planar waveguides 43.5, 43.6, 37.5, 37.6, 39.5, 39.6 and 40.4. Any adhesive should be of substantially the same refractive index as the material of the planar-optic waveguide switching circuit and the filter plate 35. In that way, interfering reflections and scattering may be substantially avoided.
Similar structural considerations hold true for affixing the photo diode switching circuits 36 and 42. These are either inserted by impact coupling into a further sawed slot or, if an integrated planar waveguide is used, they are affixed in the plane of a feed waveguide 34.3, 37.1 and 39.3 or of the connector waveguide 40.4.
The invention is not limited in its execution to the preferred embodiments described hereinbefore. Rather, a number of variants are conceivable, which make use of the described solution even in substantially differently structured embodiments. | The invention concerns optoelectronic circuits for an optical wavelength multiplexing system, the circuits being constructed with optical couplers (11; 39.2, 39.4) each having four branches (1,2,3, 4; 39.1, 39.3, 2×39.5; 2×39.6, 39.3, 39.7). Electrical and optical crosstalk is minimized both in integrated (FIG. 1) and hybrid (FIG. 5) constructions. To this end, photo diodes (6', 6"; 36) and laser diodes (5; 38) are each disposed on opposite sides of the couplers (11; 39.2, 39.4) and mutually decoupled by wavelength-selective arrangements of gratings (8, 10', 10") or filter plates (35). The circuits can be designed for bidirectional operation (FIG. 1) and for cascadable modules for multiplexers/demultiplexers with an add-drop function (5) and enable transmission and reception to be carried out simultaneously. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This present non-provisional patent application is a continuation-in-part of copending U.S. patent application Ser. No. 11/850,668 filed on Sep. 5, 2007, and entitled “TIMED WICK AND CANDLE THEREOF,” and of which the application cited above is incorporated in-full by reference herein.
FIELD OF THE INVENTION
[0002] The technology described herein relates generally to the fields of candle wicks and candles and methods of making the same. More specifically, the technology relates to a method for extinguishing a candle at timed intervals using a combustible material consisting essentially of a wick designed with the ability to automatically and slowly self-extinguish a flame in equal-time intervals.
BACKGROUND OF THE INVENTION
[0003] The purpose of a candle wick is to provide a candle with a flame. The heat from the flame melts the wax surrounding the base of the wick directly beneath it. The melted wax is then drawn up within the wick providing fuel for the flame. This ongoing cycle allows the candle to burn continuously. Wax in solid state is melted by the heat of the flame and converts to a liquid state. The liquid wax is drawn up to the top of the wick inside the flame and continues the burning process. The cycle repeats itself until the wick is no longer functioning due to lack of fuel for the flame.
[0004] Candles have been used for many years and for many different reasons; the reasons vary depending on the user. Today, a large number of candles are purchased simply for their pleasant fragrances and decorative appearance. The aromatherapy derived from a candle is widely used as well. It entices the user to relax and forget about everyday responsibilities.
[0005] However, one problem that exists between the user and the candle is that the user neglects to extinguish the candle. People today are simply too busy to remember to blow out a candle prior to leaving their homes. Panic sets in. A candle equipped with a wick that will automatically extinguish a candle flame in equal-time intervals would provide a user with the security of knowing that their candle will self extinguish in a short period of time.
[0006] Another problem that exists today is the vast number of house fires caused by leaving a candle unattended. The average burning time for a candle may be 60 to 95 hours. This time period is too long since it creates a greater risk of the candle being knocked over by a house pet, wind, or even a small child. Limiting the amount of burning time from one to four hours could significantly reduce the risk of house fires.
[0007] Related patents known in the art include the following: U.S. Pat. No. 1,067,184, issued to Lynch on Jul. 8, 1913, discloses a candle. U.S. Pat. No. 6,447,286, issued to Snuggs on Sep. 10, 2002, discloses a candle extinguishing apparatus. U.S. Pat. No. 6,805,551, issued to Feuer on Oct. 19, 2004, discloses a device for creating a self-extinguishing candle and a candle including such a device. U.S. Pat. No. 7,084,888, issued to Keiffer et al. on May 9, 2006, discloses a smart wick.
[0008] Relate published patent applications in the art include the following: U.S. Patent Application No. 2006/0019209 filed by Ortiz, Jr. and published on Jan. 26, 2006, discloses self-extinguishing safety candle wicks and methods of manufacture of the wicks. U.S. Patent Application No. 2004/0091829 filed by Mack et al. and published on May 13, 2004, discloses a self-extinguishing wick and method of producing the same. U.S. Patent Application No. 2003/0124474, filed by Elliott, III et al. and published on Jul. 3, 2003, discloses self-extinguishing candles and method of making the same.
[0009] While these patents and other previous methods have attempted to solve the problems that they addressed, none address using a combustible material to self-extinguish a candle, as does embodiments of the technology disclosed herein.
[0010] Therefore, a need exists for a timed wick and candle with these attributes and functionalities. The timed wick and candle according to embodiments of the invention substantially departs from the conventional concepts and designs of the prior art. It can be appreciated that there exists a continuing need for a new and improved timed wick and candle which can be used commercially. In this regard, the technology disclosed herein substantially fulfills these objectives.
[0011] The foregoing patent and other information reflect the state of the art of which the inventor is aware and are tendered with a view toward discharging the inventor's acknowledged duty of candor in disclosing information that may be pertinent to the patentability of the technology disclosed herein. It is respectfully stipulated, however, that the foregoing patent and other information do not teach or render obvious, singly or when considered in combination, the inventor's claimed invention.
BRIEF SUMMARY OF THE INVENTION
[0012] In various exemplary embodiments, the technology described herein provides for a candle and a method for extinguishing a candle at timed intervals using a combustible material consisting essentially of a wick designed with the ability to automatically and slowly self-extinguish a flame in equal-time intervals.
[0013] In one exemplary embodiment, the technology described herein provides a method for extinguishing a candle at timed intervals using a combustible material. The method includes: utilizing a combustible composition adapted for application to a wick segment; utilizing a combustible first wick segment; coupling a combustible second wick segment to the combustible first wick segment; placing the combustible second wick segment adjacent to the first wick segment; and configuring the combustible second wick segment to, as the combustible first wick segment, once ignited, burns down to the combustible second wick segment, interrupt and slowly self-extinguish the burning of the first wick segment. The candle wick is configured to be relit, post extinguishment, without having to physically remove a non-combustible barrier.
[0014] The method also can include: configuring the combustible first wick segment to be a predetermined length, such that, based on a candle type, length, width, and size, in which the combustible first wick segment is placed, a known burn time is approximated at which point a burning of the combustible first wick segment reaches the combustible second wick segment and automatically and slowly self-extinguishes, thereby providing the self-extinguishing, timed-interval candle wick with automatic and slow self-extinguishment at a known, approximated time subsequent to a lighting of the combustible first wick segment.
[0015] The method further can include: utilizing a plurality of combustible first wick segments; and utilizing a plurality of combustible second wick segments and interspersing one combustible second wick segment between each two combustible first wick segments. The plurality of combustible first wick segments are of generally equal widths and lengths, thereby providing a regular time interval at which the candle wick is automatically and slowly self-extinguished each time the candle is lit.
[0016] The method also can include: varying the regular time interval by increasing or decreasing the lengths of the plurality of combustible first wick segments.
[0017] The method further can include: configuring the candle wick to be relit, post extinguishment, without having to physically remove a non-combustible barrier.
[0018] The method also can include: forming the combustible second wick segment by spirally wrapping the combustible composition around a heat set and subsequently interweaving with the combustible first wick segment at a predetermined location. The combustible composition can be an organic polymer. The organic polymer can be a fatty acid created through the hydrolysis of beef fat with caustic soda and potash. The organic polymer can be a malleable solid in the form of a bead that is placed upon a combustible first wick segment at a predetermined location. The bead can be spherical.
[0019] The method further can include: adding to the combustible composition an extinguishing agent additive to increase the material resistance to burn.
[0020] The method further can include: adding to the combustible composition a metal additive to increase volatility to aid in the re-light process.
[0021] In yet another exemplary embodiment, the technology described herein provides a combustible composition for extinguishing a candle at timed intervals. The combustible composition includes: an organic polymer comprising a fatty acid created through the hydrolysis of beef fat with caustic soda and potash, wherein the organic polymer is a malleable solid in the form of a bead that is placed upon a combustible wick segment at a predetermined location.
[0022] The combustible composition also can include: an extinguishing agent additive to increase the material resistance to burn.
[0023] The combustible composition also can include: a metal additive to increase volatility to aid in the re-light process.
[0024] In yet another exemplary embodiment, the technology described herein provides a candle adapted for extinguishment at timed intervals using a combustible material. The candle includes: a polymeric base; a combustible first wick segment; and a combustible second wick segment adapted to be coupled adjacent to the combustible first wick segment. The combustible second wick segment is adapted to, as the combustible first wick segment, once ignited, burns down to the combustible second wick segment, interrupt and slowly self-extinguish the burning of the first wick segment. The candle wick is configured to be relit, post extinguishment, without having to physically remove a non-combustible barrier.
[0025] The candle also can include: a plurality of combustible first wick segments; and a plurality of combustible second wick segments interspersed one combustible second wick segment between each two combustible first wick segments. The plurality of combustible first wick segments are of generally equal widths and lengths, thereby providing a regular time interval at which the candle wick is automatically and slowly self-extinguished each time the candle is lit.
[0026] The combustible first wick segment is a predetermined length, such that, based on a candle type, length, width, and size, in which the combustible first wick segment is placed, a known burn time is approximated at which point a burning of the combustible first wick segment reaches the combustible second wick segment and automatically and slowly self-extinguishes, thereby providing the self-extinguishing, timed-interval candle wick with automatic and slow self-extinguishment at a known, approximated time subsequent to a lighting of the combustible first wick segment.
[0027] The polymeric base further can include an organic polymer having a fatty acid created through the hydrolysis of beef fat with caustic soda and potash. The organic polymer can be a malleable solid in the form of a bead that is placed upon a combustible wick segment at a predetermined location. The bead can be spherical.
[0028] Advantageously, the technology described herein provides minimal alteration to the aesthetics of a candle. Also advantageously, the combustible extinguishing barrier describer herein does not require a special tool other than the original device used to light the candle. Further advantageously, the technology described herein provides for numerous candle applications, including variations in size, style, interval timing, and extinguishment timing.
[0029] There has thus been outlined, rather broadly, the more important features of the technology in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the technology that will be described hereinafter and which will form the subject matter of the claims appended hereto. In this respect, before explaining at least one embodiment of the technology in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The technology described herein is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0030] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the technology described herein.
[0031] Further objects and advantages of the technology described herein will be apparent from the following detailed description of a presently preferred embodiment which is illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The technology described herein is illustrated with reference to the various drawings, in which like reference numbers denote like device components and/or method steps, respectively, and in which:
[0033] FIG. 1 is a schematic diagram of a timed wick structure adapted for extinguishing a candle at timed intervals using a combustible material consisting essentially of a wick designed with the ability to automatically and slowly self-extinguish a flame in equal-time intervals, according to an embodiment of the technology;
[0034] FIG. 2 is a schematic diagram of the timed wick structure depicted in FIG. 1 , shown in use in a candle, according to an embodiment of the technology;
[0035] FIG. 3A is a schematic diagram of a timed wick secured to a base prior to having a combustible substance applied, according to an embodiment of the technology disclosed herein;
[0036] FIG. 3B is a schematic diagram of the timed wick secured to a base depicted in FIG. 3A , additionally illustrating the application of a spherical combustible substance to the wick, according to an embodiment of the technology disclosed herein; and
[0037] FIG. 3C is a schematic diagram of the timed wick secured to a base depicted in FIG. 3A , additionally illustrating the application of a non-spherical spherical combustible substance to the wick, according to an embodiment of the technology disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
[0038] Before describing the disclosed embodiments of this technology in detail, it is to be understood that the technology is not limited in its application to the details of the particular arrangement shown here since the technology described is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
[0039] In various exemplary embodiments, the technology described herein provides for a candle and a method for extinguishing a candle at timed intervals using a combustible material consisting essentially of a wick designed with the ability to automatically and slowly self-extinguish a flame in equal-time intervals.
[0040] Referring now to FIGS. 1 through 3C , a timed wick 010 is shown. The timed wick 010 is comprised of a plurality of a wick segment 020 separated by combustible segment 030 . The timed wick may be secured to a base 050 prior to candle wax 040 being formed around the timed wick 010 to form a timed candle.
[0041] The technology disclosed herein is directed to creating timed intervals within a candle such that upon completing an interval the candle automatically and slowly self-extinguishes, yet is able to be relit without having to physically remove a non-combustible barrier. Rather than physically removing a barrier, the barrier itself consists of a combustible material that upon additional heat, chemically changes, allowing continued burning of the candle. The combustible material acts to both initially extinguish the burning candle and then combusts to allow continued burning of the candle.
[0042] In one embodiment the timing mechanism consists of varied amounts of magnesium metal present throughout the wick segment. The varying amounts of magnesium physically changes the burning characteristics of a candle, resulting in the desired extinguishing with the ability to re-light at a later time, starting a new timed interval designed into the candle.
[0043] A second embodiment does not require complete treatment of the wick, but instead allows for the treatment of only the end of intervals within the candle body, positioning the timing mechanism on and around various wick segments. The positioning of the combustible substance is referred to as wick treatment, but is not limited to placing a substance on the wick segment, e.g. the combustible substance may be infused into the wick. Using the magnesium calls for incorporation of the substance within the wick, and various other embodiments may require a contribution from the additives or wax type contained within the candle not just the wick.
[0044] In both of these embodiments the end result is the use of a timing mechanism that causes a candle to self-extinguish at a predetermined time, while allowing to be relit at a later time, preserving a wick segment necessary for burning, and not requiring additional effort from an operator other than applying additional heat. (The additional effort refers to many of the methods in the prior art that facilitate this process with non-combustible materials that have to be either physically removed—or require a separate wick segment to be recovered from within the wax body.)
[0045] Depending on the embodiment a combination of wick type, wax, and additives may be used to determine an approximate burn time of a candle. Once having defined a candle's burn characteristics, a burn rate in length per time can be determined. A time interval can then be set by identifying a start and end position on the wick segment. For example, a cylindrical pillar consisting of a 1.5″ diameter and standing 2.5″ in height has been determined to have a total burn time of 10 hours. The relationship between candle height by total burn time dictates that the candle is burning 0.25 inches per hour. At this estimated rate, positioning a treated segment on the wick at 1.25″ from the top of the candle would provide two burn intervals of approximately 5 hours.
[0046] In an exemplary embodiment the timing mechanism is an organic polymeric substance possessing the burn characteristics described above. The organic polymer is created through the hydrolysis of beef fat with caustic soda and potash. The process is essentially a raw version of saponification that produces a substance consisting mainly of fatty acid (FA) and glycerol (with additional unreacted reactants or byproducts). The resulting FA is a malleable solid that can be physically applied to the wick segment at a predetermined length prior to forming the candle. The treated wick is then placed within the mold and the candle is created as is customary. The FA is placed on zinc core wicks and withstands temperatures of 140° F. Paraffin wax is poured in around this combination and hardens to form a votive candle. The amount of FA applied at the designated wick length is approximately 40-55 mg and effectively extinguishes the candle when the flame comes in contact with the FA.
[0047] As is common for solid combustibles, the FA burns more effectively when a sufficient specific area ratio is heated. For example, it is easier to start a fire by lighting smaller twigs than a large branch. Similarly, as the flame approaches the FA only a small portion (specifically the top) comes into contact with the flame—thus causing the candle to burnout. The placement of the FA effectively prevents the wicking process stopping the flow of fuel to the flame. Once extinguished, the user can then take a lighter and apply a flame directly to the FA for 5 to 10 seconds, providing enough heat to quench the specific area ratio requirement and reignite the candle. At this point the FA continues to burn away exposing more of the wick beneath and simultaneously relighting the candle wick. By burning away, the wicking process is once again continued and the heat produces by the combusting FA provides a sufficient melted wax pool for further combustion.
[0048] One process for creating the bead material is as follows:
[0000] 1) Gather the following materials:
[0049] Raw beef fat (trimmings of fat obtained from butcher)
[0050] Tap Water
[0051] Potassium Hydroxide (Caustic Potash—solid)—KOH
[0052] Sodium Hydroxide (Caustic Soda—solid)—NaOH
[0053] Hot plate (stove top)
[0054] Strainer
[0055] Pipette & Bulb
[0056] Stainless Steel Bowl 6″ Diameter
[0057] Stainless Steel Bowl 4″ Diameter
[0058] 2×Glass Measuring cup (15 oz capacity)
[0059] 5 lb scale with 0.1 oz sensitivity
[0060] Minimum 100 gram scale with 0.001 gram sensitivity
[0061] Stainless steel mixing utensil
[0062] Stainless steel spoon
[0063] Stainless steel ladle
[0064] Glass stirrer
[0065] Hand and eye protection from corrosive hydroxides
[0066] Kettle or heating pot
[0067] 3×thermometers
[0068] plastic storage containers to store up to 4 oz of product
[0069] 3×250 ml glass beakers
[0070] label NaOH soln, KOH soln, and Bi-Product
[0071] exacto knife
[0000] Extract Tallow from Beef Trimmings
[0072] Add beef fat trimmings into kettle or stainless steel pot and apply gradual heating (approximately 2 lbs of fat trimmings were added per batch—this can vary depending on the fat to beef ratio on the meat samples used)
[0073] Maintain fat at approximately 167° F. for a 48 hour period to extract as much liquid tallow from the solid trimmings (required to extract a minimum of 3.2 ounces of liquid fat—depending on fat to beef ratio, may need to add more fat or may have excess)
[0074] Allow trimmings to simmer for 48 hour period—fat may be extracted and process continued. Initial mixture—Separate Fatty Acid (Bead Material) from glycerin and water in tallow
[0075] Weigh out approximately 3.2 ounces of tallow and add to stainless steel bowl (6″ diameter).
[0076] Place tallow on hot plate and bring up to 170° F.
[0077] Place 1 floz. Of water in each of the 250 ml beakers labeled NaOH soln and KOH soln
[0078] Weigh out 2 oz. of NaOH solid and gradually add to 250 mL glass beaker labeled NaOH soln—containing 1 floz of water. (Provide agitation with glass stirrer until solid has completely dissolved into soln—soln will turn clear, expect soln will heat up to a minimum temp of 150° F.)
[0079] Weigh out 2 oz. of KOH solid and add to 250 mL glass beaker labeled KOH soln and containing 1 floz. Of water. (Provide agitation with glass stirrer until solid has completely dissolved into soln—soln will turn clear, expect soln will heat up to a minimum temp of 130° F.)
[0080] Simultaneously add the two solutions to your liquid tallow sitting on hot plate and bring entire solution to 170° F. and begin to stir.
[0081] Once mixture has reached 170° F., remove from heat source and continue to stir for 12 minutes. (As mixture proceeds to cool, precipitate will begin to form as the fatty acid solidifies and is precipitated out from the mixture). Adequate cooling is dependent on a steady room temperature not to exceed 68° F. Ideally the mixture should slowly cool to room this room temperature.
[0082] After 12 minutes of stirring, allow mixture to complete cool to room temperature and sit for 24-30 hour period, leave mixture in stainless steel bowl.
[0083] Once mixture has completely solidified and sat for 24 hours at a temperature no greater than 68° F. place mixture back on hotplate.
[0084] Begin to apply gradual cooling not to exceed 100° F. This will begin to separate the solid precipitate layer from the glycerol-aqueous layer. Using your pipette and bulb, begin to extract aqueous layer from mixture, leaving only the precipitate.
[0085] Some of the aqueous layer will remain but try to remove as much water by allowing continuing to heat and allowing some of the aqueous layer to precipitate. Allow continue heating for a minimum of 15 minutes (may vary depending on how much of the aqueous layer you were able to remove using your pipette). Be sure not to heat to the point that the precipitate begins to degrade
[0086] Remove precipitate from vessel and place into a clean stainless steel (4″) bowl. Continue heating process to remove as much of the aqueous layer as possible. Using a stainless steel spoon press precipitate to squeeze out additional glycerol and press precipitate into a single solid mass.
[0087] Remove solid mass from stainless steel (4″) bowl and place into a plastic storage container for storage. Do not place lid on plastic bowl until solid mass has cooled to room temperature.
[0088] Once solid has cooled to room temperature, affix a lid and allow to sit at room temperature for 48 hours.
[0089] Having sat for 48 hours, place into refrigerator (38° F.) for an additional 4 hours.
[0090] Use this solid material for bead material.
[0091] Different ratios of KOH to NaOH can be used to produce bead material of varying physical properties including overall integrity of material ranging from brittle solid (all NaOH) to malleable semi-solid (all KOH). This particular method prepares a fatty material that is malleable enough to apply bead material to wick by hand.
[0092] One process for creating a wick for a 2 inch votive is as follows:
[0093] Begin with a primed zinc-core wick usually sold in 3 inch length
[0094] Cut to exactly 2¼ inches in length from the base clip to the end of wick
[0095] Place wick on scale and record weight to the 0.001 grams or 1 mg. Accuracy should be about +/−0.005 grams
[0096] Next mark your wick (measuring from base clip to edge) at 1⅜ inches
[0097] This mark is the location of the bead consequently the first interval. Add the bead material
[0098] Using an exacto knife, cut a sliver of material from the solid (fatty acid) mass prepared in the previous instructions.
[0099] Using your fingers apply on the marked location of the wick, using your fingers to shape the material into a sphere
[0100] Place the wick containing the spherically shaped bead onto the scale and record the weight to the 1 mg of accuracy.
[0101] Subtract the new weight by the old weight identifying the exact amount of bead material added to the wick. Ideally, you should be at about 30 to 35 mg. Use your exacto knife to remove small amounts of bead to reach goal weight. It is ideal to cut at the base of the bead leaving a mushroom shaped bead rather than cutting at the top.
[0102] Having placed bead on wick prepare to prime the treated wick by melting 148° F. paraffin wax. Once wax has cooled to just shy of 148° F., did your treated wick into the wax to add a coat of wax around entire wick.
[0103] Your wick is ready to add to candle—be sure wick is not subjected to temperatures exceeding too much higher than 148° F., this will insure your bead stays in place and intact.
[0104] Although this technology has been illustrated and described herein with reference to preferred embodiments and specific examples thereof, it will be readily apparent to those of ordinary skill in the art that other embodiments and examples can perform similar functions and/or achieve like results. All such equivalent embodiments and examples are within the spirit and scope of the disclosed technology and are intended to be covered by the following claims. | A method for extinguishing a candle at timed intervals using a combustible material is disclosed. In one exemplary embodiment, the method includes: utilizing a combustible composition adapted for application to a wick segment; utilizing a combustible first wick segment; coupling a combustible second wick segment to the combustible first wick segment; placing the combustible second wick segment adjacent to the first wick segment; and configuring the combustible second wick segment to, as the combustible first wick segment, once ignited, burns down to the combustible second wick segment, interrupt and slowly self-extinguish the burning of the first wick segment. The candle wick is configured to be relit, post extinguishment, without having to physically remove a non-combustible barrier. A combustible composition also is disclosed. A candle further is disclosed. | 5 |
PRIORITY CLAIM
[0001] This application is a continuation application of U.S. patent application Ser. No. 11/362,482 filed Feb. 24, 2006, which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] Consumers frequently purchase ready-made coffee, and other beverages, in bulk beverage containers, such as for the office and catering. Beverages are often purchased with other food items, such as pastries, sandwiches, and condiments. Many coffee-shops and fast food establishments also carry items such as compact discs, reading material, and coffee brewing equipment.
[0003] Although the bulk beverage containers are often more convenient than carrying several cups of, often hot, beverages, the consumer may still need carry serving supplies, food items and/or other items in their other hand. This may make it difficult to carry a purse, professional case, and other items that the consumer may have.
BRIEF SUMMARY OF THE INVENTION
[0004] A carrier has a bottom, a plurality of side panels connected to the bottom, and a handle panel. The handle panel is connected to one of the side panels or the bottom. The handle panel includes a fold line, a first aperture, a second aperture, a first perforated line in continuation of the first aperture and the second aperture, and a second perforated line defining a finger opening in the handle panel. Pressure applied on the first perforated line tears apart material to produce a third aperture in continuation of the first aperture and the second aperture. Pressure applied inside the second perforated line dislocates material to produce the finger opening. When the third aperture is open in continuation of the first aperture and the second aperture, the handle panel folds along the fold line over a container to facilitate penetration of a handle of the container through the first aperture, the second aperture, and the third aperture.
[0005] Other systems, methods, features and advantages of the invention will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of a container with two assembled carriers.
[0007] FIG. 2 is a top plan view of the interior surface of a blank from which the carrier of FIG. 1 can be assembled.
[0008] FIG. 3 is a front view of a container with two assembled carriers.
[0009] FIG. 4 is a top view of a container with two assembled carriers.
[0010] FIG. 5 is a perspective view illustrating a carrier separate from a container.
[0011] FIG. 6 is an exploded detail of the head and neck portion of the carrier of FIG. 1 illustrating a first step of an exemplary folding option.
[0012] FIG. 7 is an exploded detail of the head and neck portion of the carrier of FIG. 1 illustrating a second step of an exemplary folding option.
[0013] FIG. 8 is an exploded detail view of the head and neck portion of the carrier of FIG. 1 illustrating an exemplary folding option.
[0014] FIG. 9 is a perspective view of a partially assembled double carrier with an exploded detail illustration of latching components.
[0015] FIG. 10 is a perspective view of two carriers assembled together to form an alternate variation of the carrier.
[0016] FIG. 11 is a perspective view of another carrier used with the container of FIG. 1 .
[0017] FIG. 12 is a top plan view of the interior surface of a blank from which the carrier of FIG. 11 can be assembled.
[0018] FIG. 13 is a perspective view of the carrier of FIG. 11 particularly illustrating the flexibility of the handle flap.
[0019] FIG. 14 is a perspective view of the carrier illustrating folding of the alternative handle flaps into the container.
[0020] FIG. 15 is a perspective back view of the carrier of FIG. 11 , with an exploded detail view of an overlapping central portion of the handle flap.
[0021] FIG. 16 is a fully assembled view of carriers combined together.
[0022] FIG. 17 is a perspective back view of the carrier of FIG. 11 illustrating optional folding of the back flap.
[0023] FIG. 18 is a perspective back view of the carrier of FIG. 11 and with the back flap folded such that the carrier may be used independent of the container.
[0024] FIG. 19 is a partially assembled view of duplicate carriers illustrating the securing structures.
[0025] FIGS. 20 and 21 are exemplary partial perspective views of a fully assembled carrier particularly illustrating the handle flap folding over upright handle panels to form a compartment cover.
DETAILED DESCRIPTION
[0026] A carrier may be used alone or in combination with a container, such as a bulk beverage container, or other similar containers such as food containers and pet containers. The carrier may be used to carry beverages, condiments and/or other items such as food items. The carrier may fit over a handle of the container and hang on a side and/or back of the container. The carrier may also be used in combination with other carriers to form other configurations of carriers. The carrier may permit an establishment to purchase one carrier-type for multiple uses.
[0027] FIGS. 1 , 3 and 4 illustrate a container 110 and a carrier 112 in their assembled forms. The carrier includes a storage container which may convert to a one, two or more-cell container. The carrier 112 may hang from the handle 111 on the top 108 of the container 110 to a side 109 of a container 110 . The top 108 of the container 110 may be angled, and therefore not parallel with the bottom side, so a portion of the carrier 112 may also be angled.
[0028] The carrier 112 includes an upwardly open compartment 124 and a handle panel 118 that may be integral therewith. The compartment 124 may be of an elongate rectangular configuration, and other shapes may be used. The compartment has a first end panel 114 , a second end panel 119 , a first side panel 115 and a second side panel 113 extended between the end panels and joined thereto at the corners 116 , such as by appropriate fold lines. The bottom of the compartment 117 may support items that are placed inside the carrier 112 .
[0029] The compartment may include one or more separate compartments. A single compartment may be transformed to a double-space compartment with the use of a corner area 116 of the compartment that contains cutting lines 138 that form a horizontal band 139 . A compartment divider may be formed by pressing the corner area 116 of the compartment inward. The corner area 116 can be replaced in its original position 138 to regain the full space of the compartment.
[0030] The first side panel 113 may be extended and form a handle panel 118 that that fits over the handle 111 of a container 110 . The handle panel 118 may include two distinct regions: an elongated head region 120 ; and a neck region 122 that may be narrower than the head region 120 and may join the head region 120 to the compartment 124 at the first side panel 113 .
[0031] The head region 120 may contain four separate apertures 126 . These apertures 126 may afford the carrier handle panel 118 a snug, secure fitting. The apertures 126 may be arranged to permit the compartment to be placed on either side of the container 110 . The apertures 126 may be angled to accommodate an angled container 110 such that when positioned in a resting position on the container 110 , the carrier 112 may be positioned generally parallel to the ground.
[0032] Two folds 134 in the handle panel 118 align the compartment on either side of the container 110 . Holes 130 in the handle panel 118 assist in aligning the carrier 112 on the handle 111 of the container. A central flap region 128 may lie between the apertures 126 to further secure the carrier's handle panel 118 to the handle 111 of the container 110 .
[0000] The handle panel 118 may also contain cutting lines to define an alternative handle flap 136 . The flap 136 is convex only for illustrative purposes. The flap 136 may have other shapes, such as rectangular or triangular. Alternatively, the flap 136 may be replaced with one or more finger holes. Pushing inward on the flap 136 may reveal a transversely elongated finger opening. The consumer may have the option of using one or two carriers 112 on each container 110 , depending on the amount to be carried.
[0033] FIGS. 1 , 3 , and 4 illustrate the use of the container 110 with two carriers 112 . When used together, one handle flap 118 may lie on top of the other. One compartment 124 may hang on each side of the container 110 . Each compartment can hold pastries, bagels, cookies, drinks 142 , extra cups 143 , napkins, condiments 144 , and other store items, such as compact disks, reading material, and cooking utensils. These items may also be carried in the compartment 124 .
[0034] FIG. 2 shows an exemplary blank of the carrier 112 . The carrier may be composed of a generally flat material having some rigidity and being capable of being bent or scored to facilitate bending along determined lines. An exemplary material is paperboard. The material may be coated, such as to provide increased water or fluid resistance and may have printing on selected portions of the material.
[0035] Alternatively or additionally, the carrier 112 may be composed of corrugated cardboard, chipboard, plywood, SBS, metal, plastic, fabric, ceramic, polymer, fibers, mesh, screen, wood, composite, mixtures or combinations of the foregoing, or the like. The carrier 112 may be made of one or more layers of one or more of the aforementioned materials. Where multiple layers of material are used they may be joined, such as, but not limited to, being laminated, glued, or otherwise fastened together for increased strength.
[0036] The carrier 112 may be a die cut from a single sheet of material. Alternatively, two or more segments of material may be used and joined together. While the carrier 112 material is preferably scored, where a plurality of panels or segments are used they can be joined using hinge or joint mechanisms. By score, it is meant to include a cut through a portion of the carrier sheet (either a continuous cut or a line of slits, holes, or perforations), or a weakened area, or a compressed area on at least one face of the sheet or other technique to permit bending of the material along a preferred line. The carrier may be constructed of a series of generally rectangular panels denoted by numerals 113 , 114 , 115 , and 119 joined by fold or score lines 116 . Flap 240 may include an adhesive 242 , such as glue. Bottom forming panels denoted as 117 may form a pressure lock configuration, which may close to form a sturdy bottom when items are placed inside. Scored lines 250 may be used to create flexibility in the horizontal band 139 defined by cut lines 138 .
[0037] The first side panel 113 may extend to form a handle panel 118 that fits over the handle of a container such as container 110 . First 213 and second 214 scored fold lines permit the head region 120 to fold. Folding the head region brings a cut out portion 212 into alignment with the alternative handle flap 136 . The cut out 212 portion is convex only for illustrative purposes. The cut out 212 may have other shapes, such as rectangular or triangular. The cut out portion 212 provides clearance for the handle flap 136 when it is punched through to reveal the transversely elongated finger opening. A latch lug 220 may be defined on three sides by cutting lines 244 which allow the latch lug 220 to flex resiliently outward from the corresponding first side panel 113 .
[0038] Numerals 246 , 248 , 250 , 252 , 254 , 256 , 258 , and 260 provide an illustrative example of possible dimensions of the blank. The detailed description of possible dimensions that follows is merely illustrative and not limiting.
[0039] Dimension 246 of the carrier 112 may be 12.221 inches. Dimension 248 of the carrier 112 may be 15.596 inches. Dimension 250 of the carrier 112 may be ⅝ inches. Dimension 252 of the carrier 112 may be 6¾ inches. Dimension 254 of the carrier 112 may be 3 7/16 inches. Dimension 256 of the carrier 112 may be 6¾ inches. Dimension 258 of the carrier 112 may be 3 13/32 inches. Dimension 260 of the carrier 112 may be 4⅝ inches. These dimensions are illustrative only and may be varied to tailor the carrier to the dimensions of the container.
[0040] Referring to FIG. 3 , the container 110 may be fitted with a mouth 312 for passage of contents from an inside of the container 110 to an outside of the container 110 , and vice versa, such as for loading and/or emptying contents. The carriers 112 may be duplicates arranged in opposite orientations. Numeral 314 illustrates a carrier in an open state where the divider band 139 is not punched in. Numeral 316 illustrates a carrier in a multi-compartment state where the divider band 139 is punched in. Either one or both of the corner areas 116 of the carriers 112 may contain divider bands 139 which may turn a single compartment into a multiple compartment. Both carriers 112 may lie flat against the sides of the container 110 due to folding along the scored lines 134 . The head portion 120 of the handle panel 118 may lie flat against the top of the container 110 . The head portion of the first carrier may lie flat on top of the head portion of the second carrier.
[0041] FIG. 4 shows a top view of the container 110 fitted with the two carriers 112 . The carriers 112 may be suspended from the handle 111 of the container 110 by the handle panel 118 . The head region 120 may have angled apertures 126 which fit over the container's handle 111 . The central flap region 128 between the sets of angled apertures 126 may provide a snug, secure fit. The first carrier 112 may lie layered on top of the second carrier 112 . Scored bending lines 134 may allow the carriers 112 to lie against the side of the container 110 .
[0042] FIG. 5 is a perspective view of the carrier 112 independent of the container 110 . The carrier 112 is in a partially unfolded state. By folding the head region 120 , or handle flap 118 , the carrier 112 may be used as a carrier independent of the container 110 .
[0043] FIGS. 6-8 illustrate an exemplary way to fold the head portion 120 for use of the carrier 112 without a container 110 . FIG. 6 illustrates the first exemplary fold. Folding the head region 120 along the first fold line 213 brings the flap section 128 into outward orientation and the cut out region 212 into inward orientation. FIG. 7 illustrates the second exemplary fold for separate carrier set-up. Folding the head region 120 at the second head region fold line 214 aligns the cut out region 212 with the cutting lines of the alternative handle flap 136 . FIG. 8 illustrates the final exemplary orientation of the head region in the separate carrier set-up. The flap section 128 is downwardly oriented and secured by a flange 215 . The cut out region 212 is aligned with the cutting lines of the alternative handle flap 136 . Pushing in on the alternative handle flap 136 creates the transversely elongated finger opening. The carrier as described, may be used either as a companion to a container, as a single unit, or in interlocked tandem with a duplicate carrier.
[0044] FIG. 9 illustrates two carriers 112 being joined together to form another carrier larger than the carrier 112 . The joining of carriers 112 may form a tandem carrier simply and rapidly, such as by utilizing the single latch assembly 218 and 220 . The two carriers may be positioned slightly longitudinally offset from each other with the latch lugs 220 aligned with the latch apertures 218 of the opposed carrier. The carriers are then longitudinally slid toward each other to engage each latch lug 220 into the latch aperture 218 of the opposed carrier. Latching the carriers together may restrict lateral separation of the carriers. An example of the possible latching mechanism follows. The example is merely illustrative as other latching mechanisms may be used.
[0045] The latch lug 220 may be arranged continuous with the first end panel 114 . The latch lug 220 may be generally rectangular with rounded corners, but other shapes may be used. To further stabilize and insure the integrity of latching, each latch lug 220 may be retained in its final latching position by a locking notch 910 in the lower corner and flush with the first end panel 114 . Once the latch lug 220 has been projected completely through the latch aperture 218 , it may lie against the respective inner faces of the end panels 114 and 119 . By pushing down on the containers, the locking notch 910 may engage a portion of the corner panel 116 to secure the latch. When so engaged, possible accidental or unintentional disengagement of the two carriers is reduced, particularly when the compartments are occupied with store items. Any load within the compartment will, by the natural direction of the load force, retain the compartments in lateral engagement with each other. If the carriers are to be disengaged, a positive manual manipulation, involving an upward pivoting and release of the locking notch and subsequent manipulation of the lug 220 may be required.
[0046] FIG. 10 is a perspective view of two carriers 112 assembled together in tandem to form a carrier 1000 . Folding of the head region 120 and pushing inward on the alternative handle flap 136 may reveal transversely elongated finger opening 1010 . The flap 136 of the first carrier, when inserted through the finger opening 1010 of the second carrier may secure the head panels and may provide protection and cushioning for the fingers. This arrangement may allow for the transport of multiple beverages 142 and condiments 144 , or other items. With the two carriers interlocked, the first and second alternative handle flaps 136 may align transversely across the assembly and the two elongate finger openings 1010 may be positioned for easy grasping by one hand. The positive interlock between the carriers within the handles themselves, created by insertion of the alternative handle flap 136 of the first carrier through the elongate finger opening 1010 of the second carrier, provides for a positive retention of the handles against each other in a manner which substantially defines a single handle for ready access thereto.
[0047] FIG. 11 illustrates a perspective view of another carrier 1100 in its assembled form. The carrier 1100 may be made of paperboard or other materials, such as those described above. The carrier 1100 may hang on the back side of a container, such as the container 110 described above. The carrier 1100 may include one or more compartments 1124 . A handle panel 1118 may be integral with the first side panel 1113 of the compartment 1124 . The handle panel 1118 may include two apertures 1126 dimensioned to fit over the handle 111 of the container 110 , permitting a snug fit.
[0048] The compartment may be divided by two foldable handle panels 1110 , which are folded into the compartment 1124 in this configuration. A plane of the foldable handle panels may be transverse to the carrier side panels and parallel to the carrier end panels. The compartment 1124 can contain drinks 142 , extra cups 143 , napkins, condiments 144 , pastries, bagels, and other store items. The fold line 1112 may allow the carrier to lie flat against the back side of the container 110 . This carrier may make transporting numerous items more convenient.
[0049] FIG. 12 illustrates an exemplary blank of the carrier 1100 . The carrier 1100 may be advantageously configured to be constructed from a single one piece paper board plank. The carrier may be constructed of a series of generally rectangular panels denoted by numerals 1113 , 1114 , 1115 , and 1119 joined by fold lines or score lines 1116 . The flap 1240 may be secured using glue 1242 or another adhesive, from top to bottom. Bottom forming panels denoted as 1217 may be glued 1242 .
[0050] A perforated central region 1128 may extend between the two apertures 1126 in the handle panel 1118 . The handle panel 1118 may further include several scored folding lines 1212 , 1213 , and 1214 . The handle panel 1118 may also include two horizontal latching lugs 1220 which may be defined by cutting lines on three sides 1244 . The base of the latching lugs 1220 may be aligned with the second folding line 1213 such that when the handle panel 1118 is folded at the second fold line 1213 and the latching lugs 1220 are punched out, they flex resiliently outward from the second fold line 1213 . The latching lugs 1220 may be aligned with horizontal latching apertures 1218 at near the intersection of the handle panel 1118 with the first side panel 1113 . The latching lugs 1220 are shown associated with the second fold line 1213 only for illustration. The latching lugs 1220 may be multiple or singular, may be of any shape, and may be located anywhere along the handle panel 1118 . The latching apertures 1218 may be altered accordingly. Alternatively, the latching apertures may be omitted from the handle panel 1118 .
[0051] FIG. 13 is a perspective view of the carrier 1100 . This view particularly illustrates the ability of the handle panel 1118 to bend such that the apertures 1126 may be fixed over the container handle 111 . This view further illustrates that the carrier 1100 may be expanded into a box-like form from a flattened, collapsed form by asserting pressure on the container's end panels 1114 , and 1119 .
[0052] FIG. 14 is a perspective view of the carrier 1100 particularly illustrating that the foldable handles 1110 may be flexed inward and tucked into the cavity of the compartment 1124 . Folding the foldable handles 1110 into the compartment 1124 may eliminate any interference the handles might create when the carrier is affixed to a container.
[0053] FIG. 15 provides a back view of the carrier 1100 . The figure illustrates the perforated central region 1128 extending between the apertures 1126 . This region may open to allow passage of the container's handle 111 while affixing the carrier 1100 to the container 110 . However, it may close under the container handle 111 after assembly, providing a snug fit.
[0054] FIG. 16 is a perspective view of two carriers 1100 assembled in tandem. Folding the handle panel 1118 and securing two carriers 1100 in tandem results in a four-pack carrier. Pushing in on a perforated aperture 1136 may reveal a transversely elongated finger opening 1637 for carrying the four-pack carrier. The aperture 1136 is rectangular for illustration only. The aperture may be other shapes, or may be replaced with one or more finger holes. Accordingly, the finger opening 1637 may be other than transversely elongated.
[0055] FIGS. 17-19 illustrate an exemplary folding of the handle panel 1118 and assembly of duplicate carriers 1100 into a four-pack carrier. The following description is by way of example only; other folding mechanisms may be used to accomplish the same end. FIG. 17 illustrates an exemplary folding of the handle panel 1118 . The handle panel may be folded at a first 1212 and second 1213 fold line. Latching lugs 1220 may be released from the handle panel 1220 by pushing inward along the cutting lines 1244 .
[0056] FIG. 18 is a back perspective view of the carrier 1100 . Folding at the second folding line 1213 followed by folding at the third folding line 1214 may bring the latching lugs 1220 into immediate alignment with the latching apertures 1218 . The fold may be secured by inserting the latching lug 1220 through the latching apertures 1218 .
[0057] An example of a possible latching mechanism follows. The example is merely illustrative. Other latching mechanisms may be used. The first side panel 1113 may include a second latching lug 1710 defined by cutting lines along a first and second side. This latching lug may be cut along a third side to create a notch 1712 that divides the second lug 1710 from the body of the carrier 1100 at the corner region 1116 . The lug remains integral with the carrier's first end panel 1114 at its uppermost region.
[0058] FIG. 19 illustrates an exemplary assembly of two two-compartment carriers 1100 into a four-compartment carrier 1600 . The joining of two carriers 1100 to form a tandem four-compartment carrier 1600 may be effected simply and rapidly utilizing the joining lug 1710 . Attachment may be achieved by first positioning the carriers 1100 slightly offset from each other with the latch lug 1710 of the first duplicate carrier aligned with a hatch 1712 cut into the second duplicate carrier. The latch lug 1710 is inserted into the hatch 1712 , and the opposed carriers are brought into orientation by clockwise rotation such that the latch lug 1710 may fully engage the hatch 1712 . Proper alignment orients the first and second transversely elongated finger openings 1637 such that the handle tongue 1136 of the first carrier 1100 can be inserted through the finger opening 1637 of the second carrier 1100 . Latching the carriers together may restrict lateral separation of the carriers. This latching method may be replaced by or used in combination with other known latching methods.
[0059] FIGS. 20 and 21 illustrate how the handle panel 1118 can bend forward and form a compartment cover on a single carrier. With the foldable handle panel divider 1110 erect, the foldable handle panel 1110 may be inserted through the apertures 1126 and central perforated region 1128 and secured by tucking in to the compartment 1124 .
[0060] While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible that are within the scope of the invention. | A carrier has a bottom, a plurality of side panels connected to the bottom, and a handle panel. The handle panel is connected to one of the side panels or the bottom. The handle panel includes a fold line, a first aperture, a second aperture, a first perforated line in continuation of the first aperture and the second aperture, and a second perforated line defining a finger opening in the handle panel. Pressure applied on the first perforated line tears apart material to produce a third aperture in continuation of the first aperture and the second aperture. Pressure applied inside the second perforated line dislocates material to produce the finger opening. When the third aperture is open in continuation of the first aperture and the second aperture, the handle panel folds along the fold line over a container to facilitate penetration of a handle of the container through the first aperture, the second aperture, and the third aperture. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to, and claims priority from, U.S. Provisional Patent Application Nos. 60/081,866 filed Apr. 15, 1998, 60/108,287 filed Nov. 13, 1998 and 60/115,374 filed on Jan. 11, 1999, all of which are now abandoned.
BACKGROUND OF THE INVENTION
A communication network is a means for conveying information from one place to another. The information can be in audio, digital data, video, text, graphics, data, sign language or other forms. The network can be a wide area network such as an intranet in an office, store or factory. Establishing and maintaining communication networks is one of the oldest known activities of mankind ranging from the shouting and drum signals of prehistory through written messages, signal flags, signal fires, smoke signals, signal mirrors, heliographs, signal lanterns, telegraphs, radios, telephones, televisions, microwave signals, linked computers and the internet. Improving communication networks will continue to be a major technical focus in the future.
The ideal communication network would be non-intrusive, inexpensive, extremely large information carrying capability (wide bandwidth), instantaneous and suitable for use with a broad variety of transmission and reception technologies.
There have been a few reports of the use of visible lighting as a carrier in electronic communication networks. The earliest reference to using lighting to send electronic information as well as to provide illumination appears to be Dachs (U.S. Pat. No. 3,900,404) disclosing an analog amplitude-modulation (AM) scheme to modulate the arc current in a fluorescent lamp, the “carrier” signal, with an audio information signal. King, Zawiski and Yokoun (U.S. Pat. No. 5,550,434) disclosed an updated electronic circuit that also provides for AM modulation of the arc current with an analog signal. Smith (U.S. Pat. No. 5,657,145) teaches a method for encoding low-bandwidth digital information into the lamp light using a pulsed AM technique. The encoding technique involves chopping 100 microsecond slices of current out of the arc waveform. Nakada ( Japanese Patent application 60-32443, Feb. 19, 1985.)reports a FM modulation and a frequency shift keying (FSK) scheme to transmit digital data using visible lighting. Gray (U.S. Pat. No. 5,635,915 Jun. 3, 1997 and PCT WO90/13067, Oct. 11, 1991.) has reported a product pricing system for supermarket shelf labels where a signal is sent from visible lighting to individual product price labels on shelves to cause the listed prices to change when desired.
Other communication schemes have been proposed that do not use the lamp light as the carrier, but instead use the lamp fixture as an antenna for transmitting conventional radio wave or microwave signals. In Uehara and Kagoshima (U.S. Pat. No. 5,424,859), for example, the inventors disclose techniques for mounting a microwave antenna on the glass surface of fluorescent and incandescent lamps. Buffaloe, Jackson, Leeb, Schlecht, and Leeb, ( “Fiat Lux: A Fluorescent Lamp Transceiver,” Applied Power Electronics Conference, Atlanta, Ga. 1997) first outlined the possibility of using pulse-code modulation to transmit data with a fluorescent lamp. In the latter reference, a three-level code shifts the arc frequency to one of three possibilities every Tsw=2 milliseconds. The result is a steady light output, on average, with no perceptible flicker. A one or a zero bit does not correspond to a particular arc frequency, but rather, to a three level pattern in arc frequency. A logic zero bit is transmitted by varying the arc frequency first to 40 kHz, then to 38 kHz, and finally to 36 kHz. A logic one bit is transmitted by the arc frequency pattern beginning with 38 kHz, followed by 40 kHz, and ending with 36 kHz. A unique start bit, used to demarcate the beginning of a transmitted byte, is represented by a sequence in the arc frequency beginning with 36 kHz, followed by 38 kHz, and ending with 36 kHz.
In our previously filed patent applications Ser. No. 09/291,706 filed Apr. 14, 1999 and entitled “Dual-Use Electronic Transceiver Set for Wireless Data Networks” and application Ser. No. 07/292,126 filed Apr. 14, 1999 entitled “Analog and Digital Electronic Receivers for Dual-Use Wireless Data Networks”, we have disclosed visible light communications networks for analog and digital data based on frequency modulation of light. The modulation techniques include direct FM, 2 level half weight bit coding and other orthogonal bit coding schemes.
The visible light case mentioned above is a specific case of our invention which, stated generally, involves simultaneous intentional dual use of transmitted electromagnetic radiation for two completely different useful purposes.
SUMMARY OF THE INVENTION
With the new technology disclosed in our previously filed applications, the recent advances in computer technology and other improvements in electronics, a number of applications and uses are now enabled. These applications are most preferentially executed using our new technology. However, in some cases, they may be executed using some of the other technologies known in the prior art.
With reference to FIG. 4, our communication network contains the following elements in series:
a) A source ( 50 ) of the information which will be transmitted;
b) A transmitter ( 54 ), which includes lamp and a means for controlling the modulation of the lamp to cause the lamp to carry a signal;
c) A medium ( 56 ) through which the light passes from the transmitter to the receiver ( 60 , 76 or 108 );
d) A receiver for receiving and demodulating the light in order to obtain the information; and
e) A user ( 62 , 96 or 98 ) for the information. This user can be a device, like a computer or a compact disk player, or it can be a person.
Our invention embodies a number of uses and purposes for the light based communication network. One purpose is to process the signal from the light is by the receiver to control the selection of information from a computer memory, CD or other storage device for large scale storage of data, greatly increasing the effective bandwidth of the information which can be transmitted. Another purpose is to provide data to the user from the receiver from both a large scale data storage device, like a computer memory, compact disk or other such device, and from the information transmitted by the light, with segments of data from the sources interspersed in presentation to the user. Another purpose is to provide data from a device source, like a computer chip, a tape cassette a compact disk or other such device, to the transmitter. Another purpose is to repeat continually the data from the device source, providing a continuous signal of finite period to the user. Another purpose is to use two or more transmitting lights, each transmitting its own signal at the same frequency to provide spatial resolution of signal so that the receiver will receive and provide to the user information from only one of the lights at any time and the receiver may shift its reception from one light to another. Another purpose is to transmit two or more different signals simultaneously at different frequencies from one light in such a manner that two or more receivers can each pick up the different signals. Another purpose is to transmit two or more different signals containing the same information in two or more different languages or codes so that by selecting the proper frequency, the user can select information in the language or code they deem most suitable. Another purpose is to encrypt the information prior to transmission and decrypted it subsequent to receipt. Another purpose is to use the lighting of an individual exhibit to provide to the user a description of some aspect of the exhibit. Another purpose is to transmit information over the network is used to provide assistance to individuals who are visually impaired. Another purpose is to transmit information transmitted over the network to provide assistance to individuals who are hearing impaired. Another purpose is to transmit over the network to provide assistance to individuals who are mentally impaired. Another purpose is to transmit the information transmitted over the network for processing by the user and subsequent sending out of a responding signal by the user using some means. Another purpose is to use the network to provide information to a receiver and user which are moving. Another purpose is to use the network to provide information inside an aircraft, boat, submarine, bus, auto, train or other vehicle. Another purpose is to use the network to provide guidance information to a receiver and user which are moving. Another purpose is to use the network to provide safety or warning information. Another purpose is to use create a network where the same information is being provided by a plurality of different lights. Another purpose is to use the network to provide paging information to the user. Another purpose is to provide information in classrooms and other meeting rooms. Another purpose is to create a repeater network where the modulated signal initiated by one light will be received by an adjoining light, that light started modulating, etc. until all lighting in a network is being modulated and carrying the signal. Another purpose is to create a network in which the electromagnetic radiation which is modulated is infrared radiation. Another purpose is to create a network in which the electromagnetic radiation which is modulated is ultraviolet radiation. Another purpose is to create a network in which the electromagnetic radiation which is modulated is radio frequency radiation. Another purpose is to create a network in which the electromagnetic radiation which is modulated is microwave radiation. Another purpose is to create a network in which the electromagnetic radiation which is modulated is X-ray radiation. Another purpose is to create a network to transmit compressed data.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of the invention.
FIG. 2 is a schematic illustration of a guidance embodiment of the invention.
FIG. 3 is a schematic representing the relationship among various elements that may comprise the communication network of the present invention.
FIG. 4 is a schematic illustrating another embodiment of the communication network of the present invention.
FIG. 5 is a schematic illustrating how the communication network of the present invention may be used in connection with a vehicle.
FIG. 6 is a schematic representing the relationship among various elements that may comprise the communication network of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A Computer as a User
One important application for our communication network involves inputting data into a computer. In one usage of this approach, light can be used as a positional locator or a data source. One such device which would use light provided digital data we will refer to as a Personal Locator and Minder or PLAM. In this system, each modulated light will deliver a relatively simple unique signal. This signal could either be a random signal which is uniquely assigned to that light, or else could be based on some kind of geographical matrix. The Personal Locator and Minder will receive the signal from the nearest modulated light, identify the location of that light from information in its memory, compare the location of that light with the location the PLAM is scheduled to be at that particular moment, and then carry out appropriate actions in accordance with its preprogramming. This aspect has application to patients in a hospital or assisted care facility context.
Since each patient has their own PLAM programmed with their own schedule, the system can accommodate as many different patients simultaneously as is desired. Each light will be continuously communicating location. The individual patient's PLAM will be reading this location information and then giving the individualized guidance to the patient.
The second programming feature which can be included in the PLAM will be the ability to record the daily activities and mobility of a patient. In addition to providing and cueing a personal schedule for a patient, the PLAM can also record how many warnings or inconsistencies in schedule versus actual location occurred during the course of an arbitrary time interval. This information could be stored in the PLAM and downloaded when convenient giving a unique and highly detailed record of a patient's mobility and awareness at every location and time during a day.
Another important application for the computer as user will involve the use of an addressable electronic memory device. This device can be a RAM type device, ROM computer memory or storage device like a CD. The addresses can be partially or totally selected based on information provided over modulated lights. The information from the memory can then be used for any of the purposes well known in the art.
Still another application for the computer as user involves the decryption of an encrypted message. As illustrated in FIG. 3, the message is encrypted using a method known in the prior art for which there is a decryption key 64 . The key 64 is not provided to the user 68 and is not retained in the computer. The decryption key 64 is supplied continually over the modulated lights. Only when the lights are providing the key 64 can the user 68 decode the information. The security code can be varied in a timed fashion or some other method known in the art. This providing of the decryption code 66 by the lights will provide an additional level of security since only when the user is in the physical presence of the lights will the encrypted message be able to be decoded.
The most general statement of our invention is that it involves simultaneous intentional dual use of transmitted electromagnetic radiation for two or more functionally different useful purposes. An example of such a dual use of electromagnetic radiation other than visible radiation would involve the frequency modulation of a radar signal used to track civilian aircraft so that it also would carry audio information to the aircrew. Another such example would involve the modulation of an infrared illuminator used to allow night vision goggles to be used so that the operator of the illuminator could communicate with the wearer of the night vision goggles or with another user in the field of vision of the infrared illuminator. One preferred embodiment of this invention in electromagnetic wavelength ranges outside the visible is in the infrared wavelength range, another preferred embodiment is in the ultraviolet wavelength range, another preferred embodiment is in the X-ray wavelength range, another is in the radio wavelength range, another is in the microwave wavelength range.
When the wavelength range of the electromagnetic radiation used for one or more simultaneous functionally different useful purposes is outside the visible wavelength range, we will refer to that radiation as “non-visible radiation.” With reference to FIGS. 3 and 6, it is understood that under some circumstances, a source 50 which is intended to generate electromagnetic radiation outside the visible wavelength range will also generate some visible radiation, such as through transmitter 54 . If one or more of the simultaneous useful purposes makes principal use of radiation outside the visible wavelength range, it will be considered “non-visible radiation” notwithstanding the generation of the visible radiation. An example would be a suntanning booth in which the UV light source would be modulated by a means 52 in order to allow communication with the user. Even though the UV light source 50 would simultaneously generate some visible electromagnetic radiation, the useful purpose of tanning the skin would make principal functional use of ultraviolet radiation, so this radiation would qualify as “non-visible radiation.” This designation as “non-visible radiation” would pertain whether the modulated UV light is detected by the receiver 60 and used for communication, or the simultaneously generated visible electromagnetic radiation is detected by the receiver and used for communication. Since one useful purpose, namely tanning the skin, makes principal use of electromagnetic radiation outside the visible wavelength range, the radiation qualifies as “non-visible radiation.”
In one preferred embodiment of this invention, one useful functional purpose of the embodiment is communication and the other useful functional purpose is some purpose other than communication. In another preferred embodiment, both useful functional purposes of the embodiment are some purpose other than communication.
In one preferred embodiment of the invention, one of the useful functional purposes makes primary use of electromagnetic radiation outside of the visible wavelength range. In another preferred embodiment of the invention, two or more of the useful functional purposes make primary use of electromagnetic radiation outside of the visible wavelength range.
An essential part of this invention is that the electromagnetic radiation must be free from application unacceptable flicker. Generally, this application unacceptable flicker occurs when variations due to the second utility of the radiation interfere with the first utility or vice versa. An example of application unacceptable flicker for visible radiation would be visually perceptible flicker such that the light is considered unacceptable for illumination. For other examples, such as a radar set, application unacceptable flicker could mean that the flicker would interfere with radar detection.
In the examples below, the exact circuitry and systems can be designed and built by an individual of ordinary skill in the art of electrical engineering using, where appropriate, the unique communication network of our previously filed patent applications identified above.
EXAMPLE 1
Personal Locator and Minder Network
As is shown in FIG. 1, the network is created with a plurality of modulated lights 30 , each transmitting its own unique signal. In a preferred embodiment, each modulated light 30 is self contained, except optionally for a power supply, which can be either line power or battery power. The modulated lights are not controlled from a central location.
The PLAM in this example contains a photocell 32 capable of receiving light and circuitry capable of demodulating the signal from the nearest light and identifying the unique signal, a clock 34 , a computer memory 36 capable of storing the desired location of the PLAM at any specified time, and a computer 38 capable of evaluating signal received from the photocell 32 , comparing that signal with the desired location of the PLAM and presenting information to the user based on the comparison. This information could be reassurance or silence if the signal received is the desired preprogrammed location signal, while it could be guidance or remonstrance if the signal received is not the desired preprogrammed location signal.
Each of a plurality of users can have their own PLAM programmed with their own schedule. Each light will be continuously communicating location. The individual user's PLAM will be reading this location information and then giving the individualized guidance to the user.
PLAM and its enhancements can be valuable to a number of users including brain disabled individuals, such as individuals suffering from traumatic brain injury, Alzheimer's disease or other dementia; children in a child care environment; and individuals in a secure environment whose movements must be monitored and recorded.
EXAMPLE 2
Enhanced Personal Locator and Minder
PLAM is programmed with the planned schedule for the user. When the time for one of the day's scheduled activities is noted by PLAM, the device takes note of the nearest modulated light and compares that with the location where the patient should be. If the light is in the place where the user is scheduled to be, the device simply notes this. However, if the user is in a place other than where he or she is scheduled to be, the device will remind the user of their scheduled location. A more sophisticated version of PLAM will also have in its memory the proper route for the patient to take to proceed to their desired location. As the user would proceed along the path to their desired location, PLAM will take note of the lights which the device is passing and correct the patient if they should take a wrong turn or stop.
EXAMPLE 3
Personal Locator and Minder with Alarm
The PLAM also contains a radio transmitter, microwave transmitter or other transmitter device. If the user of the PLAM is determined by the computer to be in an unauthorized area, this PLAM sends a signal to an attendant. This attendant could be a nurse in a hospital environment, a teacher or day care attendant in a day care environment or a security guard in a secure environment.
EXAMPLE 4
Personalized Voice Messages
In the previous examples, the computer memory of the PLAM is programmed with a voice of personal significance to the user. We define a voice of personal significance to the user to be a voice of a person who has some significant emotional and/or historical tie to the user. Most preferred as voices of personal significance would be the voice of the person themself, or the voices of the person's parents, siblings, children, spouse, business partners, or close friends. Other examples of voices of personal significance, not intending to be limiting, would be the person's former spouse(s), school classmates, friends and acquaintances, coworkers, current or former neighbors, and physicians, nurses or other caregivers.
EXAMPLE 5
Enhanced PLAM with Recording Capability
To the PLAM of Example 2 will be the ability to record the daily activities and mobility of a user. In addition to providing and cueing a personal schedule for a user, the PLAM can also record how many warnings or inconsistencies in schedule versus actual location occurred during the course of an arbitrary time interval. This information could be stored in the PLAM and downloaded when convenient by a monitor, such as a skilled care provider, giving a unique and highly detailed record of a user's mobility and awareness at every location and time during a day.
EXAMPLE 6
Programming the PLAM Using Modulated Lighting
To the PLAM of Example 2 will be add the ability to have the programming in the computer changed by information received over the lighting. The programming information is transmitted over light using one of the techniques previously taught. The information is prefaced with a code to indicate to the computer that it is programming information. The programming information so received is then stored in the computer memory and used by the computer in making decisions and in giving guidance to the user.
EXAMPLE 7
Message Selected from Computer Memory
A memory device such as a computer memory, CD, or tape is loaded with a number of messages which can prove useful. Each message is stored in a coded, identifiable location in the memory device. A coded signal is sent over the network indicating which coded location and which message should be played. The coded signal is received, processed by a computer and used to identify and call up the message from the memory. The message from the memory is presented to the user. This message could be an audio message, textual message, graphical message or other message.
EXAMPLE 8
Mixed Message from Computer Memory and Light Carried Message
The devices of Example 7 have an enhanced capability to receive and process more extensive information from the lights. The system has the capability to present information in a mixed fashion. As an example, the system could be cued to present and then present aurally “This is the office of” from the computer memory and then “Mr. Smith” from the light transmitted audio message.
EXAMPLE 9
Encryption Code
A message is encrypted using one of a number of encryption techniques known in the art which require an decryption code. The user is not provided with the decryption code. The computer or other device provided to the user has a receptor circuit which can receive and process encoded signals from the lighting in the area. The ambient lighting is modulated to contain the decryption code. The computer is able to process and decrypt the encrypted message only so long as the receptor circuit is viewing and processing the decryption code.
EXAMPLE 10
Multiple Channels
With reference to FIG. 4, a network is constructed with two or more lights 72 , 74 in proximity transmitting information on two or more different frequencies or else with one or more lights each transmitting information on two or more different frequencies creating channels of information. A receiver 76 is provided which is able to receive and process information from these channels. Different information is transmitted on the different channels, which may be received by different users 96 , 98 .
EXAMPLE 11
Multiple Channels to Transmit Different Languages
In the network of Example 10, information is transmitted using the different channels to transmit different languages. As an example, one channel could transmit information in English and another channel to transmit the same information in Spanish.
EXAMPLE 12
Lighting to Provide Descriptions of Exhibits
In an facility where there are two or more areas with different items being exhibited, each area is provided with its own separate lighting. This lighting is modulated to provide a description of the exhibit which is being lighted. The user is provided with a receptor which will allow the user to receive a description of the exhibit. As the user moves from one exhibit to another, the lighting provides the appropriate description of the exhibit which they are viewing.
EXAMPLE 13
Assistance to the Visually Impaired
The lights in a facility are modulated to provide guidance information to individuals who are visually impaired. This information could be of the sort of “Office X is on the right” or “The stairs are on the left.” A visually impaired individual would have a receptor to process this information and receive the guidance.
EXAMPLE 14
Assistance to the Hearing Impaired—Aural
The lights in a facility are modulated to provide information to individuals who are hard of hearing and require assistance. The information could be provided through a speaker, earphones or through a neck loop into a magnetic induction type hearing aid.
EXAMPLE 15
Assistance to the Hearing Impaired—Textual
The lights in a facility are modulated to provide information to individuals who are deaf or hard of hearing and require assistance. The information could be textual, graphical or pictorial information.
EXAMPLE 16
User which is Moving
The lights in an area are modulated to contain information. A user which is moving is provided with a receiver. Information is transmitted to the user which is moving.
EXAMPLE 17
Lighting Inside a Vehicle
The lighting 58 inside or on a vehicle 82 is modulated to contain information. A user 62 inside or on the vehicle is provided with a receiver 60 . Information is transmitted to the user 62 which is inside or on the vehicle. The vehicle can be an aircraft, boat, submarine, bus, auto, tank, other military vehicle, wheelchair, spacecraft or other vehicle. The vehicle can be moving or stationary.
EXAMPLE 18
Guidance and Directional Information to a Vehicle
Lighting 58 outside a vehicle 86 is modulated to provide information. Each light or sequence of lights is modulated to contain directional information or guidance information. The vehicle has sensors which in a sequential form will view the lights. By processing the information from the lights in sequence, and determining which lights are and are not in the field of view of the sensors, the vehicle can maintain its direction of travel. This is shown in the FIG. 2 below.
EXAMPLE 19
Modulated Running Lights
Circuitry is provided to modulate the running lights on a vehicle 88 . These lights will carry information generated by a source 50 inside the vehicle 88 . A receiver 60 outside the vehicle can receive and process this modulated light and process the information to a user 62 outside the vehicle. Another embodiment of this example would be the modulation of the headlights on a vehicle.
EXAMPLE 19
Repeater Network
One light in a facility is modulated with a signal to carry information. An adjoining light has a receptor which is positioned to view the signal from the first light. This signal is processed by the circuitry in the second light and the signal from the second light is modulated to transmit the same signal as is contained in the modulated signal from the first light. A third light has a receptor which is positioned to view the signal from the second light. This light also has a repeater circuit similar to the second light. A network of lights throughout the facility is, in this manner, modulated to carry the same signal as the first light.
EXAMPLE 20
Transmission Through Fluid
A light is modulated to carry a signal. The electromagnetic radiation from this light is allowed to fall on a receiver/receptor 60 and the signal is processed. Water 90 is placed in the path between the light and the receiver 60 . No change is observed in the signal which is processed. The light is carried by a SCUBA diver who is underwater and is using the light for underwater illumination. The receiver is carried by another SCUBA diver who makes use of the information transmitted by the modulated light.
EXAMPLE 21
Transmission Through Vacuum or a Reduced Pressure Medium
A light is modulated to carry a signal. The electromagnetic radiation from this light is allowed to fall on a receiver/receptor and the signal is processed. Air or any other gas is partially or completely removed from the medium between the light and the receiver to a pressure below 0.5 atmospheres. No change is observed in the signal which is processed. The light is carried by an astronaut who is in space and is using the light for illumination. The receiver is carried by another astronaut or by a spacecraft which makes use of the information transmitted by the modulated light.
EXAMPLE 22
Signal Source from Computer Memory Provides Repetitive Signal
A computer memory is programmed to repeat, continuously, an information signal. This information signal is used to control the modulation of a light signal. A receiver receives and processes this information.
EXAMPLE 23
Signal Source Provides Non Repetitive Signal
A non repetitive signal is provided from a microphone, tape, CD, record or other information storage device. This non-repetitive signal is used to control the modulation of a light signal. A receiver receives and processes this information.
EXAMPLE 24
Lecture Hall
A network is created in a facility where two or more users are present. The users each have individual receivers and make personal use of the information transmitted by the lights.
EXAMPLE 25
Non-visible Radiation—Ultraviolet
A mercury vapor lamp capable of producing ultraviolet radiation which can tan the skin modulated to carry information. A receiver of the type taught in the co-pending application above is able to detect the fraction of the radiation in visible range, demodulate it and extract the transmitted signal. Alternately, a photodetector capable of detecting ultraviolet radiation is used and the modulated ultraviolet radiation is detected, demodulated and the transmitted signal extracted and presented to the user. The ultraviolet light is also used for tanning the skin of the user.
EXAMPLE 26
Non-visible Radiation—Infrared
An infrared illuminator is used to provide illumination for a viewing device which can receive infrared radiation and present it to a user as a visible display. This infrared illuminator is modulated to carry an analog audio signal. A receptor of the type taught in the co-pending application above is provided to receive and process this analog audio signal.
EXAMPLE 27
Non-visible Radiation—MRI
A user is placed in an MRI device. The device is operated in the normal fashion, using electromagnetic radiation of the proper wavelength to create magnetic resonance. This electromagnetic radiation is also modulated to carry information to allow communication with the user.
EXAMPLE 28
Compressed Data
Data from the signal source 50 is compressed using a compression technique known in the art. Compressed data 104 is transmitted over the network. The data is decompressed after it is received and processed by the receiver 60 . The decompressed data is presented to the user 106 . | A communications network comprised of a source of information to be transmitted in the form of a signal, one or more transmitters which emit light suitable for illumination and including means for modulating the light with the information signal, a medium such as a fluid through which the light passes, and one or more receivers for receiving the light and demodulating the signal to obtain the information. A user for the information may be a device, such as a computer or a compact disk player, or it may be a person, perhaps with some form of sensory or mental impairment. The information may be encrypted, may provide directional guidance, such as to a user moving in a vehicle, and/or may be transmitted simultaneously over multiple channels. Various types of visible light assemblies may be employed, with varying power inputs and outputs. | 7 |
TECHNICAL FIELD
[0001] The present invention concerns a system and a method of controlling and balancing the temperature of two cooperating cylinders forming a nip.
PRIOR ART
[0002] In many circumstances where two cylinders form a nip it is most important that the distance between the cylinders are kept within a certain range. Often it is also important that cooperating parts of the cylinders are kept in line with each other.
[0003] For many types of cylinders such as scoring cylinders forming a nip it is important that they are properly aligned in relation to each other. In machines for forming containers from a web of a paper or laminate material, there are normally scoring cylinders at some stage. Scores are formed in the web, to assist in the folding of the packages. One of the scoring cylinders has projections that are to go into interacting grooves of the other cylinder. Not properly aligned scoring cylinders may lead to cuts in the web to be scored. When cylinders are heated they will expand. If scoring cylinders are unevenly heated they will expand unevenly which may lead to that cooperating parts of the cylinders does not align properly. Thus, the projection of one cylinder may hit the sides of the grooves of the other cylinder, which probably will cut the web.
SUMMARY OF THE INVENTION
[0004] In view of the above one object of the present invention is to eliminate or at least reduce the risk of cutting of a web at a scoring unit due to uneven heating.
[0005] One aspect of the present invention is to control the temperature of the two cylinders forming the nip. According to the invention the temperature of the cylinders including bearings and drive are measured continuously in a number of separate points. The algorithm for the temperature control is based on the highest registered temperature, which temperature will form the set point. The other parts of the cylinders, bearings and drive are then heated to the registered highest temperature, i.e. the set point.
[0006] In another aspect of the present invention the temperature at different parts of the cylinders, bearings and drive are still registered. Heaters ate still provided for heating of the different parts of the cylinders. However, according to this aspect of the present invention the cylinders are placed displaceable at the ends in relation to each other. Either only one or both cylinders are displaceable. The cylinder or cylinders are displaced based on the sensed temperatures.
[0007] By means of the present invention the temperature of the cylinders are evenly distributed. Without a control system such as according to the present invention there may be a relatively large difference between the highest and the lowest temperature of the cylinders of the nip.
[0008] Even tough the present invention is normally described in connection with scoring cylinders at machines for forming containers, a person skilled in the art realises that the principles of the present invention may be used for other cylinders forming a nip.
[0009] The control cycle of the present invention is developed for webs having a thickness of at least 150 μm.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention will be described further below by way of examples and with reference to the enclosed Figs. In the Figs.,
[0011] FIG. 1 is a schematic side view of two scoring cylinders incorporating the present invention,
[0012] FIG. 2 is a detailed view of a part of a nip of the scoring cylinders of FIG. 1 ,
[0013] FIG. 3 is one example of a heater assembly that may be used with the present invention, and
[0014] FIG. 4 is a schematic end view of one of the cylinders of FIG. 1 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0015] In FIG. 1 two scoring cylinders 1 , 2 are shown, as one example. Each end of the cylinders 1 , 2 is received in a bearing housing 3 , 4 , 5 , 6 . One of the bearing housings 6 includes a drive unit.
[0016] One of the scoring cylinders 1 has projections 8 formed on the surface of the cylinder 1 . The projections 8 are to be received in grooves 7 of the other scoring cylinder 2 . If the cylinders 1 , 2 are unevenly heated they will expand in various degrees. If the projection 8 of one scoring cylinder 1 due to such uneven heating gets too close to the groove 7 of the other cylinder 2 , the web to be scored may be cut in the contact between projection 8 and groove 7 .
[0017] Heaters 23 - 28 are arranged along each cylinder 1 , 2 . Normally at least three heaters 23 - 28 are arranged for each cylinder 1 , 2 , one at each end and one in the middle. A person skilled in the art realises that the exact number of heaters are decided in each case depending on the dimensions of the cylinders, the demands on sensitivity etc. In FIG. 3 one example of a heater is shown as a ramp 9 having a number of IR-carbon light heaters 10 . In this embodiment heaters may be placed also inside the bearing housings 3 - 6 , which heaters may be air heaters. In other embodiments there are no heaters in the bearing housings 3 - 6 as the drive unit and bearings normally generates much of the heat during use. The bearing housings 3 - 6 include oil that assists in distributing the generated heat inside the bearing housings 3 - 6 .
[0018] A sensor 11 is associated with at least each heater 23 - 28 but further sensors may be arranged. The sensors 11 measure the temperature at specific points 12 - 21 on the cylinders or parts associated with the cylinders. The sensors 11 are normally IR-sensors, but any suitable type of sensor may be used.
[0019] In use one IR-sensor 11 is directed against points of measuring 13 - 15 , 17 - 19 on the cylinders 1 , 2 . The IR-sensors measure without contact. In the bearing housings 3 - 6 other types of temperature gauges may be used, such as a strain gauge. In each bearing housing 3 - 6 a point of measuring 12 , 16 , 20 , 21 is established. The points of measuring 13 - 21 are indicated in FIG. 1 . In the example shown in FIG. 1 there are six heater assemblies 23 - 28 , one at each end and one in the middle of each cylinder 1 , 2 . The six heaters 23 - 28 are associated with one point of measuring 13 - 15 , 17 - 19 each. A person skilled in the art realises that many different types of sensors and heater assemblies may be used.
[0020] To reduce the risk of the heaters 23 - 28 influencing the sensors 11 , one or several shields 22 may be placed between the heaters and the sensors along each cylinder 1 , 2 , as indicated in FIG. 4 . The shields 22 will extend directed away from the cylinders 1 , 2 .
[0021] The control system of the present invention is based on the highest sensed temperature. Said highest sensed temperature will be used as set point for the other points of measuring 12 - 21 . Thus, if the sensed temperature of a specific measuring point is below the hottest sensed measuring point, the heater associated with that measuring point is activated. If the difference to the highest sensed temperature is above a predetermined value, the associated heater will be run at full effect. When the difference is below said predetermined value the heater will be run at less than 100% and will normally be controlled in such a way that the temperature of the specific measuring point will approach the established set point without exceeding it.
[0022] As long as the temperatures of the points of measuring 12 - 21 are within a certain interval the cylinders 1 , 2 will expand relatively evenly, which means that the risk of cutting of the web to be scored is reduced dramatically. A person skilled in the art realises that the temperature interval and the maximal allowed temperature difference between specific points of measuring 12 - 21 will depend on a number of factors, such as the dimensions of the cylinders 1 , 2 , the dimensions of the cooperating projections 8 and groove 7 in the forming of the scores, the quality and material of the web, the speed of the web.
[0023] In one example the heaters 23 - 28 are run at full effect if the sensed difference between a specific point of measuring 12 - 21 and the set point exceeds 2° C. When the difference is below 2° C. the specific heater 23 - 28 is controlled to let the temperature approach the set temperature without exceeding it. If the temperature in one specific point exceeds the set temperature, that higher temperature will be the new set temperature, if it still exceeds the former set temperature after a predetermined time interval. In one example this time interval was set to 8 minutes.
[0024] In one other embodiment the distances between the ends of the cylinders 1 , 2 may be altered. This is done in that either only one of the cylinders 1 , 2 or both cylinders 1 , 2 are arranged moveable, in relation to each other in such a way that there mutual distance is varied. Normally only one of the cylinders 1 , 2 is arranged moveable. In this embodiment there are no heaters in the bearing housings 3 - 6 , but there are heaters along the cylinders 1 , 2 in the same way as described above. Also in this embodiment the highest sensed temperature is the set temperature for the rest of the points of measuring 12 - 21 .
[0025] The sensors 11 , heaters 23 - 28 and possible actuators to move one or both cylinders 1 , 2 are connected to a controller, such as a computer or a CPU. The controller will hold the algorithm by which the heaters 23 - 28 and possible actuators are controlled, based on the temperatures sensed by the sensors 11 .
[0026] In some embodiments fans, vortex tubes or other cooling means are placed together with the heaters 23 - 28 , in which case the temperature control may be done by a combination of heating and cooling or only by cooling. Often the cooling means are only placed at end shafts of the cylinders 1 , 2 .
[0027] The temperature range and the time interval are determined based on the dimensions of the cylinders 1 , 2 and the scoring parts 7 , 8 of the cylinders 1 , 2 , on the expected temperature of the cylinders 1 , 2 and on the quality and dimensions of the web to be scored.
1 . cylinder (scoring cylinder) 2 . cylinder (scoring cylinder) 3 . bearing housing 4 . bearing housing 5 . bearing housing 6 . bearing housing, drive 7 . groove 8 . projection 9 . ramp 10 . IR-carbon light heater 11 . IR-sensor 12 . point of measuring 13 . point of measuring 14 . point of measuring 15 . point of measuring 16 . point of measuring 17 . point of measuring 18 . point of measuring 19 . point of measuring 20 . point of measuring 21 . point of measuring 22 . shield 23 . heater 24 . heater 25 . heater 26 . heater 27 . heater 28 . heater | Method and arrangement for controlling the temperature of two cylinders forming a nip. The temperature of at least one point on each cylinder is sensed by sensors, forming a point of measuring, wherein the highest sensed temperature is used as set point and wherein the cylinders are heated in areas where the sensed temperature is below the set point. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to electro-optical sensing devices for detecting the presence or concentration of an analyte in a liquid or gaseous medium. More particularly, the invention relates to (but is not in all cases necessarily limited to) optical-based sensing devices which are characterized by being totally self-contained, with a smooth and rounded oblong, oval, or elliptical shape (e.g., a bean- or pharmaceutical capsule-shape) and a size which permit the device to be implanted in humans for in-situ detection of various analytes.
[0003] 2. Discussion of the Background
[0004] U.S. Pat. No. 5,517,313, the disclosure of which is incorporated herein by reference, describes a fluorescence-based sensing device comprising indicator molecules and a photosensitive element, e.g., a photodetector. Broadly speaking, in the context of the field of the present invention, indicator molecules are molecules one or more optical characteristics of which is or are affected by the local presence of an analyte. In the device according to U.S. Pat. No. 5,517,313, a light source, e.g., a light-emitting diode (“LED”), is located at least partially within a layer of material containing fluorescent indicator molecules or, alternatively, at least partially within a wave guide layer such that radiation (light) emitted by the source strikes and causes the indicator molecules to fluoresce. A high-pass filter allows fluorescent light emitted by the indicator molecules to reach the photosensitive element (photodetector) while filtering out scattered light from the light source.
[0005] The fluorescence of the indicator molecules employed in the device described in U.S. Pat. No. 5,517,313 is modulated, i.e., attenuated or enhanced, by the local presence of an analyte. For example, the orange-red fluorescence of the complex tris(4,7-diphenyl-1,10-phenanthroline)ruthenium(II) perchlorate is quenched by the local presence of oxygen. Therefore, this complex can be used advantageously as the indicator molecule in an oxygen sensor. Indicator molecules whose fluorescence properties are affected by various other analytes are known as well.
[0006] Furthermore, indicator molecules which absorb light, with the level of absorption being affected by the presence or concentration of an analyte, are also known. See, for example, U.S. Pat. No. 5,512,246, the disclosure of which is incorporated by reference, which discloses compositions whose spectral responses are attenuated by the local presence of polyhydroxyl compounds such as sugars. It is believed, however, that such light-absorbing indicator molecules have not been used before in a sensor construct like that taught in U.S. Pat. No. 5,517,313 or in a sensor construct as taught herein.
[0007] In the sensor described in U.S. Pat. No. 5,517,313, the material which contains the indicator molecules is permeable to the analyte. Thus, the analyte can diffuse into the material from the surrounding test medium, thereby affecting the fluorescence of the indicator molecules. The light source, indicator molecule-containing matrix material, high-pass filter, and photodetector are configured such that fluorescent light emitted by the indicator molecules impacts the photodetector such that an electrical signal is generated that is indicative of the concentration of the analyte in the surrounding medium.
[0008] The sensing device described in U.S. Pat. No. 5,517,313 represents a marked improvement over devices which constitute prior art with respect to U.S. Pat. No. 5,517,313. There has, however, remained a need for sensors that permit the detection of various analytes in an extremely important environment—the human body. Moreover, further refinements have been made in the field, which refinements have resulted in smaller and more efficient devices.
[0009] U.S. Pat. Nos. 6,400,974 and 6,711,423, the disclosures of which are incorporated herein by reference, each describe a fluorescence-based sensing device comprising indicator molecules and a photosensitive element that is designed for use in the human body.
SUMMARY OF THE INVENTION
[0010] In one aspect, the present invention provides an electro-optical sensing device. In one particular embodiment, the sensing device includes: a housing having an outer surface; a plurality of indicator molecules located on at least a portion of the outer surface of the housing; a circuit board housed within the housing; a support member having a side that lies on a plane that is substantially perpendicular to a plane on which a top side of the circuit board lies; a radiation source attached to the side of the support member and positioned a distance above the top side of the circuit board; and a photodetector connected to the circuit board for detecting a response of the indicator molecules.
[0011] Advantageously, to facilitate attachment of the support member to the circuit board, the circuit board may have a groove in the top side thereof and the support member may have an end inserted into the groove.
[0012] The sensing device may further include a reflector that is spaced apart from the radiation source and that has a reflective side that faces the radiation source. The photodetector may be positioned in a location beneath a region between the radiation source and the reflective side of the reflector.
[0013] In another embodiment, the sensing device includes: a housing having an outer surface; a plurality of indicator molecules located on at least a portion of the outer surface of the housing; a circuit board housed within the housing; a photodetector having a top side and a bottom side, wherein the photodetector is electrically connected to a circuit on the circuit board and at least a top side of the photodetector is photosensitive; a filter having a top side and a bottom side, the bottom side being positioned over the top side of the photodetector; and a radiation source positioned over the top side of the filter.
[0014] In some embodiments, the sensing device may further include a base having a top side and a bottom side, with the bottom side being attached to an end of the circuit board, and with the bottom side of the photodetector being mounted on the top side of the base. Preferably, the top side of the base lies in a plane that is substantially perpendicular to a plane on which a top side of the circuit board lies and the top side of the photodetector is generally parallel with the top side of the base. To facilitate attachment of the base to the circuit board, the bottom side of the base may have a groove therein, and an end of the circuit board may be inserted into the groove.
[0015] In other configurations, the top side of the photodetector lies in a plane that is substantially parallel with a plane on which a top side of the circuit board lies. Additionally, an opaque base may be disposed between the radiation source and the filter. The base may be made from molybdenum.
[0016] The above and other features and advantages of the present invention, as well as the structure and operation of preferred embodiments of the present invention, are described in detail below with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The accompanying drawings, which are incorporated herein and form part of the specification, help illustrate various embodiments of the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention. In the drawings, like reference numbers indicate identical or functionally similar elements. Additionally, the left-most digit(s) of a reference number identifies the drawing in which the reference number first appears.
[0018] FIG. 1 is a schematic, section view of a fluorescence-based sensor according to an embodiment of the invention.
[0019] FIG. 2 is a schematic, section view of a fluorescence-based sensor according to another embodiment of the invention.
[0020] FIG. 3 is a perspective, top view of a circuit board according to an embodiment of the invention.
[0021] FIG. 4 is a schematic, section view of a fluorescence-based sensor according to another embodiment of the invention.
[0022] FIG. 5 is a schematic, section view of an assembly according to an embodiment of the invention.
[0023] FIG. 6 is a schematic, section view of a fluorescence-based sensor according to another embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0024] FIG. 1 is a schematic, section view of an optical-based sensor (“sensor”) 110 , according to an embodiment of the invention, that operates based on the fluorescence of fluorescent indicator molecules 116 . As shown, sensor 110 includes a sensor housing 112 . Sensor housing 112 may be formed from a suitable, optically transmissive polymer material. Preferred polymer materials include, but are not limited to, acrylic polymers such as polymethylmethacrylate (PMMA).
[0025] Sensor 110 may further include a matrix layer 114 coated on at least part of the exterior surface of the sensor housing 112 , with fluorescent indicator molecules 116 distributed throughout the layer 114 (layer 114 can cover all or part of the surface of housing 112 ).
[0026] Sensor 110 further includes a radiation source 118 , e.g. a light emitting diode (LED) or other radiation source, that emits radiation, including radiation over a range of wavelengths which interact with the indicator molecules 116 . For example, in the case of a fluorescence-based sensor, radiation sensor 118 emits radiation at a wavelength which causes the indicator molecules 116 to fluoresce. Sensor 110 also includes a photodetector 120 (e.g. a photodiode, phototransistor, photoresistor or other photosensitive element) which, in the case of a fluorescence-based sensor, is sensitive to fluorescent light emitted by the indicator molecules 116 such that a signal is generated by the photodetector 120 in response thereto that is indicative of the level of fluorescence of the indicator molecules. Two photodetectors 120 a and 120 b are shown in FIG. 1 to illustrate that sensor 110 may have more than one photodetector. Source 118 may be implemented using, for example, LED model number EU-U32SB from Nichia Corporation (www.nichia.com). Other LEDs may be used depending on the specific indicator molecules applied to sensor 110 and the specific analytes of interested to be detected.
[0027] The indicator molecules 116 may be coated on the surface of the sensor body or they may be contained within matrix layer 114 (as shown in FIG. 1 ), which comprises a biocompatible polymer matrix that is prepared according to methods known in the art and coated on the surface of the sensor housing 112 . Suitable biocompatible matrix materials, which preferably are permeable to the analyte, include some methacrylates (e.g., HEMA) and hydrogels which, advantageously, can be made selectively permeable—particularly to the analyte—i.e., they perform a molecular weight cut-off function.
[0028] Sensor 110 may be wholly self-contained. In other words, the sensor is preferably constructed in such a way that no electrical leads extend into or out of the sensor housing 112 to supply power to the sensor (e.g., for driving the source 118 ) or to transmit signals from the sensor. Rather, sensor 110 may be powered by an external power source (not shown), as is well known in the art. For example, the external power source may generate a magnetic field to induce a current in inductive element 142 (e.g., a copper coil or other inductive element). Additionally, circuitry 166 may use inductive element 142 to communicate information to an external data reader. Circuitry 166 may include discrete circuit elements, an integrated circuit (e.g., an application specific integrated circuit (ASIC), and/or other electronic components). The external power source and data reader may be the same device.
[0029] In an alternative embodiment, the sensor 110 may be powered by an internal, self-contained power source, such as, for example, microbatteries, micro generators and/or other power sources.
[0030] As shown in FIG. 1 , many of the electro-optical components of sensor 110 are secured to a circuit board 170 . Circuit board 170 provides communication paths between the various components of sensor 110 .
[0031] As further illustrated in FIG. 1 , optical filters 134 a and 134 b , such as high pass or band pass filters, may cover a photosensitive side of photodetectors 120 a and 120 b , respectively. Filter 134 a may prevent or substantially reduce the amount of radiation generated by the source 118 from impinging on a photosensitive side 135 of the photodetector 120 a . At the same time, filter 134 a allows fluorescent light emitted by fluorescent indicator molecules 116 to pass through to strike photosensitive side 135 of the photodetector 120 a . This significantly reduces “noise” in the photodetector signal that is attributable to incident radiation from the source 118 .
[0032] According to one aspect of the invention, an application for which the sensor 110 was developed—although by no means the only application for which it is suitable—is measuring various biological analytes in the human body. For example, sensor 110 may be used to measure glucose, oxygen, toxins, pharmaceuticals or other drugs, hormones, and other metabolic analytes in the human body. The specific composition of the matrix layer 114 and the indicator molecules 116 may vary depending on the particular analyte the sensor is to be used to detect and/or where the sensor is to be used to detect the analyte (i.e., in the blood or in subcutaneous tissues). Preferably, however, matrix layer 114 , if present, should facilitate exposure of the indicator molecules to the analyte. Also, it is preferred that the optical characteristics of the indicator molecules (e.g., the level of fluorescence of fluorescent indicator molecules) be a function of the concentration of the specific analyte to which the indicator molecules are exposed.
[0033] To facilitate use in-situ in the human body, the housing 112 is preferably formed in a smooth, oblong or rounded shape. Advantageously, it has the approximate size and shape of a bean or a pharmaceutical gelatin capsule, i.e., it is on the order of approximately 500 microns to approximately 0.85 inches in length L and on the order of approximately 300 microns to approximately 0.3 inches in diameter D, with generally smooth, rounded surfaces throughout. This configuration permits the sensor 110 to be implanted into the human body, i.e., dermally or into underlying tissues (including into organs or blood vessels) without the sensor interfering with essential bodily functions or causing excessive pain or discomfort.
[0034] In some embodiments, a preferred length of the housing is approx. 0.5 inches to 0.85 inches and a preferred diameter is approx. 0.1 inches to 0.11 inches.
[0035] In the embodiment shown in FIG. 1 , source 118 is elevated with respect to a top side 171 of circuit board 170 . More specifically, in the embodiment shown, source 118 is fixed to a support member 174 , which functions to elevate source 118 above side 171 and to electrically connect source 118 to circuitry on board 170 so that power can be delivered to source 118 . The distance (d) between source 118 and side 171 generally ranges between 0 and 0.030 inches. Preferably, the distance (d) ranges between 0.010 and 0.020 inches. Support member 174 may be a circuit board. Circuit board 170 may have a groove 180 for receiving a proximal end 173 of member 174 . This feature is further illustrated in FIG. 3 , which is a perspective, top view of board 170 .
[0036] In some embodiments, support member 174 may include an electrical contact 158 (e.g., a conductive pad or other device for conducting electricity) disposed on a surface thereof and electrically connected to source 118 . The contact 158 electrically connects to a corresponding electrical contact 157 that may be disposed in groove 180 through an electrical interconnect 159 (e.g., a circuit trace or other transmission line). Contact 157 may be electrically connected to circuit 166 or other circuit on circuit board 170 . Accordingly, in some embodiments, there is an electrical path from circuit 166 to source 118 .
[0037] As further shown in FIG. 1 , a reflector 176 may be attached to board 170 at an end thereof. Preferably, reflector 176 is attached to board 170 so that a face portion 177 of reflector 176 is generally perpendicular to side 171 and faces source 118 . Preferably, face 177 reflects radiation emitted by source 118 . For example, face 177 may have a reflective coating disposed thereon or face 177 may be constructed from a reflective material.
[0038] Referring now to photodetectors 120 , photodetectors 120 are preferably disposed below a region of side 171 located between source 118 and reflector 176 . For example, in some embodiments, photodetectors 120 are mounted to a bottom side 175 of board 170 at a location that is below a region between source 118 and reflector 176 . In embodiments where the photodetectors 120 are mounted to bottom side 175 of board 170 , a hole for each photodetector 120 is preferably created through board 170 . This is illustrated in FIG. 3 . As shown in FIG. 3 , two holes 301 a and 301 b have been created in board 170 , thereby providing a passageway for light from indicator molecules 116 to reach photodetectors 120 . The holes in circuit board 170 may be created by, for example, drilling, laser machining and the like. Preferably, each photodetector 120 is positioned such that light entering the hole is likely to strike a photosensitive side of the photodetector 120 , as shown in FIG. 1 . This technique also diminishes the amount of ambient light striking photodetector 120 .
[0039] As further illustrated in FIG. 1 , each hole in board 170 may be contain a filter 134 so that light can only reach a photodetector 120 by passing through the corresponding filter 134 . The bottom side and all sides of the photodetectors 120 may be covered with black light blocking epoxy 190 to further diminish the amount of ambient light striking photodetector 120 .
[0040] In one embodiment, photodetector 120 a is used to produce a signal corresponding to the light emitted or adsorbed by indicator molecules 116 and photodetector 120 b is used to produce a reference signal. In this embodiment, a fluorescent element 154 may be positioned on top of filter 134 b . Preferably, fluorescent element 154 fluoresces at a predetermined wavelength. Element 154 may be made from terbium or other fluorescent element that fluoresces at the predetermined wavelength. In this embodiment, filter 134 a and filter 134 b filter different wavelengths of light. For example, filter 134 a may filter wavelengths below 400 nm and filter 134 b may filter wavelengths below 500 nm.
[0041] Referring now to FIG. 2 , FIG. 2 illustrates a sensor 210 according to another embodiment of the invention. As shown in FIG. 2 , sensor 210 is similar to sensor 110 . A primary difference being that reflector 176 is replaced by a support member 202 , which is connected to end 194 of board 170 and to which source 118 is fixed. In this embodiment, and support member 174 is replaced with a reflector 209 . Like reflector 176 , reflector 209 has a reflective face 211 that faces source 118 . Additionally, so that photodetector 120 a remains closer to source 118 , photodetector 120 a may switch places with photodetector 120 b and filter 134 a may switch places with filter 134 b . Fluorescent element 154 may also be re-positioned so that it remains on top of filter 134 b.
[0042] As shown in FIGS. 1 and 2 , in some embodiments, indicator molecules 116 may be positioned only in a region that is above a region 193 , which region is between source 118 and reflector 176 .
[0043] Referring now to FIG. 4 , FIG. 4 is a schematic, section view of an optical-based sensor 410 , according to another embodiment of the invention. Sensor 410 includes many of the same components as sensor 110 . However, the positioning of source 118 , photodetector 120 a and filter 134 a in sensor 410 is different than the positioning in sensor 110 .
[0044] As shown in FIG. 4 , a base 412 is mounted to an end 413 of circuit board 170 . A top side 414 and bottom side 416 of base 412 each may lie in a plane that is generally perpendicular to a plane in which side 171 of board 170 lies. Bottom side 416 may have a groove 418 therein that receives end 413 of board 170 . Groove 418 facilitates fixing base 412 to board 170 .
[0045] Photodetector 120 a may be mounted on top side 414 of base 412 . Preferably, photodetector 120 a is mounted on base 412 so that photosensitive side 135 of photodetector 120 a lies in a plane that is generally perpendicular to the plane in which side 171 of board 170 lies and faces in the same direction as top side 414 .
[0046] Filter 134 a is preferably disposed above side 135 of photodetector 120 a so that most, if not all, light that strikes side 135 must first pass through filter 134 a . Filter 134 a may be fixedly mounted to photodetector 120 a . For example, a reflective index (RI) matching epoxy 501 (see FIG. 5 ) may be used to fix filter 134 a to photodetector 120 a.
[0047] In some embodiments, base 412 may include at least two electrical contacts disposed thereon (e.g., on side 414 ). For example, as shown in FIG. 4 , a first electrical contact 471 and a second electrical contact 472 are disposed on side 414 of base 412 . A wire 473 (or other electrical connector) preferably electrically connects photodetector 120 a to electrical contact 471 and a wire 474 (or other electrical connector) preferably electrically connects source 118 to electrical contact 472 . Contact 471 electrically connects to a corresponding contact 475 via an electrical interconnect 476 . Similarly, contact 472 electrically connects to a corresponding contact 477 via an electrical interconnect 478 . Contacts 475 , 477 are preferably disposed on the end of board 170 that is inserted into groove 418 . Contacts 475 , 477 may be electrically connected to circuit 166 or other circuit on circuit board 170 . Accordingly, in some embodiments, base 412 provides a portion of an electrical path from circuit 166 to source 118 and/or photodetector 120 a.
[0048] Referring now to FIG. 5 , FIG. 5 further illustrates the arrangement of photodetector 120 a , filter 134 a and source 118 . As shown in FIGS. 4 and 5 , source 118 is mounted on a top side 467 of filter 134 a . Accordingly, as shown in FIGS. 4 and 5 , photodetector 120 a , filter 134 a and source 118 are aligned. That is, as shown in FIG. 5 , both filter 134 a and source 118 are each disposed in an area that is over at least a portion of photosensitive side 135 of photodetector 120 a.
[0049] Preferably, a non-transparent, non-translucent base 431 is disposed between source 118 and filter 134 . Opaque base 431 functions to prevent light emitted from source 118 from striking side 467 of filter 134 a . Base 431 may be a gold-clad-molybdenum tab (molytab) or other opaque structure. Epoxy 555 may be used to fix source 118 to base 431 and base 431 to filter 134 a.
[0050] Preferably, in this embodiment, source 118 is configured and oriented so that most of the light transmitted therefrom is transmitted in a direction away from side 467 , as shown in FIGS. 4 and 5 . For example, in the embodiment shown, the light is primarily directed towards an end 491 of housing 102 . Preferably, indicator molecules 116 are located on end 491 so that they will receive the radiation emitted from source 118 . As discussed above, indicator molecules 116 will respond to the received radiation, and the response will be a function of the concentration of the analyte being measured in the region of the indicator molecules 116 . Photodetector 120 a detects the response.
[0051] Referring now to FIG. 6 , FIG. 6 is a schematic, section view of an optical-based sensor 610 , according to another embodiment of the invention. Sensor 610 includes many of the same components as sensor 110 . Also, sensor 610 is similar to sensor 410 in that, in sensor 610 , photodetector 120 a , filter 134 a and source 118 are preferably aligned. Further, like in sensor 410 , in sensor 610 filter 134 a may be fixedly mounted on side 135 of photodetector 120 a and source 118 may be fixedly mounted on side 467 of filter 134 a , and the photodetector 120 a , filter 134 a , source 118 assembly may be located adjacent an end 491 of housing 102 , as illustrated in FIG. 6 .
[0052] However, the orientation of source 118 , photodetector 120 a and filter 134 a in sensor 610 is different than the orientation in sensor 410 . For example, in sensor 610 , side 135 of photodetector 120 a faces in a direction that is substantially perpendicular to the longitudinal axis of housing 102 . Additionally, in sensor 610 , filter 134 a and/or photodetector 120 a are directly fixed to board 170 such that base 412 may be removed. In the embodiment shown, filter 134 a and/or photodetector 120 a are directly fixed to end 413 of board 170 .
[0053] In one or more of the above described embodiments, housing 102 may be filled with a material to keep the components housed in housing 102 from being able to move around. For example, housing 102 may be filled with an optical epoxy either before or after board 170 and the components attached thereto are inserted into housing 120 . EPO-TEK 301-2 Epoxy from Epoxy Technology of Billerica, Mass. and/or other epoxies may be used.
[0054] While various embodiments/variations of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents. | The present invention provides an electro-optical sensing device for detecting the presence or concentration of an analyte. More particularly, the invention relates to (but is not in all cases necessarily limited to) optical-based sensing devices which are characterized by being totally self-contained, with a smooth and rounded oblong, oval, or elliptical shape (e.g., a bean- or pharmaceutical capsule-shape) and a size which permits the device to be implanted in humans for in-situ detection of various analytes. | 6 |
RELATIONSHIP TO PRIOR APPLICATION
[0001] This is a U.S. non-provisional application relating to and claiming the benefit of U.S. Provisional Patent Application Ser. No. 60/876,802, filed Dec. 21, 2006.
FIELD OF THE INVENTION
[0002] This invention relates to electrical appliances. In particular, this invention relates to a two-component electrical supply apparatus and distribution system for human use whenever installation of electrical supply is needed and whenever access to electrical supply is needed.
[0003] This invention relates to a safety interlock power supply apparatus and more particularly to a mechanical interlock connector mechanism for supplying power to an electrically powered device from a structure's permanently installed wiring.
[0004] This invention relates to an interlocking electrical supply apparatus that allows for the harnessing of multiple levels of voltage power to be accessed via one intermediary component, without having to replace the intermediary component to access the different levels of power desired.
BACKGROUND OF THE INVENTION
[0005] Various attempts have been made to overcome the problem of providing access to electrical current for the supply of power to electrical appliances while avoiding unnecessary hazards, such as electrical shock, burns, improper operating modes, and high labor costs.
[0006] There exist options to provide electrical supply in a physical structure, such as the use of a metal box with specific slots for bringing a wire into the box to make a connection to an outlet used as a connector for an appliance or the like.
[0007] There also exist electrical components that allow the user to adjust the placement of electrical supply for lighting specific appliances, as in the common track lighting systems.
[0008] While the above electrical supply systems have worked, their one major flaw is the extensive installation and labor intensive electrical renovation required to change the electrical supply outlet's composition to allow the user the freedom to switch end use of a particular power supply outlet. An example is the switching from a standard 110 volt lamp to a ceiling fan unit or to a smoke detecting unit.
[0009] Accordingly, there is a need for the end user to be able to newly install or to retrofit the electrical supply in a structure based on current needs for a particular electrical supply at a specific point of electric distribution.
[0010] Accordingly, it is an object of the invention to provide a multi-component electrical supply system.
OBJECTS OF THE INVENTION
[0011] Another object of the invention is to make it easy for the user to be able to achieve freedom from expensive installation charges without violating national electrical installation ordinances.
[0012] Another object of the invention is to provide an interlocking fastening system so as to conduct electricity via connected conducting contact surfaces.
[0013] Yet another object of the invention is to provide a swiveling motion so as to interconnect the conducting contact surfaces creating a locking mechanism by such action.
[0014] A further object of the invention is to provide a handle on the public facing side of an intermediary component so as to allow ease of use of the intermediary component when attaching or un-attaching the components together.
[0015] Yet another object of the invention is to provide the opportunity for the end user to install and or uninstall an intermediary component so as to achieve the necessary electrical supply for a particular location in the surface of the structure.
[0016] Another object is to allow the conversion of the electrical supply into a variety of different configurations without the need for an electrician. An example of this object is the housing of a 440 volt electrical supply along with a 220 volt electrical supply to be housed in the same separate base and intermediary components and via the pivoting of a control on the intermediary component be able to switch access between the voltage options.
[0017] Another object of the invention is to allow the full force of the available source of electrical supply to enter the base component and be selectively harnessed within the intermediary component by the interlocking of the metal contact surfaces in a multitude of configurations for the purpose of accessing multiple power configurations without the need to remove or replace the intermediary component.
BRIEF SUMMARY OF THE INVENTION
[0018] What is needed, therefore, is an inexpensive, easy to use and safe electrical supply apparatus consisting of two separate components which make up the whole of an interlocking electrical supply apparatus which is suitable for use in residential and commercial applications.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a side isometric view, partially cutaway, of safety interlocking electrical supply apparatus in a supinated position showing portions of the safety interlocking electrical supply apparatus including the intermediary component and the base component.
[0020] FIG. 2 is a bottom isometric view of the intermediary component showing conductor appendages.
[0021] FIG. 3 is a partially cutaway side isometric view of intermediary component showing some of its internal mechanisms and shown with two standard 110 volt electrical outlet configuration.
[0022] FIG. 4 is a partially cutaway side isometric view of the intermediary component shown with two standard 110 volt electrical outlet configuration.
[0023] FIG. 5 is an isometric side view of the intermediary component showing its external parts.
[0024] FIG. 6 is an isometric side view of the intermediary component shown in a smoke detector configuration.
[0025] FIG. 7 is an isometric exploded view of the entire two part electrical supply apparatus in one of its configurations in which the intermediary component includes a ceiling fan.
[0026] FIG. 8 is a bottom isometric view of the base component shown with a four (4) wire configuration.
[0027] FIG. 9 is a partially cutaway side view of the base component shown with three (3) contact entrance points configuration.
[0028] FIG. 10 is an isometric side view of the external top and side of the base component showing the male glides and the finger grasp/connector.
[0029] FIG. 11 is a side isometric partially cutaway view of the base component shown with the multi-electrical supply configuration, as a dual electrical supply apparatus and a portion of the intermediary component.
[0030] FIG. 12 is a top partially cutaway view of the base component showing multiple metal contact points for the multi-power supply configuration within the base component.
[0031] FIG. 13 is an isometric view of the structural housing box unit.
[0032] FIG. 14 is a top view of the rim cover plate for the intermediary component.
[0033] FIG. 15 is a partial isometric view of the rim cover plate.
[0034] FIG. 16 is a side isometric view of the intermediary component configured to supply two (2) electrical supply options without necessitating the removal and replacement of the intermediary component.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] An interlocking electrical supply apparatus that is primarily made up of two components, namely an intermediary component and a base component, which are housed in a separate safety box housing. The electrical connection is made when the intermediary component is inserted into the base component with a pivoting action interlock and as a whole create an electrical supply system which can be installed and uninstalled by the consumer with a low risk to personal safety.
[0036] The base component of the system, along with the electrical box, is installed by an electrical professional, permanently into the surface wall of the physical structure. The intermediary component is a replaceable unit. The intermediary component is designed to be installed, removed and reinstalled as is needed by the user. Furthermore, the intermediary component is also designed to allow for a multitude of electrical output options without necessitating the removal and replacement of the intermediary component. The intermediary component can also be removed and replaced by any one of a number of different intermediary units, which configure the electrical supply into different configurations for the end user's need. This electrical supply apparatus will supply an uninterrupted, grounded, electrical current to any product assumed to utilize electricity via the interlocking connection between the permanently installed base component and the semi-permanent intermediary component which can be physically unattached from the permanently installed base component and replaced with any number of configurations suiting a variety of electrical supply standards. This electrical supply apparatus will conduct energy through two separate, independent components the sum of whose parts will deliver the electrical supply to the end use (e.g., a ceiling fan or two 110 volt power outlets). The semi-permanently installed intermediary component will preferably include the end use mechanism, such as a smoke detector installed into the intermediary component. This will allow the user the ease of changing electrical supply options for a particular base location based on the need at the moment for that base location, without the need for a certified professional to install or uninstall the intermediary component, and with no risk to the user.
[0037] Examples of another end use mechanism for the intermediary component would be a traditional 110-volt, three-prong, grounded electrical outlet, which is used to plug in standard 110-volt electrical products (e.g., a lighting fixture). Another example would be the standardized ceiling fan that would be built into the intermediary component. The electrical supply apparatus will provide a base component that will be installed at the time of construction or during retrofit of the electrical supply system which will be housed in the electrical housing box.
[0038] In addition, the electrical apparatus having two interlocking components housed in one modified electrical support housing box can be utilized, within the intermediary component, to harness power in different configurations. This can be done without needing to replace the intermediary component. Access to a power source (e.g., between a 440 or 220 volts supply) can be obtained by simply adjusting and thence reengaging the electrical contact points within the intermediary component within the permanently installed base component. This adjustment and reengagement can be achieved in any number of ways including rotating the intermediary component in an opposite direction while staying engaged in the base component.
[0039] FIG. 1 shows the safety interlocking electrical supply apparatus (hereafter referred to as “Apparatus 1 A”) in an inverted position. Apparatus 1 A comprises a structural box 39 having a cavity into which a base component 50 may be slidably removed or inserted. Base component is a housing which receives electrical parts described below. Box 39 comprises two sliding female guides 31 to allow the male appendages 32 on the intermediary component 2 A to slidably attach to the internal wall of the structural box cavity 39 . The structural box cavity 39 is sized to closely mate with base component 50 , thereby properly aligning and positioning base component 50 so the base component can be properly clamped into position by the interaction of clamp 28 as seen in FIG. 10 and clamp receiver 35 in FIG. 13 . Apparatus 1 A also comprises an interlocking intermediary component 2 A appendages 2 which are inserted into openings in base component 50 by way of physical pressure. Once inserted, the intermediary component 2 A is pivoted or swiveled with the use of handle 1 which with the use of pressure creates a locked or snapped position of conductor appendage 2 and conductor platform 27 and therefore allows the conduction of electrical energy via the internal mechanism pathways as seen in FIG. 3 .
[0040] When fully inserted into base component 50 , intermediary component 2 A is affixed with a trim cover plate 40 as seen in FIG. 14 , which screws around the edge of the intermediary component 2 A′ at pathway 15 as seen in FIG. 16 . The present invention is directed to a safety interlock power supply system that automatically eliminates component voltage upon removal of the intermediary component 2 A from base component 50 , thereby permitting safe installation and removal of the intermediary component 2 A from the base component 50 .
[0041] FIG. 2 shows the intermediary component's 2 A bottom, or conductor appendages 2 , 3 , 4 . The number of appendages could vary within the realm of this invention, determined by the supply and configurations needed for the intermediary component's 2 A end point usage. Intermediary component 2 A handle 1 is illustrated and would be utilized to assist in the interlocking of the two components and thence the conductor appendages 2 , 3 , 4 together.
[0042] The pathway of electrical current will now be described as seen in FIGS. 3 , 4 , 6 , 8 , 9 and 11 . An electrical current pathway is established by the connection of the mother supply wires 80 , 81 , and 82 to 16 , 17 and 18 as seen in FIG. 9 . What is now described is the electrical pathway for any electrical current brought through into the base component 50 .
[0043] This pathway can be replicated any number of times to meet the electrical needs, but is shown in FIGS. 1 , 2 , 3 , 4 , 6 , and 9 as an example with only three conductors and pathways. Alternatively, there can be conduction of electricity with unlimited potential for number of conductors. Once the mother wire is connected to the supply wires 16 , 17 and or 18 of base component 50 , the electrical current is carried up through into the internal mechanism of the base component 50 where it supplies electrical current to the conductors housed within 27 or 81 . The wire is affixed to a metal pin or screw 80 which is directly affixed to the metal conducting platform 27 , 81 that when in contact with the pivoting conductor appendage 2 continues the electrical current up via the conducting appendage into the intermediary component 1 A which then carries the electrical current to metal pins or screw 8 and or 9 to which is connected either an individual wire or a number of wires up through holes 13 located in the distribution platform 14 ( FIG. 3 ). The distribution platform's 14 purpose is to isolate the individual wires 11 , 12 which in and of themselves continue the pathway of electrical current so that they can be affixed to the appropriate undesignated conductor pins or screw which will attach to any number of configurations of the end product mechanism which will end the electrical pathway of the invention and allow the end user to utilize the intermediary component 2 A as intended.
[0044] FIG. 3 is shown with the intermediary component 2 A configured to house two 110 volt electrical outlets. This intermediary component 2 A could be configured to house any number of electrical components. An example would be the intermediary component 2 A outfitted with a smoke detector fixture which would receive its electrical power supply as apart of the entirety of the Apparatus 1 A.
[0045] FIG. 4 is a cutaway view of the internal mechanism of the intermediary component 2 A configured to house two 110 volt electrical outlets. The metal conductor appendages 2 provide a pathway of electrical power supply which are attached securely via metal wire 11 , 12 to the head of the metal conductor appendage 10 via screws or penetrating pins 8 , 9 . The pathway is thus continued via the internal wires 11 , 12 up through the distribution platform via holes 13 which are intended to keep the wires separated. The wires are then connected to the individual ground, neutral and hot plates within which are inserted the plug from the 110 volt appliance. The ground, neutral and hot plates 90 , 91 , 92 can be situated on a raised platform 93 above the distribution platform 14 .
[0046] FIG. 5 is a view of the intermediary component 2 A in one of its potential configurations for higher voltage power supply, such as 220 or 440. Two handles 1 are potentially configured to assist in the attachment of the intermediary component 2 A to assist in the ease of connection of the intermediary component 2 A to the base component 50 . The view shows the ridged screw pathway 15 around which the rim cover plate 40 will be affixed via a turning motion. The insertion plug holes 7 show the location at which the 220 volt appliances plug will be inserted. This is just one potential configuration of the intermediary component 2 A. The intermediary component has multiple end use configurations. In one possible configuration, by turning the intermediary component within the base component, different levels of voltage are accessed.
[0047] FIG. 6 is an isometric cutaway view of the intermediary component 2 A as configured in one of its potential configurations as a smoke detector unit. The metal conductor appendages are shown 2 , 3 , 4 along with the screws or penetrating pins 8 which are affixed to the heads of the conductor plates 10 .
[0048] FIG. 7 is a view of the intermediary component 2 A shown in its configuration as a ceiling fan. The handles are shown 1 , as are the ceiling fan wings 61 , and the ridged screw edge 15 around which the rim cover plate 40 from FIG. 14 would be affixed. The drawing also shows the base component 50 as housed in the box unit 39 which is attached to two supporting structures. The box unit 39 is affixed via the extendable support arms 60 via screws or nails which enter into the holes 60 penetrating the holes and entering into the supporting structure, thusly creating a firm support for the box unit 39 .
[0049] FIG. 8 is an isometric drawing showing the bottom of the base component 50 . The main supply wires 16 , 17 , 18 , 99 protrude from the bottom of the base component 50 through wire supply holes 24 .
[0050] FIG. 9 is a cutaway view of the internal mechanism of the base component 50 . Conductor appendages 2 are inserted into the base component 50 via appendage entry points 19 . Such action causes the internal electrically insulated security covers 20 to depress inwards or downwards which causes the spring 21 to compress inwards. This action allows the conductor appendage 2 to enter into the base component 50 while also allowing the base component's internal electrical supply conductor platform 27 , 81 ( FIG. 11 ) or platforms to be covered from unintended entrance of non-intentional material or materials. When the conductor appendage 2 is inserted, the user then turns or pivots, with the assistance of the intermediary component 2 A, handle 1 . The intermediary component 2 A thus causes the conductor appendage 2 and conductor platform 27 or 81 ( FIG. 11 ) to engage and create the pathway for the electrical current.
[0051] FIG. 10 shows the external body of the base component 50 . The appendage entry points 19 are shown in one potential configuration. The male glides 32 which are slid into the female supports 31 ( FIG. 1 ) are shown. The finger press 28 which engages a further support feature 35 ( FIG. 11 ) is shown.
[0052] FIG. 11 is a cutaway view of the base component 50 as configured for one of its potential purposes to harness multiple power options within the same base component 50 . The drawing shows the appendage entry points 19 and the internal security cover 21 which is described in FIG. 9 . The screws or penetrating pins 80 serve to affix the main supply wires 16 to the metal conducting plates 27 , 81 which continues the pathway of electrical force ultimately making it available for contact with the conductor appendages 2 from FIG. 2 . In its intended configuration, the metal conductor plates 27 , 81 can be engaged by rotating the intermediary component 2 A in different directions which will create two potential contact points between the metal appendages 2 and the conductor plates 27 , 81 when rotated in opposite directions. The internal distribution platform 22 is shown, which separates the base component 50 into separate chambers. There are wire holes 24 , 25 through which the supply wires 16 feed.
[0053] FIG. 12 is an overhead view of the base component 50 and the potential relation between the appendage entry points 19 and the conductor plates 27 .
[0054] FIG. 13 is a drawing of the box unit 39 which is supported by its supporting arms 60 and supporting plate 33 , each of which have holes 34 to use to affix the box unit 39 to the structure in question. Multiple potential punch-out mother wire supply openings 36 , 37 are shown. The female support glide guide 31 is shown in the inside 38 of the unit 39 with the pathway 32 for the male glides to enter shown. The finger catch support 35 is shown on the surface of an internal wall, this engages with the finger catch 28 of FIG. 10 . The supporting arms 60 are adjustable in length 98 .
[0055] FIG. 14 is a top view of the rim cover plate 40 .
[0056] FIG. 15 a view of the rim cover plate 40 . The rim cover plate 40 has ridges 41 , 42 , 43 on the inside of its cover plate which allow it to be threaded onto the intermediary component 2 A ridges 15 ( FIG. 1 ). The outside surface of the rim cover plate 40 is contoured to provide a smooth protective cover for the space surrounding the base component 50 and any surrounding surface.
[0057] FIG. 16 is an isometric view of the intermediary component 2 A′ configured to provide dual power supply via the metal contact appendages 2 . Two handles 1 are affixed to the side of the component to assist in the rotation of the intermediary component 2 A. Insertion openings 90 , 91 , 92 are to provide entry way for the external appliances contact plugs in a variety of configurations.
Drawing Elements Guide
[0000]
2 A Intermediary Component
1 Handle for Intermediary Component
2 , 3 , 4 , 5 Metal Conductor Appendage
7 Opening for external plug
8 , 9 Screw or penetrating pins Intermediary Component
10 Head of the metal appendage
11 , 12 Supply Wire Intermediary Component
13 Supply Wire Holes Intermediary Component
14 Distribution Platform
15 Ridges for Rim Plate
16 , 17 , 18 Supply Wires Base Component
19 Appendage Entry Points
20 Internal Security Cover
21 Spring
22 Distribution Platform
24 Hole for Supply Wire Base Component
25 Supply Wire Base Component
27 Metal Conductor Plate
28 Finger Press
31 Female Glide Support
32 Male glides
33 Structural Support plate
34 Holes for external screws
35 Finger Press Catch
36 , 37 Potential Punch Out Hole for Mother supply Wires
38 Internal area of Box Unit
39 Box Unit
40 Rim Cover Plate
41 , 42 , 43 Ridges for Rim Cover Plate
50 Base Component
61 Ceiling Fan wings
80 Screw or Penetrating Pins Base Component
81 Metal Conductor Plate
83 Wire connectors
90 , 91 , 92 Insertion openings for plug from external appliance
93 Support platform within Intermediary Component
94 , 95 Metal Contact Points for external appliance plug
98 Slide portion of Adjustable Structural Support Arm 60 | A safety interlocking electrical supply apparatus including a base component housing at least two base electrical contacts which are wired to a source of electrical energy. The base component has a least two apertures. An intermediary component is provided having at least two intermediary electrical contacts extending therefrom. The apertures in the base component are adapted to removably receive the intermediary electrical contacts. The intermediary electrical contacts are adapted to make contact with the base electrical contacts. The intermediary component includes an end use mechanism. The intermediary component may be readily and safely connected to and removed from the base component without the need to make wire connections or disconnections. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates generally to the use of plasma polymerization to apply a very thin top coating of of a chemically resistant polymeric material over the surface of a polymeric substrate to protect the substrate from chemical attack by the electrolyte and also to preserve surface treatments performed on the substrate prior to deposit of the top coating. More particularly, the present disclosure relates to an improved membrane for an electrolytic cell and a method of preparation thereof utilizing plasma polymerization techniques to deposit a continuous top coating of approximately 100 to 2000 Angstroms on a substrate material generally a copolymeric cation exchange material having pendent sulfonic acid groups with polymers of tetrafluoroethylene or of an amide. The resultant coated membrane surfaces produced current efficiencies exceeding those of the untreated membranes or surface treated membranes prior to coating thereof due to the drastic reduction of the permeability of the membrane material with a minimal effect upon the bulk properties and the cell potential, while maintaining good lifetimes under corrosive conditions.
Electrochemical methods of manufacture are becoming ever increasingly important to the chemical industry due to their greater ecological acceptability, potential for energy conservation, and the resultant cost reductions possible. Therefore a great deal of research and development has been applied to the electrochemical processes and the hardware for these processes. One major element for the hardware aspect of the electrolytic system is the cation exchange membrane which separates the anode compartment from the cathode compartment within the electrolytic cell to provide a divided electrolytic cell for more efficient electrochemical production.
Presently the membrane having the greatest utility is one capable of usage in a chlorine and caustic (sodium hydroxide) cell since chlorine and caustic in this country are produced almost entirely electrolytically from aqueous solutions of sodium chloride. Chlorine and caustic are essential and large volume commodities which are basic chemicals required by all industrial societies and presently a large portion of their manufacture comes from the diaphragm-type electrolytic cells. In the diaphragm cell process, brine (sodium chloride solution) is fed continuously into the anode compartment and flows through the diaphragm usually made of asbestos, backed by a cathode. To minimize back migration of the hydroxide ions, the flow rate is always maintained in excess of the conversion rate so that the resulting catholyte solution has sodium chloride present. Hydrogen ions are discharged from the solution at the cathode in the form of hydrogen gas. The catholyte solution, containing caustic, unreacted sodium chloride and other impurities, generally has been concentrated and purified to obtain a marketable alkali metal hydroxide commodity and an alkali metal chloride which can be reused in a chlorine and caustic electrolytic cell for further production of alkali metal hydroxide. This is a serious drawback since the costs of this concentration purification process are rising rapidly.
With the advent of technological advances such as the dimensionally stable anode which permits ever narrowing gaps between the electrodes and the hydraulically impermeable cation exchange membrane, it has become readily apparent that the electrolytic cell will be more economical in the future. If the membrane can produce at high current efficiencies and withstand the anolyte solution which normally contains highly corrosive concentrations of free halide for extended periods of time, a significant purity and concentration increase in the end product may be possible with a given electrolytic cell thus saving secondary steps in such a process.
To date the membrane which seems to have the longest life time is a thin film of fluorinated copolymer having pendent sulfonic acid groups. Membranes of this general type are available from E. I. duPont deNemours & Co. under the trademark NAFION. It has been found that certain types of surface treatments of the NAFION-type membrane substrate will yield higher current efficiencies but generally with a corresponding higher cell potential and a reduction in the useful lifetime of the membrane in the corrosive surroundings of a chlorine and caustic electrolytic cell. It would therefore be very advantageous to provide an improved membrane which will have a substantially longer useful lifetime in addition to having the improved current efficiency characteristics of membranes currently for use in various types of electrolytic cells for electrochemical production.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an improved membrane and a method for the preparation thereof which will have the improved current efficiency characteristics and a commercially feasible lifetime in the corrosive surroundings of a chlorine and caustic electrolytic cell.
It is another object of the present invention, to provide an improved membrane and method for preparation thereof that will improve the current efficiency without chemical reaction with the substrate with very little power penalty.
It is a further object of the present invention to provide a surface on a membrane which will drastically reduce the permeability of the substrate with a minimal effect upon the bulk properties utilizing almost any organic molecule having a appreciable vapor pressure at 1 millimeter of mercury pressure as a monomer.
These and other objects of the present invention, together with the advantages thereof over existing and prior art forms which will become apparent to those skilled in the art from the detailed disclosure of the present invention as set forth hereinbelow, are accomplished by the improvements herein described and claimed.
It has been found that an improved hydraulically impermeable cation exchange membrane can be made up of a substrate having a copolymeric backbone and ion exchange pendent groups in sufficient number to produce --SO 3 H an equivalent weight in the range of 1000 to 1400 and on at least one side of the substrate, a thin coating in the range of 100 to 2000 Angstroms of a second polymeric material to provide a pin hole free coating that is integrally bonded to the substrate surface.
It has also been found that a method for preparation of an improved hydraulically impermeable cation exchange membrane can be accomplished by selecting a substrate from a group of: ##STR1## in which R 1 is fluorine, or perfluoralkyl of 1 to 10 carbon atoms; Y is fluorine or trifluoromethyl; m is 1, 2 or 3; n is 0 or 1; x is fluorine, chlorine or trifluoromethyl; and x 1 is x or CF 3 --CF 2 -- a O-- wherein a is 0 or an integer from 1 to 5; the units of formula (I) being present in an amount to provide a copolymer having an --SO 3 H equivalent weight of about 1000 to 1400;
copolymers of tetrafluoroethylene and hexafluoropropylene having grafted thereon a 50-50 mixture of styrene and alpha methylstyrene; or
an insoluble, infusible copolymeric matrix formed from at least 20 percent by weight of a polyvinyl aromatic compound and not more than 80 percent of a monovinyl aromatic compound with a reinforcing material therein or no more than 70 weight percent by weight of a monovinyl aromatic compound without a reinforcing material therein, sulfonate groups chemically bonded to the aromatic nuclei of the matrix and a solvating liquid in cell relationship with the matrix, the sulfonate groups being present in an amount of no more than four equivalents of sulfonate groups for each mole of polyvinyl aromatic compound and not less than one equivalent of sulfonate groups for each 10 moles of poly- and monovinyl aromatic compound; the sulfonating liquid being at least 25 percent by volume of the resin; and
applying a top coating selected from the group of polyamide or polytetrafluoroethylene to the surface of at least one side of the substrate by means of plasma polymerization to produce a thin pin hole free coating in the range of 100 to 2000 Angstroms integrally bonded to the substrate.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The improved hydraulically impermeable cation exchange membrane which will overcome many of the disadvantages of the prior art forms and accomplish the objects of the invention as stated hereinabove has a substrate film material. The substrate material may be any of a number of commercially available hydraulically impermeable cation exchange membranes which are chemically resistant to the electrolytes to be used in the electrolyte cell for the particular process for which the membrane is desired, as long as it has a low resistance value so as to accomplish a high current efficiency for the given cell, and a sufficient lifetime so as to make its use in the given electrolytic cell economical for commercial electrochemical production.
One type of substrate material which may be used in the present invention as a thin film of fluorinated copolymer having pendent sulfonic acid groups. The fluorinated copolymer is derived from monomers of the formula
CF.sub.2 ═CF--R--.sub.n SO.sub.2 F (1)
in which the pendent --SO 2 F groups are converted to --SO 3 H groups, and monomers of the formula
CF.sub.2 ═Cxx.sup.1 ( 2)
wherein R represents the group ##STR2## in which the R 1 is fluorine or fluoroalkyl of 1 thru 10 carbon atoms; Y is fluorine or trifluoromethyl; m is 1, 2 or 3; n is 0 or 1; x is fluorine, chlorine or trifluoromethyl; and x 1 is x or CF 3 --CF 2 -- a O--, wherein a is 0 or an integer from 1 to 5.
This results in copolymers having the repeating structural units ##STR3## and
--CF.sub.2 --Cxx.sup.1 -- (4)
In the copolymer there should be sufficient repeating units according to formula (3) above, to provide an --SO 3 H equivalent weight of about 1000 to 1400. Materials having a water absorption of about 25 percent or greater are preferred since higher cell voltages at any given current density are required for materials having less water absorption. Similarly, materials having a film thickness (unlaminated) of about 8 mils or more, require higher cell voltages resulting in a lower power efficiency.
Typically, because of large surface areas of the membrane in commercial cells, the substrate film material will be laminated to and impregnated into a hydraulically permeable, electrically non-conductive, inert, reinforcing member, such as a woven or non-woven fabric made of fibers of asbestos, glass, TEFLON, or the like. In film/fabric composite materials, it is preferred that the laminating produce an unbroken surface of the film resin on at least one side of the fabric to prevent leakage through the substrate film material.
The materials of this type are further described in the following patents which are hereby incorporated by reference: U.S. Pat. Nos. 3,041,317; 3,282,875; 3,624,053; British Pat. No. 1,184,321 and Dutch Published Application No. 72/12249 corresponding to U.S. Pat. No. 3,784,399. Substrate materials as aforedescribed are available from E. I. duPont deNemours and Co. under the trademark NAFION XR.
A second type of substrate material has a backbone chain of copolymers of tetrafluoroethylene and hexafluoropropylene and grafted onto this backbone a 50-50 mixture of styrene and alpha methyl styrene. Subsequently, these grafts may be sulfonated or carbonated to achieve the ion exchange characteristic. This type of substrate while having different pendent groups has a fluorinated backbone chain so that the chemical resistivities are reasonably high.
Another type of substrate film material which would have application in cells with less caustic conditions than that of a chlorine and caustic cell like those for electrochemical production of organic compounds, would be polymeric substances having pendent sulfonic acid groups wherein the polymeric backbone is derived from the polymerization of a polyvinyl aromatic component with a monovinyl aromatic component in an inorganic solvent under conditions which prevent solvent evaporation and result in a generally copolymeric substance although a 100 percent polyvinyl aromatic compound may be prepared which is satisfactory.
The polyvinyl aromatic component may be chosen from the group including: divinyl benzenes, divinyl toluenes, divinyl napthalenes, divinyl diphenyls, divinyl-phenyl vinyl ethers, the substituted alkyl derivatives thereof such as dimethyl divinyl benzenes and similar polymerizable aromatic compounds which are polyfunctional with respect to vinyl groups.
The monovinyl aromatic component which will generally be the impurities present in commercial grades of polyvinyl aromatic compounds include: styrene, isomeric vinyl toluenes, vinyl napthalenes, vinyl ethyl benzenes, vinyl chlorobenzenes, vinyl sylenes, and alpha substituted alkyl derivatives thereof, such as alpha methyl vinyl benzene. In cases where high-purity polyvinyl aromatic compounds are used, it may be desirable to add monovinyl aromatic compounds so that the polyvinyl aromatic compound will constitute 30 to 80 mole percent of polymerizable material.
Suitable solvents in which the polymerizable material may be dissolved prior to polymerization should be inert to the polymerization (in that they do not react chemically with the monomers or polymer), should also possess a boiling point greater than 60° C, and should be miscible with the sulfonation medium.
Polymerization is effected by any of the well known expedients for instance, heat, pressure, and catalytic accelerators, and is continued until an insoluble, infusible gel is formed substantially throughout the volume of solution. The resulting gel structures are then sulfonated in a solvated condition and to such an extent that there are not more than four equivalents of sulfonic acid groups formed for each mole of polyvinyl aromatic compound in the polymer and not less than one equivalent of sulfonic acid groups formed for each 10 mole of poly- and monovinyl aromatic compound in the polymer. As with the NAFION type material these materials may require reinforcing of similar materials.
Substrate film materials of this type are further described in the following patents which are hereby incorporated by reference: U.S. Pat. Nos. 2,731,411 and 3,887,499. These materials are available from Ionics, Inc. under the trademark IONICS CR6.
Materials as above described have been used as membranes in electrolytic cells for electrochemical production. The NAFION type being the most chemically resistant is the type that is generally used for the chlorine and caustic type electrolytic cells whereas the IONICS type which is less chemically resistant is generally used for organic chemical production or in situations where the electrolyte solutions are not as caustic or corrosive as that of the chlorine and caustic cells. Various means of improving these substrate materials have been sought, one of the most effective of which is the surface chemical treatment of the substrate itself. Generally these treatments consist of reacting the sulfonyl fluoride pendent groups with substances which will yield less polar bonding and thereby absorb fewer water molecules by hydrogen bonding. This has a tendency to narrow the pore openings through which the cations travel so that less water of hydration is transmitted with the cations through the membrane. An example of this would be to react the ethylene diamine with the pendent groups in the sulfonyl fluoride form to tie two of the pendent groups together by two nitrogen atoms in the ethylene diamine. Generally, in a film thickness of 7 mils, the surface treatment will be done to a depth of approximately 2 mils on one side of the film by controlling the time of reaction. This will result in good electrical conductivity and cation transmission with less hydroxide ion and associated water reverse migration.
It has been found that a substrate material can be improved to an even greater extent by use of plasma polymerization techniques to deposit a continuous thin film upon the surface of the substrate material of almost any electrically conducting organic structure to improve the current efficiency of a given membrane and while maintaining good lifetimes for a given membrane in the corrosive surroundings of the electrolytic cell. This type of coating may be applied over the surface of the raw substrate material as described above or over the surface treated substrate material. Plasma polymerization chemistry deals with the occurrence of chemical reactions in partially ionized gas composed of ions, electrons and neutral species. This state of matter can be produced through the action of either very high temperatures, strong electric current fields or magnetic fields. Since very high temperatures would degrade a polymeric substance and be of little value as far as producing a film of such a material, electric fields are used for the plasma polymerization processes. It is known for instance that polymerization can be initiated in a non-equilibrium or cold plasma utilizing almost any organic molecule having an appreciable vapor pressure at 1 millimeter of mercury pressure as a monomer. Unsaturation in this case is not a requirement. In an electric discharge, free electrons gain energy from an imposed electric current field and lose energy through collosions with neutral gas molecules. The transfer of this energy to the molecules leads to the formation of a variety of new species including atoms, free radicals and ions. In the instant case the free radicals and ions are of particular interest in that they can initiate a polymerization process. These products are all active chemically and thus serve as precursors to the formation of new stable compounds such as the polymeric film being deposited upon the surface of the substrate material.
Plasma polymerization techniques have the advantage that the coatings are deposited in a clean environment of a partial vacuum thus preventing dust particles from the surrounding environment from collecting on the substrate material surface either prior to deposition or thereafter. Such dust particles can cause membrane imperfections such that conventional casting methods yield membranes with imperfections which greatly minimize the effectiveness of such a film. The films prepared by plasma polymerization are generally found to be pinhole free and in thicknesses considerably less than that casting technology would presently permit.
There are presently available a variety of deposition systems which are suitable for preparing polymerized coatings to be laid down upon a substrate material. An example of a suitable apparatus would be one having a discharge vessel consisting of glass sealed off from the atmosphere such that a partial vacuum may be maintained therein allowing the vessel to be placed into an inductive coil. Also a means for measuring the pressure inside the vessel is necessary to control the partial vacuum and the partial pressures of monomeric materials introduced to the vessel. The discharge vessel has appropriate monomer inlets for allowing the monomeric materials into the discharge vessel for the plasma polymerization onto the surface of the substrate film material. Since all the parts can be made of glass and assembled by means of ground glass joints, the reaction vessels are interchangeable for cleaning and degassing steps. All glass parts are cleaned by immersing in chromic acid cleaning solution for several hours followed by rinsing, scrubbing with "alkonox" solution and a final copious deionized water rinse. The small amount of deposition occasionally left behind by this process is removed by baking in a glass annealing oven. Because standard taper joints and stopcocks can be used, the reaction vessels loaded with a sample can be degassed first on an auxiliary vacuum system, thereby increasing the number of samples prepared within a given time.
The discharge vessel, when mounted in the plasma apparatus is connected to a McLeod gauge to check the reference vacuum for a differential pressure transducer (less than 10 -5 millimeters of mercury) and also to calibrate the pressure gauge. Also the discharge vessel is connected to a differential pressure transducer. Since the pressure of the monomer vapor cannot be measured by McLeod gauge due to condensation of the vapor during the compression process of the measurement, all pressure readings in either the closed or flow systems are taken with the transducer.
The apparatus can be evacuated to less than 10 -5 millimeters of mercury by a mercury diffusion pump backed by a rotary pump, however, for most cases the diffusion pump will be found not to be necessary and can be bypassed. The reference vacuum for the pressure transducer is always connected to the diffusion pump and kept at a level of less than 10 -5 millimeters of mercury.
The plasma is produced by an electrodeless radiofrequency discharge used to initiate the plasma. The RF power supply is a radiofrequency transmitter. The output is fed into a linear amplifier having a 500 watt capacity which is in turn connected to the RF coil through a network of tunable capacitors. A coupler may be used to measure the RF power and the RF power supply operates at 13.56 megaHertz to deliver continuously variable output power from 0-200 watts. A tuning circuit, located between the generator coil and the coupler, is used to match the impedance of the discharge vessel and the impedance of the amplifier output allowing the tuning circuit to be adjusted so that the reflected power is maintained at the minimum.
The substrate material may be placed into the discharge vessel such that upon introduction of monomeric materials to the vessel and production of a glow discharge plasma within the vessel, a very thin coating of a polymeric material will be deposited on the substrate material. To obtain the coating on only one side of the substrate material it must be attached to a backup plate such as a glass plate or covered on one side with a removable covering material.
In a typical procedure the monomer will be placed in a reservoir which is attached to a flow-meter and to the apparatus by several ground glass joints. The purified material to be used as a monomer is usually degassed and kept in the reservoir always at a vacuum pressure. After degassing of the system the apparatus is pumped down to less than 10 -3 millimeters mercury then the gas and vapor of the monomer are introduced by controlling the opening of needle valves, while the downstream side of the vessel is kept in a vacuum state by continuous pumping. A steady state pressure must be maintained within the apparatus such that the monomer vapor pressure or the partial vapor pressure of the various monomer components can be controlled rather precisely.
After a steady pressure of the gas monomer mixture is accomplished, the discharge is allowed to operate for a given time at a fixed power. After the discharge is stopped the pressure of each component is checked by reading the total pressure in the discharge vessel in order to make sure that no change occurred during the run, and the residual gases were pumped out before the air was admitted to the vessel.
The breakdown energy to initiate plasma by the electrodeless RF discharge is dependent upon (1) the pressure, (2) the frequency of the AC current, and (3) the dimensions of the vessel. It can be observed that generally speaking the wattage of the generator will necessarily be increased above the planned wattage to initiate the glow discharge. As soon as the glow discharge is initiated the wattage can be reduced to the pre-determined wattage for the process. The power requirements will be dependent upon the sizes of the reaction vessels, therefore for any given setup these calculations must be made independently. Various aspects of plasma polymerization techniques are further described in the following book which is hereby incorporated by reference: Hollaham and Bell, Techniques and Applications of Plasma Chemistry, New York, John Wiley and Sons, 1974.
In the case of the present invention the copolymeric substrate material was laid flat within the reaction vessel and the discharge maintained so as to coat the material on one side with a thickness of about 100 to 200 Angstroms of the polymeric material on the surface of the substrate material. The resultant membrane materials have significant advantages in a chlorine and caustic cell by reason of their increased current efficiencies and good lifetimes within the corrosive surroundings of chlorine and caustic cells. This generally applies to the fluorinated copolymeric substrate material with either a fluorocarbon or carbonyl (amide) material coated onto the surface thereof. Substrate materials with the polyvinyl and monovinyl backbone chain can be used for electrochemical production of organic substances where the conditions of this electrolytic cell are less abrasive. Substrate materials having fluorinated copolymers of ethylene and propylene in the backbone chain and styrene/alpha methyl styrene pendent groups may have many applications in the electrochemical processes having medium levels of corrosive electrolytes present.
In order that those skilled in the art will more readily understand the present invention and certain preferred aspects by which it may be carried into effect the following specific examples are afforded.
EXAMPLE 1
A NAFION substrate material as described above was coated with a 100 to 200 Angstroms layer of polytetrafluoroethylene on one side by means of plasma polymerization of tetrafluoroethylene gas. The resultant membrane material was then tested for gel water capacity by placing the sample in boiling water for 10 hours and measuring the weight gain for the given material. The material of Example 1 produced a gel water of 19.2 percent. Electrical conductance studies at 2 kilo Hertz showed a specific resistance 2201 to 2450 ohm centimeters. The membrane material of Example 1 was placed in a 3 square inch laboratory chlorine and caustic test cell wherein: the coated side was placed toward the cathode; the resultant sodium hydroxide concentration was in the range of 400 to 500 grams per liter or 35 to 42 percent; the potential across the cell ran in the range of 4.00 to 5.56 volts at current densities in the range of 1 to 3 amperes per square inch (155 milliamperes per square centimeter); the cell was run at a temperature in the range of 80° to 85° C; and the current efficiency based on daily runs ran in the range of 70 percent to 81.5 percent. The membrane was run in the cell for approximately 200 days with no signs of failure, thus showing a good lifetime.
EXAMPLE 2
A NAFION substrate material was coated with a 100 to 200 Angstroms layer of polyamide by means of plasma polymerization of acetylene, nitrogen and water vapors. This material when tested for gel water according to Example 1 yielded a result of 21.3 percent. The sample of Example 2 yielded a specific resistance of 286 to 330 ohm centimeters. When this membrane material was placed in a laboratory electrolytic cell under conditions, according to Example 1, the resultant sodium hydroxide concentration was approximately 500 grams per liter or 39 percent, the potential in the range of 3.42 volts to 5.00 volts and a current efficiency in the range of 66.8 to 83.1 percent. The membrane was run in the cell for approximately 65 days with no signs of failure. It should be noted that the potential is lower for the polyamide coating because it is hydrophilic which makes it a better electrical conductor than the hydrophobic polytetrafluoroethylene coating.
EXAMPLE 3
A NAFION substrate material was coated with a 100 to 200 Angstroms layer of allylamine on one side by means of plasma polymerication of allylamine gas. The resultant membrane material when tested for gel water was found to exhibit 21.7 percent gel water content. The specific resistance was found to be in the range of 1520 to 2024 ohm centimeters. When this resultant membrane material was tested in an electrolytic cell according to Example 1 it was found that the potential across the cell ran in the range of approximately 3.62 to 4.4 volts and exhibited a current efficiency in the range of 51 percent to a high of 72 percent. The resultant sodium hydroxide concentration was approximately 450 grams per liter or 35 percent. This membrane was run in the laboratory test cell for a period of 18 days with no signs of failure.
EXAMPLE 4
A NAFION substrate material as described above was coated with a 100 to 200 Angstroms layer of hydrocarbon on one side by means of plasma polymerization of cyclohexane vapor. The resultant membrane material was tested for gel water according to Example 1 and exhibited a gel water of 21.3 percent. The specific resistance ran in the range of 264 to 352 ohm centimeters. This material was also tested in the laboratory test cell according to Example 1 exhibiting a potential in the range of 3.6 to 4.2 volts and current efficiencies in the range of 50 to 62 percent. This membrane was run in the electrolytic cell for a period of 46 days, with no sign of failure.
EXAMPLE 5
Example 5 is a standard NAFION membrane material as described above for comparison against the plasma polymerized coating type membrane surfaces. A gel water test according to Example 1 generally yields a 20 to 25 percent gel water. It exhibited a specific resistance of 220 to 308 ohm centimeters. Upon testing this membrane material in the laboratory test cell according to the Example 1 it exhibited a potential in the range of 3.7 to 4.0 volts and the current efficiency in the range of 53 to 62 percent. This membrane was run in the electrolytic cell for a period of 56 days with no signs of failure.
EXAMPLE 6
The substrate material was a copolymeric material of polytetrafluoroethylene and polyhexafluoropropylene having grafted thereon a 50-50 mixture of styrene and alpha methyl styrene. This material was then sulfonated to obtain the ion exchange characteristics. The resultant substrate material was coated with a 100 to 200 Angstrom layer of polytetrafluoroethylene on one side by means of plasma polymerization of tetrafluoroethylene gas. The resultant membrane material yielded a gel water of 71.7 percent when tested according to Example 1. It was found to exhibit a specific resistance of 341 ohm centimeters. When tested in a chlorine and caustic electrolytic cell, the membrane cracked near the gaskets but this was not attributed to the membrane material. EXAMPLE 7
A substrate material according to Example 6 was coated with 100 to 200 Angstroms layer of polyamide on one side by means of plasma polymerization of a mixture of nitrogen, acetylene, and hydrogen vapors. The resultant membrane material yielded a gel water of 64.5 percent when tested according to Example 1. It exhibited a specific resistance of 670 ohm centimeters. When tested in a chlorine and caustic electrolytic cell, the resultant sodium hydroxide concentration ran in the range of 240 to 377 grams per liter or 19 to 30 percent, the potential across the cell ran about 3.0 volts, and the current efficiency in the range of 15 to 30 percent. This membrane was run in the cell for 15 days when the cathode punctured the membrane.
EXAMPLE 8
A substrate material according to Example 6 was coated with 100 to 200 Angstroms layer of hydrocarbon on one side by means of plasma polymerization of cyclohexane vapors. The resultant membrane material yielded a gel water of 72 percent when tested according to Example 1. It exhibited a specific resistance of 462 ohm centimeters. When tested in a chlorine and caustic electrolytic cell, the resultant sodium hydroxide concentration ran in the range of 362 to 473 grams per liter or 30 to 37 percent, the potential across the cell ran about 3.8 volts, and the current efficiency in the range of 29 to 45 percent. This membrane was run in the cell for 18 days when it cracked near the gasket material.
Although the membranes of Examples 6, 7 and 8 did not perform well in the corrosive surroundings of a chlorine and caustic cell, it is believed that these membranes might be useful in less corrosive surroundings such as organic electrochemical production, or in dialysis electrolytic cells.
Thus it can be seen that membrane materials with coatings of polytetrafluoroethylene and polyamide according to Examples 1 and 2 exhibited the best results with current efficiencies significantly superior to the unmodified base membrane of Example 5 at comparable voltages and current densities. Also it can be seen that the NAFION type modified membranes can withstand the chlorine and caustic surroundings of the electrolytic cell to exhibit good lifetimes well within the range of the commercial feasibility and nearly equal to that of the unmodified NAFION membrane.
Thus it should be apparent from the foregoing description of the preferred embodiments that the composition herein described accomplishes the objects of the invention and solves the problems attendant to such membrane materials for use in electrolytic cells for electrochemical production. | Disclosed is an improved hydraulically impermeable cation exchange membrane for an electrolytic cell and a method for the preparation of such a membrane using a copolymeric substrate and applying to the surface thereof by means of plasma polymerization, a very thin top coating of a second polymeric material to drastically reduce the permeability of the substrate material with a minimal effect upon the bulk properties of the resultant membrane. Such top coatings may be applied over the basic substrate or over surface treated substrates to enhance the chemical resistivity of the membrane to chemical breakdown occasioned by the electrolyte within the electrolytic cell. | 8 |
The invention concerns a wiper bearing housing having a bearing region and at least one mounting element. The invention further concerns a method for producing a wiper bearing housing having a bearing region and at least one mounting element.
BACKGROUND OF THE INVENTION
Wiper bearing housings—also referred to simply as wiper bearings—are used primarily in the automotive industry. They have the task of supporting a wiper shaft or the bearing rotating link in rotatable fashion. In general, the wiper bearing housing is outfitted with at least one mounting element. Said mounting element can be realized as a fixing eye, for example, that is fastened to the body of a motor vehicle. Furthermore, tubular regions are arranged on certain types of wiper housings. These tubular regions are pushed onto holding bars of a wiper system.
It is known to design wiper bearing housings out of aluminum or zinc die casting, or plastic injection molding, or as a sheet-metal component to be bent, for instance.
The geometry of the wiper bearing furthermore determines the orientation of the wiper axis in relation to the body and, in particular, in relation to the motor-vehicle window to be cleaned. The wiper axis position is vehicle-specific, i.e., it depends on the geometry of the windshield. Additionally, the wiper bearing geometry must be adjusted individually for the vehicle type with regard for the fastening to the body. For this reason, the wiper bearings must be newly adjusted for nearly every vehicle type, so that high tool costs are incurred for production of the wiper bearing housings.
Sheet-metal bearing housings have the advantage that they are cost-effective, in particular in the case of large numbers of units. The costs are dependent on the number of units, because a complex and expensive tool having, e.g., 15 to 20 tool stages, must be used.
A further set of problems regarding wiper bearing housings concerns vehicle safety. Wiper bearing housings that are designed rigid in nature pose a safety risk, e.g., if a pedestrian is thrown onto a moving vehicle. It is already known to provide wiper bearing housings with a set fracture point or to also arrange a selected tube on the wiper bearing housing that can deform upon impact. These additional measures involved in the design of wiper bearing housings also lead to undesired additional costs.
SUMMARY OF THE INVENTION
The invention is based on the generic wiper bearing housing in that at least one transitional region between the bearing region and the mounting element is deformable. Due to the deformability of the transitional region between the bearing region and the mounting element, the angle of the wiper axis can be selected in variable fashion in relation to the vehicle body. It is therefore possible to use the same basic type for different vehicles, which markedly reduces the tool costs for creating vehicle-specific wiper bearings. Costs can also be reduced by increasing the number of units, which is then made possible.
A fixing eye is preferably provided as mounting element. Using such a fixing eye, the wiper bearing housing can be fastened to the vehicle body. Due to the deformability of the transitional region between the bearing region and the fixing eye, the wiper axis angle can be adjusted.
It is preferrable for a tubular region to be provided as the mounting element. With a tubular region of this type, the wiper bearing housing is generally pushed onto a holding bar of a wiper system. The wiper housing is rotatable on the tubular region. As a result of a deformable region that can be situated between the bearing region and the tubular region, additional degrees of freedom are available for the orientation of the wiper axis.
The deformability of the at least one transitional region is realized preferably by means of a corrugated region. In general, such a corrugated region is simple to produce, and it can be designed so that sufficient deformability is available.
It is advantageous in particular when the wiper bearing housing is designed as a sheet-metal component to be bent. This is a cost-effective variant of wiper bearing housings. In the case of large numbers of units, in particular, the invention can reveal its advantageous, cost-saving effects in this fashion.
It is furthermore advantageous when the wiper bearing is deformable or strainable under the influence of increased axial force. In this fashion it can be achieved that the bearing region can shift position when an axial force is applied. In this fashion, the forces acting on persons in the case of impact can be reduced.
It can be advantageous if a deformability or strainability is plastic. A deformation of the wiper bearing housing can therefore be irreversibly shaped, so that, after an impact, one is required, for safety considerations, to replace the wiper bearing housing, which was seriously damaged by the impact.
It can also be advantageous, however, when a deformability or strainability is elastic. In this case, in particular after a light impact, the wiper bearing housing returns to its original position, so that a functional wiper system exists without the need for further repair.
The invention is based on the generic method in that at least one deformable transitional region is situated between the bearing region and the mounting element. The angle of the wiper axis in relation to the vehicle body can be selected in variable fashion by means of the deformability of the transitional region between the bearing region and the mounting element. It is possible, therefore, to use the same basic type for different motor vehicles, which markedly reduces the tool costs for producing vehicle-specific wiper bearings. Costs can also be reduced by increasing the number of units, which is then made possible.
The forming of the deformable transitional region preferably takes place in a forming tool. Accordingly, the production process can take place in such a fashion that the forming tool stages are integrated in the tool, e.g., as tool inserts. In the first tool stages, therefore, the universal shape of the wiper bearing housing is first produced with the deformable regions. In the final tool stages, the forming desired for the specific application is then carried out.
It can also be practical when the forming of the deformable transitional region takes place outside of a tool. The forming can therefore take place independently of the actual production process.
It is preferable that a tubular region is provided as the mounting element, and that the tubular region is pushed onto a holding tube before the transitional region is formed, whereby the tubular region can rotate in an axial direction. It is possible, therefore, to wait until assembly to bring a wiper bearing housing comprising a universal shape into its final form, whereby the additional degree of freedom of rotation on a holding tube is utilized.
A corrugated transitional region is preferably moulded. Generally speaking, such a corrugated region is simple to produce, and it can be designed so that a sufficient deformability is available.
It is furthermore advantageous when a sheet-metal component is used as the starting workpiece. This is a cost-effective variant of wiper bearing housings. When large numbers of units are involved, in particular, the invention can reveal its advantageous, cost-saving effects in this fashion.
The invention is based on the surprising finding that, on account of the deformability of transitional regions, a universally-usable wiper bearing housing can be produced. The required wiper axis position can be realized in the wiper bearing with comparably low expense by means of the deformation regions, in particular by adapting the orientation of the connecting pin in relation to the sheet-bar tube and/or the orientation of the fixing eye, and on account of the free orientation of the wiper bearing by means of rotation in relation to the sheet-bar tube. The cost reductions are based, on the one hand, on the fact that individual tools for every new vehicle model need not be made available, whereby the increase in the number of units of the produced wiper bearing housing plays an important role here in particular.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be explained with reference to the accompanying drawings based on preferred exemplary embodiments.
FIG. 1 shows a perspective view of a wiper bearing housing according to the invention;
FIG. 2 shows a further perspective view of a wiper bearing housing according to the invention;
FIG. 3 shows a further perspective view of a wiper bearing housing according to the invention;
FIG. 4 shows a sectional view of a wiper bearing housing according to the invention in an initial state;
FIG. 5 shows a sectional view of a wiper bearing housing according to the invention in a second state;
FIG. 6 shows two perspective views of wiper bearing housings according to the invention in different states of deformation;
FIG. 7 shows a further perspective view of a wiper bearing housing according to the invention;
FIG. 8 shows a sectional view of a wiper bearing housing according to the invention in a non-deformed state; and
FIG. 9 shows a further sectional view of a wiper bearing housing according to the invention in a deformed state.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description of the preferred exemplary embodiments, identical reference numerals refer to identical or similar elements.
A perspective view of a wiper bearing housing 10 according to the invention is shown in FIG. 1 . The wiper bearing housing 10 has a cylindrically-shaped bearing region 12 . The wiper shaft or the bearing rotating link is supported in rotatable fashion in this bearing region 12 . The wiper bearing housing 10 further comprises two mounting elements, one of which is developed as a fixing eye 14 , and the other as a tubular region 16 . In general, the wiper bearing housing 10 is fastened to a motor vehicle body with the fixing eye 14 . In general, the tubular region 16 is pushed onto a holding bar of a wiper system, and after orientation of the wiper bearing housing, the tubular region 16 can be welded to the holding bar. In the exemplary embodiment according to FIG. 1, both the fixing eye 14 and the tubular region 16 are interconnected with the bearing region 12 by means of deformable regions 18 , 20 . The deformable regions are realized by means of a corrugation.
FIG. 2 shows a second perspective view of the wiper bearing housing 10 that is shown in an initial perspective view in FIG. 1 .
A perspective view of a wiper bearing housing 10 is also shown in FIG. 3 . In addition, a line 22 representing an intersecting plane is shown.
In FIG. 4, the wiper bearing housing according to FIG. 3 is shown in a sectional view along the line indicated with numeral 22 in FIG. 3 . FIG. 4 shows the basic geometry of the wiper bearing housing 10 and, therefore, a non-deformed state. It is apparent that the wiper bearing housing is designed as a single component, whereby the sheet-metal bending technique was preferably used.
The wiper bearing housing according to FIG. 3 is shown in a sectional view in FIG. 5, which said sectional view corresponds to that shown in FIG. 4, although a deformed state is shown here. The angles of deformation in the deformable regions 18 , 20 are indicated.
FIG. 6 shows two wiper bearing housings 10 . The wiper bearing housing according to FIG. 6 a and the wiper bearing housing according to FIG. 6 b have parallel axes with regard for the orientation of the fixing eye 14 and with regard for the orientation of the mounting tube 16 . On account of the deformable regions it is possible, however, that the axes of the bearing region form an angle β with each other, so that the wiper axis can be oriented in relation to the motor vehicle window to be cleaned.
FIG. 7 shows a further exemplary embodiment of a wiper bearing 10 according to the invention. The special feature of this wiper bearing 10 lies in the fact that the deformable regions 18 , 20 between the bearing region 12 and the fixing eye 14 or the tubular region 16 are extended in design. A greater deformability is therefore available, on the one hand, which can increase the range of application of the wiper bearing housing. On the other hand, the variant according to FIG. 7 offers greater impact protection in case of accidents. An intersection line 22 is shown in FIG. 7 .
FIG. 8 shows an illustration of a wiper bearing housing 10 according to FIG. 7 along the intersection line 22 in FIG. 7 . The basic geometry of the wiper bearing housing 10 is shown.
FIG. 9 shows the wiper bearing housing according to FIG. 7 in a deformed state, whereby the perspective corresponds to that shown in FIG. 8. A state is shown in which a force F acts on the bearing region 16 in the axial direction, which can be the case, for example, if a pedestrian is thrown onto the vehicle. It is apparent that the deformable regions 18 , 20 have deformed in such a fashion that the bearing region 12 can retract downwardly. This dampens the impact of a pedestrian. The deformability or the strainability of the transitional regions 18 , 20 can be designed to be plastic or elastic.
The preceding description of the exemplary embodiments according to the present invention is intended for illustrative purpose only and is not intended to limit the invention. Various changes and modifications are possible within the framework of the invention without leaving the scope of the invention or its equivalents. | The invention concerns a wiper bearing housing having a bearing region ( 12 ) and at least one mounting element ( 14, 16 ), whereby at least one transitional region ( 18, 20 ) between the bearing region ( 12 ) and the mounting element ( 14, 16 ) is deformable. The invention further concerns a method for producing a wiper bearing housing ( 10 ). | 1 |
This is a continuation of application Ser. No. 08/424,239, filed Apr. 19, 1995, now abandoned, which is a continuation of application Ser. No. 08/157,390, filed Nov. 23, 1993, now abandoned.
The present invention refers to nonhuman transgenic animals which can be used as model system for the identification of agents which induce or repress epidermal hyperproliferation, such as, for instance, radiations, chemical and cosmetic compounds, pathologies, etc. The invention is also useful for the detection of agents which influence the hair cycle.
Transgenic animals are animals which bear an exogenous gene (called transgene) in their genome which has been introduced either in them themselves or in an predecessor. Due to the fact that the exogenous gene is also present in the germ cells of these animals, the transgene is transmitted from parent to children so that it is possible to establish lines of transgenic animals from a first founder animal. The introduction of the transgene into the fertilized oocyte maximizes the possibilities of the transgene being present in all the cells, both somatic and germinal, of the founder animal. The latter will transmit the transgene to approximately half of its descendants, which will carry it in all its cells. If the transgene is introduced in a later embryonic stage, the founder animal would be a mosaic since not all its somatic and germinal cells will carry the transgene. This would have the result that a smaller proportion of descendants carries the transgene; however, the descendants which inherit it would carry in all their cells, including the germ cells.
One problem when transgenic animals are generated is that not all of them are founders and therefore the corresponding lines generated from them express the transgene which they carry. This effect, known as position effect, is due to the fact that the transgene can be integrated in any place of the genome of the transgenic animal. If the integration takes place in a heterochromatin region, the activity of the transgene may be suppressed in whole or in part. Alternatively, if the transgene is integrated near the regulator region of a gene, the activity of the transgene may be altered or even come to be controlled by this "foreign" regulator region instead of by the one which it bears. For this reason, once the transgenic animals have been identified, it is necessary to proceed to determine in which of them the transgene is suitably expressed.
Although it is possible to generate transgenic animals of different species, most of the work in this field has been done with mice. Transgenic animals in general, and mice in particular, are of great utility as model systems for studying the mechanisms which regulate the control of the genetic activity, as well as for determining the role of specific factors in animal physiology and their alterations.
Although there are various possibilities, the most usual manner of introducing the transgene is by microinjection of DNA in the pronucleus of embryos in the single-cell state (Gordon et al., 1980, Proc. Natl. Acad. Sci., U.S.A. 77:7380; Brinster et al., 1981, Cell 27:223; Wagner et al., 1981, Proc. Natl. Acad. Sci. U.S.A. 78:6376;
Gordon and Ruddle, 1981, Methods Enzymol. 101C:411). Up to the present time, a considerable number of genes have bean introduced and studied in transgenic animals, basically mice (for a survey, see Palmiter and Gordon, 1986, Ann. Rev. Genet. 20:405). There have also been introduced into transgenic animals recombinant genetic constructions which contain a regulator region and a coding region for a protein which come from different sources. These "compound" transgenes, although present in all the cells of the animal, are only expressed in those tissues which normally activate the specific regulator element used in the genetic construction. In this way, using suitable regulator elements, it is possible to direct the activity of genes of varied interest (clinical, pharmaceutical, biological or biotechnological) to preselected tissues of the transgenic animal. One class of particularly interesting regulator sequences is those which are inducible, due to the fact that they make it possible to regulate the expression of the structural gene to which they are attached, controlling the presence or absence of the inductor required in order to activate said regulator regions.
The generation of transgenic animals is well-established and is known to the corresponding experts (Gorton and Ruddle, 1983, Methods in Enzymol. 101C:1244; Hogan, Constatini and Lacy, 1986, Manipulating a Mouse Embryo. A Laboratory Manual. Cold Spring Harbor Laboratory, Cold Spring Harbor).
Skin is the tissue which covers the surface of the body, it being formed of two main layers--the surface epithelium or epidermis and the underlying conjunctive tissue layer or dermis (Fawcett, 1986, in "Bloom and Fawcett, A Textbook of Histology," 11th Edition, published by W. B. Saunders Company, pages 543-575).
The specific functions of the skin depend to a great extent on the properties of the epidermis. This epithelium forms a continuous cellular cover over the entire surface of the body but is specialized also to form certain cutaneous appendages--the hair, the nails and the glands.
The epidermis is a stratified flat epithelium which is divided into two cell layers: the basal layer, formed of a single layer of cuboid cells which have the ability to divide, and the suprabasal layer, formed of cells coming from the basal layer and which have lost the ability to divide. In the suprabasal layer, one can distinguish prickle-cell, granular and horny layers. The suprabasal cells are embarked in a program of terminal differentiation during which, instead of migrating towards the surface of the epithelium, suffer drastic morphological changes which finally give rise to the corneocytes of the horny layer. These flat, strongly keratinized dead cells finally become detached from the skin by desquamation.
Hairs are thin filaments of keratin which arise from a tubular invagination of the epidermis, the hair follicle, which extends deep down to the dermis. The hairs are developed from the invagination of the bulbous terminal expansion of the active follicle. Both the hair proper and the follicle which surrounds it are complex structures formed by several different concentric cellular layers (Fawcett, 1987, op. cit.).
The hair is not an organ which grows continuously, but rather alternates phases of growth with periods of rest, greatly varying the structure of the follicle in accordance with the stage of growth of the hair. Thus, in the growth phase, the follicle is lengthened until reaching its maximum length while the epithelial cells which surround the dermal papilla are differentiated in their various characteristic types. The cells of the matrix, in the invagination which surrounds the dermal papilla, start to proliferate actively. The cells derived from the matrix also maintain a high mitotic index while keratinized in the keratogenic zone of the bulb, immediately above the dome of the dermal papilla, giving rise to the hair stem with its three main components: medulla, cortex and cuticle.
Most, if not all, cells of vertebrates contain a cytoskeleton formed by the so-called intermediate filaments. This cytoskeleton can be formed by at least six different classes of proteins which are expressed in a specific manner for each cellular type. The keratins form the cytoskeleton of intermediate filaments of the epithelial cells and their appendages (nails and hairs) (Mol et al., 1982, Cell 31:11; Heid et al., 1986, Differentiation 32:101). These proteins constitute a family of about 30 members which is characterized also because its expression in groups of 2 to 8 polypeptides is specific to each type of epithelial cell. Thus, in the epidermis, the basal cells synthesize the K4 and K14 keratins while, when the cells differentiate to suprabasal, they replace these keratins by the K1 and K10 pair (Eichner et al., 1984, J. Cell Biol. 98:1388 Stoller et al., 1988, J. Cell Biol. 107:427). On the other hand, the K6 keratin which is present in various internal stratified epithelia such as tongue, palate, vagina or the external root layer of the hair follicle, is not expressed in interfollicular epidermis (Quinlan et al., 1985, Annals New York Acad. Sci. 455:282). However, this keratin is induced in the suprabasal cells of the epidermis in all hyperproliferative disorders of this tissue (Weiss et al., 1984, J. Cell. Biol. 98:1397; Stoller et al., op. cit.). This keratin is also induced by topical treatments of the skin with TPA, retinoic acid, and other hyperplasia-inducing agents (see, for example, Schweizer et al., 1987, J. Invest. Dermatol., 125; Eichner et al., 1992, J. Invest. Dermatol., 154).
By everything which has just been described, the DNA sequences which regulate the expression of the gene of the K6 keratin can be identified and they are coupled functionally to form a marker gene in a genetic construction in such a way that the expression of the marker gene remains under the control of the regulator region of the K6 gene, a transgenic animal bearing such construction would be an excellent model system for identifying substances, factors or processes which lead to epidermal hyperproliferation. In the presence of these stimuli, the regulator region of the K6 gene would be activated in the suprabasal layers of the epidermis, which would lead to the synthesis of the product coded by the marker gene, which would easily be detected by methods which are described further below. And the present invention consists precisely in the generation of transgenic animals bearing the transgene formed of the regulator region of the gene of K6 keratin coupled to a suitable marker gene in order to be used to identify physical, chemical, biological agents, etc., which induce epidermal hyperproliferation. Alternatively, these animals also would permit identifying substances and factors which protect the epidermis from the action of hyperproliferative stimuli or which inhibit epidermal hyperproliferation. An animal treated with such an epidermal hyperproliferation protective substances will respond to the hyperproliferative stimuli with less or no intensity than an untreated animal. Accordingly, the K6 regulator region will be induced with less or no intensity, which will be visualized as less or no induction of the corresponding marker gene coupled to it.
For the visualizing of the hyperproliferative state of the epidermis, suitable selection of the marker gene which is to be coupled to the regulator region of the K6 gene is of great importance; said marker must code for an easily identifiable product. In the invention, the gene of β-galactosidase (β-gal) has been selected as marker in order to be placed under the control of the regulator region of the K6 keratin and introduced into the genome of transgenic animals. When the skin of the resultant transgenic animals is subjected to hyperproliferative stimuli in the presence of X-gal, the substrate of β-gal, the epidermal suprabasal cells, including those of the tail, develop a blue color the intensity of which will depend on the intensity of the induction of the transgene, which, in its turn, will depend on the intensity of the hyperproliferative stimulus to which the epidermis has been subjected. In similar manner, there will also be dyed blue all those cells and tissues in which the regulator regions of the gene of the K6 keratin used in the genetic construction is activated, in either a constituent manner or dependent on an inductor stimulus.
Another marker gene of great interest would be that of luciferase (Ow et al., 1986, Science 234:856). Using this marker gene, the cells of the epidermis which is subjected hyperproliferative stimuli will produce luciferase which, in the presence of luciferin and under suitable conditions will result in the emission of light. Other possible marker genes, although probably less interesting in view of the characteristics of this invention would give rise to chemical products biochemically detectable as such, for instance chloramphenicol acetyltransferase (Gorman et al., 1982, Mol. Cell Biol. 2: 1044), xanthine-guanine phosphoribosyl transferase (Nulligan and Berg, 1980, Science 209:1422), the T antigen of virus SV40 or the growth hormone. Other possible marker genes characterized by giving rise to biologically active products such as, for example, oncogenes or cytokines, although possible, would be less useful in the present invention.
Other advantages and characteristics of the invention will become clear from the description of the invention which follows as well as from the claims.
DESCRIPTION OF THE INVENTION
Drawings
FIG. 1 shows the insert of the plasmid pkIV*Z(8.8), consisting of 8.8 kilobase pairs (kpb) of the 5' region which precedes the genes of the bovine keratin IV* to which the coding region of the marker gene of β-galactosidase has been united. Bovine keratin KIV*, so-called for historic reasons, is equivalent to the human K6 (Jorcano et al., Differentiation . . . ). Therefore, throughout this invention, we will speak of the K6 keratin, whether of bovine or human origin. An E. coli strain containing plasmid pkIV*Z (8.8) was deposited with National Collections of Industrial and Marine Bacteria Ltd., 23 St. Machar Drive Aberdeen, Scotland as deposit no. NCIMB 40539 on Feb. 25, 1993.
CONSTRUCTION OF THE TRANSGENE KIV*Z(8.8)
In order to create an inducible gene in the epidermis in response to hyperproliferative stimuli, a DNA fragment of 8.8 Kpb of the 5' region which precedes the gene of the bovine keratin K6 is united to the coding region of the gene of the β-galactosidase in accordance with the recombinant DNA techniques described in Maniatis et al. (1982) Molecular Cloning: A Laboratory Manual (Cold Spring Harbor Laboratory, Cold Spring Harbor).
FIG. 1 describes the transgene; in it there are shown the cutting sites of various restriction enzymes as well as the parts which come from the regulator region of the gene of the K6 keratin (K6; continuous line), of the gene of β-galactosidase (lacZ; rectangular zone) and of the vector (pPolyIII.1; broken line).
This construction was carried out in various steps:
Step 1: Cloning of lacZ in the plasmid pPolyIII.1.
Start from the plasmid pRSV-lacZ-pUC8 which contains the lacZ gene bound to the LTR of the RSV virus which are cloned in the pUC8 vector. This plasmid comes from the plasmid pZ-1 (Norton and Coffin, 1985, Mol. Cell. Biol. 5:281), in which the vector pBR322 was replaced by pUC8. The lacZ gene was isolated from this plasmid through a double digestion with the enzymes KpnI and BamHI and this fragment was cloned in the plasmid p.PolyII.1 (Lathe et al., 1987, Gene 57:193) digested, in its turn, with the same enzymes KpnI and BamHI. This construction was given the name of pZIII.1.
Step 2: Cloning of the regulator region of the gene of the K6 keratin in the plasmid pZIII.1.
This cloning was carried out, in its turn, in various steps:
Step 2.1: Starting from the genome clone λ6 (Blessing et al., 1987, EMBO Journal. 6:567), which contains approximately 11 Kpb of the region preceding the gene of the bovine keratin and 4 Kpb of the coding region of the gene. The bovine genotheca from which this λ6 clone was isolated as well as the λA clone which will be mentioned below was constructed in the vector λEMBL3.
λ6 was directed with the enzymes EcoRI and BamHI which cut in the region which precedes the K6 gene in the -8.8 Kpb positions respectively. This fragment was inserted in the plasmid pBluescript (Stratagene) digested with the same enzymes, that is to say EcoRI and BamHI, to give rise to the plasmid pIVx5'E/B.
Step 2.2: Start from the genome cone λA (Blesing et al., 1987, op. cit.) which contains approximately 3.6 Kpb of the 5' region which precedes the bovine gene of K6 keratin, plus the entire coding region of the gene plus approximately 3Kpb of DNA in 3'. λA was digested with the enzymes BamHI and KpnI which cut in the positions -3.6 Kpb and +3 Kpb of the K6 gene respectively. This fragment was cloned in the plasmid pUC 18, digested with the same enzymes BamHI and KpnI, to give rise to the plasmid pIV*B/K.
Step 2.3: The insert pIV*5'E/B was separated from the vector by a double digestion with the enzymes SalI and BamHI. This fragment was cloned in the plasmid pIV*B/K, also digested with SalI and BamHI, to give rise to the plasmid pIV*S/K, which contained the 8.8 kpb which preceded the gene of the K6 bovine keratin plus 3Kpb of the coding region of the gene.
Step 2.4: The plasmid pIV*S/K was digested with SalI and NaeI (which cuts in the position +115 pb of the gene of the K6 keratin) to free a fragment which extends from the -8.8 Kpb position to the 115 pb position of the gene of the K6 keratin. This fragment was bound in the plasmid pZIII.1 previously digested with SalI and Asp718, the latter site being converted by treatment with the Klenow polymerase. The product of this ligation is the plasmid pKIV*Z(8.8) which contains the transgene which will be introduced within the genome of the transgenic animals.
Production of transgenic mice containing the recombinant construction pKIV*.Z(8.8)
The above-described plasmid pHIV*.Z(8.8) was directed with NotI (4 units of enzyme per μg off DNA for 1 hour at 370° C.), an enzyme located on both side of the multiple cloning site of the vector pPolyIII.1, in order to separate the insert, the transgene KIV*.Z(8.8) from the vector. The products of the digestion were subjected to an electrophoresis in a gel of 1% agarose of low melting point and the band of approximately 12 Kb containing the transgene was cut from the gel. In order to purify the transgene, the agarose was melted at 65° C., cooled to 37° C., and extracted with one volume of phenol. The aqueous phase of the extraction s was extracted with a volume of phenol/chloroform (1:1 v:v); the aqueous phase of this extraction was again extracted with one volume of chloroform and the DNA was precipitated from the aqueous phase of this last extraction with two volumes of ethanol at -70° C. and sedimented by centrifuging at 15,000 ×/g for 15 minutes. The DNA was dissolved in 500 μl of 0.2 M NaCl, 20 mM Tris-HCl (pH 7.5), 1 mM/EDTA, and purified additionally by filtration in a column of Elutip-d (Sleicher and Schuell) on 10 mM Tris-HCl (pH 7.5), 0.1 mM/EDTA. The DNA was precipitated with ethanol and dissolved to 2 μg/ml. Between 250 and 400 copies of the purified transgene were microinjected in the pronucleus of fertilized eggs in the one-cell stage in accordance with the methods described by Wagner et al., 1981 (op. cit.) and Hogan et al., 1986 (op. cit.). The eggs were obtained from hybrids C57B1/6J×balb/c; the mice were obtained from the Jackson Laboratories (U.S.A.).
After the microinjection, the eggs were incubated in M16 medium (Hogan et al., 1986, op. cit.) at 37° C. and 5% CO 2 overnight. On the following day, the eggs which had withstood the treatment were transferred to a pseudo-pregnant mother (previously paired with a vasectomized male) in accordance with well-established protocols (Gordon and Ruddle, 1983 [op. cit.]; Hogan et al., 1986 [op.cit.]). The imported embryos developed to term of the adoptive mother, the new mice being born at the end of 20 to 21 days.
All the animals were kept in a stable at 22° C., 50% humidity, with a cycle of 12 hours light/12 hours darkness.
At 3 weeks after delivery, the animals born were analyzed to determine which of them were transgenic, that is to say carriers of the transgene. For this, approximately 1 cm was sectioned under anesthesia from the tip of their tails. The DNA was extracted from this tissues basically in accordance with the method of Hogan et al, 1986 (op. cit.) by incubation overnight with proteinase K in the presence of 0.5% SDS, followed by two extractions with phenol:chloroform (1:1 v:v) and another extraction with chloroform. The nucleic acids were precipitated with ethanol at room temperature and redissolved in 250 μl of 10 mM Tris-HCl, pH 7.5, 1 mM/EDTA. Approximately 10 μg of DNA were digested with EcoRI, subjected to electrophoresis in gels of 1% agarose and transferred to nitrocellulose membranes, basically in accordance with the method described by Southern, 1975, J. Mol. Biol. 98:503. The nitrocellulose filters were hybridized at 42° C. with a radioactive probe for one night in a buffer solution containing 50% formamide, 5×SSC, 5×Denhardt solution, 1% SDS 10 mM Tris HCl, pH 7.5, 10% dextran sulfate. Thereupon they were washed twice in 2×SSC, 0.1% SDS at room temperature for 15 minutes and twice with 0.1×SSC, 0.1% SDS at 65° C. for 30 minutes, all in accordance with the method described by Maniatis et al., 1982 (op. cit.).
As radioactive probe there was used a HindIII/EcoRI fragment of the plasmid pRSV-lacZ-pUC8, containing the gene lacZ radioactively marked with a high specific activity by the method of Feinberg and Vogelstein, 1983, Anal. Biochem. 132:6. Hybridization indicated that four animals carried the transgene (between 5 and 50 copies) without any type of reorganization detectable by this technique. These four founder animals (1 male and 3 females) were crossed with hybrid mice C57b1/6J×balb/c of suitable sex and all transmitted the transgene to their descendants, it being possible to establish the corresponding transgenic lines.
Although described here for normal mice, the present invention is not limited to any given species of animal, but can be applied to any nonhuman species which provides a model of interest of human epidermis. For example, certain mutant mice characterized by a lack of hair, rabbits and hogs, to mention only a few, are animals in which transgenic skins of interest for man could be produced. Furthermore, as will be determined further below, the animals bearing the transgene KIV*.Z(8.8) can be good model systems for investigating substances and factors capable of stimulating the growth of hair. For these purposes, ewes would also be transgenic models of great interest.
Furthermore, other models different from the microinjection expressly described here can be used to produce transgenic animals, such as electroporation of DNA, transfection of DNA to embryonic cells, transfection of DNA to spermatozoa, etc.
Expression of the Transgene HIV*.Z(8.8) in Transgenic Mice
The activity of transgene in various tissues of transgenic mice was measured by visualizing in situ the amount of β-galactosidase produced by the cells of these tissues. For this, sections by freezing of 7-10 μm were incubated with X-gal in accordance with the method of Xothary et al., 1989, Development, 105:707, in such a manner that, depending on the amount of enzyme synthesized, the cells develop a blue color of greater or lesser intensity. For this, sections by freezing of 7-10 μm were washed with PBS and fixed for 5-20 minutes at 4° C. in 0.2% genteraldehyde in PBS. After being washed twice in PBS, they were incubated in the blue color developing mixture consisting of 0.04% a-chloro-5-bromo-3-indolylfl-β-D-galactopyranodium (X-gal, SIGMA), 1 mM MgCl 2 , 10 mm potassium ferrocyanide and 10 mM protassium ferrocyanide. The incubation was continued for 2-18 hours, depending on the intensity of the color developed.
As can be seen from Table I, in which there are shown the tissue studied in which β-galactosidase activity existed or did not exist, the constituent expression pattern of the transgene was very similar to that of K6 keratin (compare Table I with Quinlan et al., 1985 [op. cit.]). Not only was expression detected in the suitable stratified epithelial tissues but, in addition, within it, there were the suprabasal cells which dyed blue, in accordance with what was expected if their expression was to emulate that of keratin K6.
The interfollicular skin of various regions of the body, including the tail, were in all the lines negative, in accordance with what was expected. In order to verify whether in this case the transgene is induced in those regions of the epidermis subjected to hyperproliferative stimuli, retinoic acid and TPA was applied topically to the tail of transgenic animals of the different lines. For this, employing the protocol of Schweizer et al. (op. cit.), the tail of the animals was topically treated for a period of 14 days, either daily with 30 μg of all-trans-retinoic acid (retinoic acid) dissolved in 100 μl of acetone or every two days with 20 nmol of TPA in 100 μl of acetone. As an alternative, the expression of the transgene was examined in wounds in process of cicatrization produced by us on the ears or produced spontaneously by the anima is themselves on their sides. There was also studied the expression of transgene in skin tumors of the back produced chemically by initiation with DMBA and promotion with TPA (Yuspa and Poitier, 1988, Adv. Cancer Res. 50:25). In all these cases, there was observed a strong induction of blue color in the suprabasal cells of the skin involved, which developed hyperplasia; this color was not observed in the untreated surrounding regions which, therefore, had remained histologically normal. On the tails of the animals treated with retinoic acid, it was verified by bi-dimensional gels (O'FareIl et al., 1977, Cell 12:1133) that the induction of the blue color due to the transgene corresponded to the appearance of the endogenous K6 keratin. In order to determine at what moment of the treatment with retinoic acid the transgene was induced, the tails of seven mice of the same line were treated in the manner described above for 0, 3, 5, 7, 9, 11 and 14 days respectively. At the end of these times, the zone treated was removed from the tail under anesthesia. A portion of this tail was used for sectioning on a microtome and these sections were incubated in the presence of X-gal in order to observe whether a blue color developed. Tail skins of nontransgenic animals treated in the same manner were employed in order to extract RNA by the phenol/acid method as described by Chomezynski and Sacchi, 1992, Anal. Bioderm. 162:156). The total RNA thus extracted was analyzed by Northern type hybridizations in the following manner: 20 μg of RNA of each tail were subjected to electrophoresis in gels of 1% agarose, 1% formaldehyde and transferred to nitrocellulose filters in accordance with the method of Lerach et al., 1979, Biochemistry 16:4743. Thereupon, the filters were hybridized with a specific probe of the K6 keratin of mice (Finche et al., 1992, J. Invest. Dermatol.), radioactively marked, in a manner similar to that explained for the Southern type hybridizations described previously for the characterizing of the transgenic mice. It was observed that both the expression of the transgene visualized in the stainings with X-gal as well as that of the endogenous K6 keratin started after three days of treatment, both increasing progressively in parallel until reaching maxima on the ninth day of treatment. In other words, staining with X-gal of the skin sections of the transgenic mice of the invention developed a blue color which was detectable already at early moments of the treatment with retinoic acid and before a clear hyperplastic reaction appeared in the skin of the treated animals. This shows that the transgenic animals proposed in this invention as model system for the identification of agents which produce hyperproliferation of the skin, together with the method of detection proposed, constitute a very sensitive system which gives positive results with short times of treatment.
Another region of great interest in which expression of transgene was detected was in two parts of the hair follicle, namely the outer root sheath and the keratogenic zone of the bulb. In addition, in this latter zone, the blue color was only found in hair in early phase of growth, in anagen. This expression of the transgene in the keratogenous zone of the hair bulb as a function of the cycle was found in the hair of all the zones of the body investigated--tail, snout and trunk. Therefore, an additional property of this transgene would be its use in the detection of substances which stimulate the growth of the hair. The transgenic mice treated with these substances will have a greater density of hair with the keratogenous zone of the bulb capable of giving blue color. As an alternative, and based on similar reasoning, said transgenic animals can be used for the identification of substances which repress hair growth. The same type of reasoning can be applied to transgenic ewes with respect to the growth of wool, or any other animal of cattle of industrial interest.
Utility of the Transgenic Animals of the Invention
These animals can be used to identify agents which produce hyperproliferation in epidermis or protect against its appearance or cause it to regress once it has manifested itself. They may also be used in the identification of agents which alter, both positively and negatively, the growth cycle of the hair or the equivalents thereof in other species of animals, such as the wool of ewes.
The transgenic animals of the invention, together with the method proposed for detecting the transgene, constitute a sensitive, rapid model system. In addition to being based on the visualization of a molecular marker of easy detection, the method is, on the one hand, more objective and, on the other hand, simpler for the operator who carries it out than other methods commonly used to determine hyperproliferation, such as ones which count cell layers in the epidermis or judge the histological aspect of the cells of the basal layer and their cytoplasm/nucleus ratio, which methods require a high degree of experience and histological knowledge. Other methods of determining hyperproliferation used in the laboratory, such as the incorporation of radioactive thymidine by cells which divide actively are not very practical in a hospital or industrial context, due to their long length of time and the high degree of technical and practical specialization which they require on the part of the personnel which carries them out. Furthermore, in order to be able to be carry out the tests on the skin of the tail the animals suffer relatively little damage and it is not necessary to sacrifice them; furthermore, as only a small portion of the tail is required, a single animal can be used in more than one test. In the event that the tests are carried out on the skin of another part of the body, only a relatively small biopsy of the treated zone is required, the damage imparted to the animal being also only slight. And, since skin regenerates easily, one and the same animal can be used again for a long time.
Treatment and Detection
The agents to be investigated will be applied preferably topically on the skin of the animal, although they may also be ingested, injected or administered in any other more convenient manner.
In those experiments intended to determine the ability to produce hyperproliferation of a given substance, it will be applied topically either on the tail or on the back, preferably shaven. The induction of a blue color by incubation with X-gal of histological sections of the treated skin will be compared with similar sections of control animals treated only with the vehicle in which the substance being studied was dissolved. As an alternative, a positive control can be used, treating animals with retinoic acid or TPA following the protocols previously described, based on those used by Schweizer et al., 1987 (op. cit.).
If it is intended to check the possible hyperproliferation inhibiting or antiproliferative effect of a substance, the transgenic animals will be treated with this substance prior to or at the same time as another substance known for its ability to produce hyperproliferation, such as, for instance, TPA, retinoic acid, ultraviolet light, etc. The animals thus treated will be compared with other treated only with the hyperproliferation-producing agent. As an alternative, local hyperplasia will be induced in the transgenic animals by any known method or by any concrete object of study. Thereupon, a part of the animals will be treated with the substance the possible general concrete antiproliferative ability of which with respect to a given type of hyperplastic proliferation it is desired to determine. The rest of the animals will not be treated with this substance but will be left as controls with which the animals treated with the antiproliferative substance will be compared.
In order to study substances which may have an influence on hair growth, these substance will be applied preferably to the skin of the back. The density of hair showing, in histological sections incubated with X-gal, staining in the keratogenic zone of the bulb as compared with animals treated with the vehicle alone, will give a measure of the ability of the substance studied to stimulate or inhibit the growth.
In the case of both epidermal hyperproliferation and growth of the hair, there are model animals, in particular mutant mice (Lyon and Searle, 1989, Genetic Variants and Strains of the Laboratory Mouse, Oxford University Press--Gustav Fischer Verlag, publishers). In these cases, transgenic lines carrying the transgene KIV*.z(8.8) can be generated from these animals. Alternatively, the transgene could be transferred to mutant strains through suitable crosses with non-mutant strains carrying the transgene.
The method of detecting the activity of the agent under study will always be the visualizing of its action on the activity of the transgene. This visualizing will preferably be carried out by incubating histological sections of the skins of treated animals with X-gal, using the method previously described (see the section entitled "Expression of Transgene KIV*.Z(8.8 in transgenic mice"). Alternatively, if it is of interest to visualize the staining in larger zones, areas of several square millimeters can be surgically extracted and subjected to the same process of staining as the histological sections.
TABLE 1______________________________________SPECIFIC TISSUE EXPRESSION OF TRANSGENE pKIV*Z(8.8).______________________________________Epidermis: Back - Tail - Plantar skin +(suprabasal) Hair follicles +(external root and vibrissae sheath and keratogenic zone) Digestive Epithelia Oral cavity +(suprabasal) Tongue +(suprabasal) Palate +(suprabasal) Pharynx +(suprabasal) Esophagus +(suprabasal) Stomach +(transition between glandular and aglandular zone) Nasal Epithelium: + Others: Brain, liver, kidney, colon,) duodenum, pancreas, lung,) ) Negative muscle, thymus, bladder, ) connective tissue. )______________________________________ | A vertebrate, non-human transgenic animal whose cells, both somatic and germinal, contain a recombinant genetic construction formed of a marker gene and a regulator region capable of being induced in the epidermis of said transgenic animal in response to hyperproliferative stimuli, the genetic construction of which has been introduced into the animal or into an antecessor of the animal in an embryonic stage. The genetic construction is induced also in the bulb of the hair in the phase of active growth or anagen. The said genetic construction consists of a marker gene characterized by the fact that it is easily detectable, under the control of the regulator region of the gene of the K6 keratin, this protein being characterized by its ability to be induced in the suprabasal layers of the epidermis in response to hyperproliferative stimuli both endogenous (tumors, cicatrization of wounds, diseases which, such as psoriasis, produce hyperproliferation, etc.) and exogenous (topical treatments with retinoic acid, TPA, etc.). Therefore, transgenic animals carrying this genetic construction in their genome are useful in the identification of physical, chemical or biological agents which lead to epidermal hyperproliferation and growth of the hair, or inhibit these processes. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to video recording and playback, and more particularly relates to video recording discs and their playback.
2. Background Art
The videodisc is a storage medium for video information, on which video signals are recorded as spiral or circular tracks of indicia which are readable by way of electrical, optical, or other means. Videodiscs, in particular optical videodiscs which are readable optically by way of an imaged beam of laser light, offer enhanced playback flexibility as compared with video tape. To cite just one example, a videodisc player can be programmed to "search" for a particular frame or field of video, and that search can be effected quite rapidly as the imaged beam of laser light is easily moved in a radial direction across the full span of a disc much more rapidly than a video tape can be cycled from beginning to end even in a fast forward or fast reverse mode.
One limitation imposed by the videodisc, however, at the present level of technology, is in the amount of video information which can be stored on one "side" of a disc. Current optical videodisc standards provide for 54,000 circular or spiral tracks on a disc, with the innermost, limiting track carrying no more than two fields of video. Constant angular velocity ("CAV") discs, which are rotated at a constant angular velocity as they are played, carry two fields of video in each of the 54,000 tracks. Constant linear velocity ("CLV") discs, which are played at a varying angular velocity such that the linear velocity of the reading spot of light along any track on the disc is constant, carry a varying number of fields of video on each track, varying from two on the innermost track to six on the outermost track. The maximum permissable play time for a CLV disc is approximately one hour per side, while for a CAV disc the play time is limited to approximately one half hour per side.
Arrangements have been proposed to extend the play time of videodiscs. For example, U.S. Pat. No. 3,908,080, entitled "Method of Making an Extended Play Videodisc Record", which issued on Sept. 23, 1975 to Kent D. Broadbent, describes a system wherein only one of the video frames of a consecutive plurality of frames is recorded on a videodisc. The sound associated with the recorded video frame and with the omitted video frames is multiplexed and written on the disc track along with the recorded frame. On playback, the recorded frame is read repeatedly by the player a sufficient number of times to substitute for the omitted frames and each repeat is accompanied by the sound corresponding to the omitted frames, in proper sequential order. The system disclosed in the '080 patent provides a system by which the play time of a videodisc may be extended by a factor of two, three or more times. The system lends itself particularly well to applications wherein one frame is recorded on each spiral track revolution of the videodisc. In this way, the mechanics of repeating a single frame is rendered relatively simple, utilizing the standard technique of "freeze frame" videodisc playback.
However, the '080 patent system has limitations. For example, since whole frames are dropped, the maximum motion update rate is 15 per second. This gives marginal motion fidelity. In addition to this, whenever Field 1 and Field 2 of the frame being repeated are different, the transition between the fields is seen the same number of times the frame is repeated, exaggerating the jerking motion.
The present invention solves these problems, while permitting up to 2/3 of the video signals to be omitted, thus giving three times the normal play time for a videodisc.
SUMMARY OF THE INVENTION
The present invention resides in an improved long-play videodisc having a disc base of the type suitable for the recording thereon of spiral or circular tracks of indicia representing video signals. The disc base has recorded thereon a plurality of fields of video in each track revolution, each field being noncontiguous with each of the said fields adjacent thereto. The disc is played by reading a field of video, storing it, and playing it repeatedly a plurality of times.
The present invention is particularly useful in connection with a videodisc wherein bandwidth compressed video is recorded thereon such that four fields of video are recorded on each track, and wherein those fields comprise one out of every three fields of video from a standard segment of video. This arrangement allows for an expansion of the play time of a videodisc by a factor of six, thus permitting up to three hours of video program material to be recorded on a single side of a constant angular velocity disc. A novel arrangement permitting the playback of such a disc is disclosed herein.
Providing fields generally noncontiguous with each of their adjacent fields recorded therewith, and in particular replaying one out of every "N" field only of an otherwise standard segment of video, provides improved performance as compared with systems which provide complete frames taken from such otherwise conventional video. For example, such single-field repetition gives motion smoothness superior to repeatframe systems. Comparing a one out of three skip field with a one out of two skip frame system, the basic motion sampling rate of the skip field system is twenty times per second, as compared with fifteen times per second for the skip frame system. In addition, any transition between dissimilar fields is seen only once with the skip field system, preventing the fluttering motion discontinuity which is possible with the repeatframe system. The price for this improved motion fidelity would normally be a decrease in vertical resolution. However, in the one out of three skip field system, recorded fields alternate between "ODD-field" scan lines and "EVEN-field" scan lines, thus retaining information covering the entire normal TV vertical resolution. In a continuous running display, "full resolution" and "half resolution" frames will thus alternate, providing on the average, a twenty-five percent reduction in vertical resolution. As will be evident later in this description, this is the result of the fact that each field is displayed three times in a row. Therefore, every other displayed frame has two like fields, and every other intervening displayed frame has two different fields.
It will be appreciated from the foregoing that the present invention represents a significant advance in the field of videodisc recording and reproducing systems. In particular, it provides a convenient technique for increasing the effective storage capacity of a recording disc without substantial loss in reproduction fidelity. Other aspects and advantages of the invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram depicting the arrangement of fields on a videodisc constructed according to the preferred embodiment of the present invention.
FIG. 2 consisting of (A)-(D), is a diagram showing the arrangement in time of fields of video as they are read off of the disc shown in FIG. 1 as compared with the arrangement of fields of such video as they are replayed for viewing on a monitor or receiver.
FIG. 3 is a block diagram of circuitry which can be incorporated in a conventional player to permit it to play the videodisc shown in FIG. 1.
FIGS. 4(A)-(F) are signal diagrams of several signals generated by the circuits shown in FIG. 3.
FIGS. 5(A)-(D) are signal diagrams of further signals generated by the circuits shown in FIG. 3.
FIG. 6 is a block diagram of a portion of the circuitry shown in FIG. 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The preferred embodiment of the present invention involves the use of a CAV optical videodisc, in which four fields of video are stored on each spiral track. FIG. 1 is a diagram showing the arrangement of fields on such a videodisc 10. The disc 10 is conventional in all aspects except for the arrangement of the video information on the recording surfaces thereof. Thus, the disc has a central aperture 12 of conventional dimensions, and an annular recording surface on each side which extends from an inner circular boundary 14 to an outer circular boundary 16 near the edge of the disc 10. The disc 10 is played such that the reading spot of laser light advances around the disc in the direction depicted by arrow 18.
A standard, conventional CAV optical videodisc has two fields per revolution of the spiral track and is rotated at a rate of approximately 1800 RPM. This results in the video information being read off the disc at standard NTSC rate. In order to read the disc 10 of the preferred embodiment of the present invention at a rate which would cause the video information to be read off at standard NTSC rate, the disc rotation rate would be approximately 900 RPM. However, according to the principles of the present invention, the disc 10 is rotated at a rate of approximately 1500 RPM.
The reason for this difference is explained by reference to FIG. 2, which is a diagram showing the relationship between original fields of video selected (FIG. 2(A)), fields of video scanned on the disc (FIG. 2(B)), fields of video as they are actually regenerated to drive either a television monitor or receiver (FIG. 2(C)), and jump back pulses (FIG. 2(D)). Frames scanned on the disc are designated by reference numeral 20, while frames provided as output signals are designated by reference numeral 22. The diagram depicts a sequence of play of frames of a given spiral track, designated arbitrarily as track "A". The immediately preceding track is therefore designated "A-1", and the subsequent track "A+1". The first field on a track is designated by "F1", the second field by "F2", and so forth. Field "F1" corresponds to original video Field "OV1", Field "F2" corresponds to original video Field "OV4", and so forth. Original video Fields "OV2", "OV3", "OV5", etc. are skipped, that is, not recorded.
The fields which are recorded on the disc correspond to one out of every three fields of a standard NTSC video format program segment. In playback, a field is read off of the disc 10, digitized, stored, and then read out of storage three times in a row and converted back into an analog signal as it is read out of storage. During the last readout of a field from storage, the next field on the disc is read into storage so that the process can continue uninterrupted in cyclical fashion.
The disc 10 is rotated at a rate such that the reading beam of laser light scans 11/4 rotations, or tracks, in the time it takes to play three fields of video at NTSC rate. Thus, referring now to FIGS. 2B and 2C, it can be seen that during the third and final playback of the fourth field of track "A-1", Field 1 (F1) of track A is being stored in memory. The sequencing is arranged such that the first field of track A is completely stored just as the readout of the fourth field of track A-1 is completed, or shortly thereafter.
It will be appreciated that five fields of video on the disc are scanned in the time that it takes to play back each stored field of video three times. It will also be appreciated that the special rotation rate of the disc mentioned above makes this overlapping timing scheme possible.
Proper scanning of the reading spot of laser light along the spiral track is assured by the implementation of a Jump Back signal 23, shown in FIG. 2(D), which causes the spot of light to jump back to the immediately preceding track, immediately following storage of each field of video.
Audio is stored on the disc with each field as three channels of audio information, similar to the scheme of audio channel storage which is described in U.S. patent application Ser. No. 314,910, now abandoned in favor of related application Ser. No. 146,819, now U.S. Pat. No. 4,353,090 issued Oct. 5, 1982. With each separate playback of a field of video, a different one of the audio channels is played along with that video. The combination of all three channels provides the complete audio information for the playing of all three fields.
It will be appreciated that whereas conventional CAV discs presently have only two fields per track, in order to fit four fields of video on each spiral of the track, bandwidth compression of the stored video and audio is required, if the same size and spacing indicia are to be employed. In fact, the preferred embodiment of the present invention contemplates a bandwidth compression of two to one. Many conventional bandwidth compression techniques are available and may be used for this purpose.
FIG. 3 is a block diagram of circuitry constructed in accordance with the preferred embodiment of the present invention, usable in connection with a conventional videodisc player mechanism to permit playback of the optical videodisc shown in FIG. 1. The FM signal recovered from the disc is applied to a signal line 30, and is conveyed to a Demodulator and Sync Extractor 32 and to the input of a second, three channel Audio Demodulator 34. The Demodulator and Sync Extractor 32 demodulates the FM signal, and provides as outputs recovered Disc Video and Disc Sync, on lines 36 and 38 respectively.
It will be appreciated from the foregoing discussion that the timing of the Disc Video and Disc Sync is substantially equal to 5/3×NTSC rates. Thus, for example, the burst frequency of the Disc Video is approximately equal to 5.96 megahertz. Other rates, such as horizontal sync, follow the same proportion.
As in a conventional player, the Disc Sync on line 38 is applied to the Spindle Servo circuit of the disc player along with Disc Sync Ref, described below, and serves to ensure the proper rotation rate of the spindle, and thus of the disc, for the FM signal to be read off the disc at the proper rate. Disc Sync on line 38 is also applied to an Active Video Window Generator 42 and to a Load Gate and Jump Back Pulse Generator 44, both of which are discussed in further detail below.
Disc Video on line 36 is applied to a Video Sample Clock Generator 44 and to an A-D Converter 46. The Video Sample Clock Generator 44 generates a square wave Sample Clock signal at a rate equal to three times the burst frequency of the disc "color subcarrier", and phase locked to the burst signal. This Sample Clock signal is applied on line 48 to one input of an AND gate 50. The signal on line 48 is also applied to a Divide-By-150 device 52, the output of which is applied to one input of an AND gate 54. The output of AND gate 54 is applied to the SAMPLE input of a three port A/D Convertor 56, which is described in further detail below. The output of AND gate 50 is applied to the SAMPLE CONVERT input of A/D Converter 46.
The output of A/D Converter 46 is applied to a FIFO Register 58. The output of the FIFO Register 58 is applied to a Memory device 60. A handshake interconnection between register 58 and 60 is provided by way of Data Stored line 62 and Write Request line 64. The output of Memory 60 is connected to a Buffer Register 66, the output of which is connected to a Digital-To-Analog Converter 68. The output of D/A Converter 68 is applied to a Sync and Color Burst Insert circuit 70. The output of circuit 70 comprises recovered NTSC video.
The output of the Active Video Window Generator 42 comprises a series of pulses which are high during those portions of the Disc Video signal in which visual or data content video signals can occur, that is, excluding horizontal blanking intervals and that portion of the vertical blanking interval extending from line 1 through line 9. Although lines 10 through 20 of the vertical blanking interval do not contain visual content video information, they frequently do contain digitally encoded data signals. The output of circuit 42 is applied to one input of an AND gate 72, the output of which is connected to the other input of AND gate 50.
The Load Gate and Jump Back Pulse Generator 44 has two outputs. The first output, on line 74, is a Load Gate signal which is high only during the time when a field is to be read from the disc. It is applied to the other inputs of AND gate 54 and 72, and to the input of an Inverter 76, the output of which is applied to the WRITE ADDRESS RESET input of memory 60. The other output of generator 44 is a Jump Back pulse signal and is applied to line 78. This pulse is provided to the read spot jump back circuitry of the player which, in response thereto, causes the reading spot of laser light to jump back to the last preceding track, as is known in the art.
A Reference Timing Generator circuit 80 provides as an output a square wave reference pulse signal at the rate of the Disc Sync. This signal, Disc Sync Ref, is applied to line 82 which is connected to the Spindle Servo which utilizes it in the control of the rate of rotation of the spindle, as mentioned above. The Reference Timing Generator 80 also has an output, on line 84, which is the Video Memory Cycle Clock signal. This clock signal is a square wave pulse signal at the rate at which digital words are read out of Memory 60. During one third cycle of the clock the Memory 60 is enabled to read, while in the other two thirds of the cycle the Memory 60 is enabled to write, twice if necessary. In this way the Memory 60 is able to continue reading out the stored digital data during the last full field readout of that data, while at the same time reading into storage the digital data corresponding to the next field of video to be played. Such a Memory circuit 60 is known in the art.
Another output of Generator 80 is applied to a further line 86. This output is the Video Read Clock signal. This signal is also a square wave at the frequency at which digital data is read out of Memory 60. Line 86 is applied to the input of a Read Address Counter 88, which in response thereto counts cyclically from zero. The count output of counter 88 is applied to the READ ADDRESS input of Memory 60.
Generator 80 also provides as an output a vertical sync pulse signal ("V Sync") at NTSC rate, which is applied on line 90 to the RESET input of Counter 88.
Generator 80 also provides as an output, on line 92, a series of pulses corresponding to those portions of video omitted through the action of the Active Video Window 42. This output is the Insert Gate pulse signal.
Generator 80 also produces NTSC Comp Sync and Color Burst, which are output on a further line 94. Lines 92 and 94 are applied to the Sync and Color Burst Insert circuit 70, wherein the NTSC Comp Sync and Color Burst signals are inserted into the Analog Video from the Digital-to-Analog Converter 68.
The Disc FM on line 30 is, as mentioned above, applied to a three channel Demodulator 34. This Demodulator 34 demodulates the three audio channels mentioned previously and applies them separately on three different lines 96 to the three port A/D Converter 56 mentioned above. Each of the three channels of audio is digitized by A/D Converter 56 and the separate outputs thereof are applied by way of lines 97 to a FIFO Register 98. The output of the FIFO Register 98 is applied to the input of an Audio Memory 100, which is analogous to Memory 60. The output of Audio Memory 100 is applied to a Buffer Register 102, the output of which is applied to a Digital-to-Analog Converter 104. The output of D/A Converter 104 comprises the audio output.
Timing Generator 80 provides as an output an Audio Read Clock signal pulse on a line 106 which is applied to the COUNT input of an Audio Read Address Counter 108. Likewise, the load gate signal conditions the next reset to also reset the channel port of the READ ADDRESS to the first channel so that the audio channels may be properly sequenced for readout. V Sync is applied to the RESET input of Counter 108. The COUNT output of Counter 108 is applied to the READ ADDRESS input of Audio Memory 100, while the square wave output of Counter 108 is applied to the READ STROBE input of Audio Memory 100.
Timing Generator 80 also has as an output on line 112 an Audio Memory Cycle Clock signal. This signal, like the Read Write Cycle signal on line 84 provides for interlaced writing and reading.
The circuit shown in FIG. 3 operates as follows. The Disc FM on line 30 is applied to the Demodulator and Sync Extractor 32 which extracts Disc Sync and applies it on line 38 to the Spindle Servo 40 along with the Disc Sync Reference signal on line 82, as mentioned above. The Disc Video is applied on line 36 to the Video Sample Clock Generator 44 which generates a Sample Clock referenced to the burst frequency of the Disc Video. The Disc Sample Clock signal is gated through AND gate 50 and applied to the Sample Convert input of A/D Converter 46. The arrangement of Load Gate and Jump Back Pulse Generator 44, Active Video Window Generator 42, AND gate 72 and AND gate 50 cause the Sample Clock pulses on line 48 to be applied to the A/D Converter 46 only during those portions of active video when the reading beam of laser light in the player is scanning a field to be read and stored.
FIG. 4 aids in understanding the timing described in connection with the SAMPLE CONVERT input of A-D converter 46. FIG. 4 (A) is a signal diagram showing the output of the Active Window Generator 42. As can be seen, the signal is low during pulses 200, corresponding to horizontal blanking intervals, and from the beginning of vertical blanking through line 9 within the vertical blanking interval.
FIG. 4 (B) shows the output on line 74 from the Load Gate and Pulse and Jump Back Pulse Generator 44. That output is high during the entire time in which a field of video is read off of the disc 10 (FIG. 1). The Jump Back Pulse output on line 78 is identical to that on line 74, with the difference that when a stop motion command is received on line 75 the output on line 74 is disabled, and only the Jump Back pulse output is provided. Details of the circuitry in the load gate and jump back pulse generator are provided below in connection with FIG. 6.
FIG. 4 (C) shows that the Video Sample Clock Generator output is a continuous series of pulses at three times the rate of the Disc Video "color subcarrier" burst frequency.
The SAMPLE CONVERT input of A/D Converter 46 is shown in FIG. 4 (D).
Digital words are generated in the A/D Converter 46 at the rate the pulses are provided to the SAMPLE CONVERT input thereof, and are applied to FIFO Register 58. From FIFO Register 58 they are loaded in a conventional handshake operation into memory 60, as memory write time becomes available. Memory 60 has an internal write address generator which operates in conjunction with the handshake operation just described, and the internal write address is reset to zero following the complete storage of a field. The digitized words of video information are thus stored sequentially in memory 60 starting with address zero.
The combination of the Reference Timing Generator 80 and Read Address Counter 88 cyclically generate a series of pulses for Memory 60 readout corresponding to the pulses controlling the Memory 60 write operation, however bearing a timing relationship thereto of 5 to 3, and synchronized so that the zero address of the Read Address Counter 88 is generated before the last word of digitized data is converted by A-D Converter 46. A slight delay will occur before the last word of digitized data is stored into Memory 60 following the last conversion of that video data, due to the time sequence in the storage into register 58 and the above-described handshake operation to store the digitized data into memory 60. This does not, however, affect the performance of the system, but rather provides "slack" to the system and thereby helps to relieve the criticality of the relative timing between writing and reading to and from memory 60.
It will be appreciated that the continuous recycling of memory 60 allows for a "freeze-field" video picture image to be maintained, even when the player is "searching" or "seeking" a new track of data and cannot write new data into Memory 60. It will also be appreciated that because the Video Sample Clock Generator 44 is phase locked to the Disc Video burst signal frequency, and the Read Clock is referenced to generator 80 which generates NTSC synchronized signals, that the circuit of FIG. 3 provides automatic time base correction intrinsically in the process of sampling, storage, and readout. In fact, no further time base correction should be necessary for most purposes.
FIG. 4 (E) shows the read clock output signal.
The D/A Converter 68 converts the digital output from Memory 60, buffered by way of Buffer Register 66, into analog video. Because of the gating action of the Active Video Window Generator 42 and AND gates 72 and 50, the converted analog video output from D/A Converter 68 has "holes" in it during the horizontal blanking intervals and a portion of the vertical blanking interval. The insert gate signal on line 92 is a series of pulses corresponding to those "holes". They provide windows for the Sync and Color Burst Insert circuit 70 during which NTSC comp sync and color burst on line 94 are inserted in those holes in a conventional manner.
An analogous process of demodulation, storage and readout is performed by the circuitry comprising Demodulator 34, A/D Converter 56, FIFO Register 98, Audio Memory 100, Buffer Register 102, and D/A Converter 104. Sampling is done at a rate 150 times slower than that of the video sampling, by virtue of Divide-By-150 device 52. The Sample Clock is gated against the load gate output from Generator 44, by way of AND gate 54. However, since the audio is "active" throughout the field, no window generators are provided, nor are any reinsert circuits provided. In read-out, Audio Memory 100 simply cycles cyclically through the digitized stored audio data of channels 1, 2, and 3, respectively.
FIG. 5 is a signal diagram which aids in understanding the relationship of signals utilized in connection with the audio recovery and playback function of the circuit shown in FIG. 3. FIG. 5(A) shows the Load Gate signal found on line 74. FIG. 5(B) represents the Sample Clock output from device 52. FIG. 5(C) shows the output of AND gate 54 which is applied to the three part A/D Converter 56. It will be appreciated that the signal represented in FIG. 5(C) is merely the Divide-By-150 52 output gated against the Load Gate output on line 74.
FIG. 5(D) shows the Audio Read Clock which is a continuous pulse train provided at a frequency substantially equal to 3/5 times the Divide-By-150 52 Sample Clock output shown in FIG. 5(B), approximately 70 kHz.
FIG. 6 is a circuit diagram of the Load Gate and Jump Back Pulse Generator circuit 44 of FIG. 3. Line 38, which carries Disc Sync from the Demodulator and Sync Extractor 32 (FIG. 3) is applied to the input of a Vertical Sync Extractor 202. The output of the Vertical Sync Extractor 202 is applied to a Count-To-Four Counter 204. Line 75, carrying the stop motion command signal, is connected to the LOAD VALUE input of Counter 204, and to the input of an Inverter 206. The output of Inverter 206 is connected to the input of an AND gate 208. The Carry output of Counter 204 is connected to the other input of AND gate 208 and to the LOAD ENABLE input of Counter 204. The output of AND gate 208 comprises line 74, and the Carry output of Counter 204 comprises line 78.
In operation, the circuit shown in FIG. 6 operates as follows. V-Sync is extracted from the Disc Sync on line 38 and is applied as a pulse input to Counter 204. In the absence of a stop motion command signal, line 75 is low, and consequently Counter 204 counts from zero up to four, i.e., a count of five. With line 75 low, the output of Inverter 206 is high, and thus the Carry output of Counter 204 is passed directly to line 74. The signal contents of lines 74 and 78 are thus substantially identical, as mentioned above.
With each pulse output at the Carry output of Counter 204 the LOAD ENABLE input of Counter 204 is activated and the value on line 75 is loaded into the counter. If a stop motion command is present on line 75, the load value is a 1. In that case, Counter 204 is thus a four count counter, and Inverter 206 provides a low level signal to one input of AND gate 208, thus blocking an output from line 74, yet providing for a trip back once around each revolution of the disc, keeping it from advancing to new tracks.
It will be appreciated that the invention described herein represents a significant advance in the field of video recording generally, and more particularly in videodisc recording and reproducing systems. The invention provides for the production of disc video programs with significantly longer program times than would otherwise be obtainable, and makes efficient use of the storage space on a disc by eliminating redundant video information from the original program, all without significant loss of program content. In addition, it provides a similar technique for recording a continuous audio information signal, and recreating the continuous audio signal during the reproduction phase. It will also be appreciated that, although a specific embodiment of the invention has been described in detail for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited except as by the appended claims. | An extended play videodisc and a method and apparatus for playing it. The disc carries every m th segment of a video program and the segments are repeated m times to approximate the original program. Prior art extended play discs have contained every other frame or every third frame of video, but the repeating of an entire frame results in poor motion reproduction and flickering scene transitions. The present invention preferably includes the repeating of a field of video an odd number of times. The fields are preferably arranged in order on the disc with n fields per revolution, the disc being rotated such that a new field is read every one and 1/n th revolution of the disc. The new segment is preferably read during the final repeating of the previous segment. | 7 |
TECHNICAL FIELD
This invention relates to antireflective microtextured surfaces. It further relates to microtextured antireflective polymeric films and resins. The present invention also relates to polymeric films that may be attached, adhered, or otherwise disposed onto optically transparent substrates to enhance their visual properties. Further, the present invention relates to methods for producing surface structures with gradient change of index of refraction. The invention also relates to the fabrication of large area, visually seamless microtextured surfaces.
BACKGROUND OF THE INVENTION
A need exists for an antireflective treatment that is characterized by extremely low reflectance and high transmittance over a broad wavelength band, even at high angles of incidence. Additionally, it must be cost effective, flexible, and able to cover large areas. Such a solution would be particularly useful as an easily distributed antireflective treatment that may be applied onto glazing materials for the picture frame industry, TV screens, personal handheld devices, cellular phones, shop windows, and other applications.
Optical coatings involving either single or multiple thin layers are well known in the prior art for antireflective purposes. This technique uses destructive interference from the interfaces between materials of different indices of refraction to reduce the overall reflectance. Production of such thin film treatments requires constant effort to maintain coating thickness and composition uniformity, and therefore they are difficult to form on large surfaces. Thin film antireflective coatings (AC) have traditionally been reserved for high-end optics, since they can have excellent optical properties, but have yet to be manufactured cost-effectively. For example, the optical characteristics of a single layer AC are highly sensitive to the wavelength, and have narrow angular acceptance. To get broadband and wide angular acceptance, an antireflective coating with multiple layers should be employed. However, that dramatically increases associated technical problems and significantly raises the cost.
The requirement for inexpensive solutions was understood many decades ago. Adams U.S. Pat. No. 2,348,704 describes a two-step acid etch process used to reduce the reflectivity of glass. The result of the acid etch was the formation of a microscopic network of pores, or skeletonized structure, in a thin layer near the surface of the glass. Precise control of the thickness of this porified layer allowed it to serve as a thin film of intermediate index in analogy to conventional optical coatings. Recently, a similar acid etching method has been proposed by Zuel et al. U.S. Pat. No. 5,120,605 to produce an antireflective treatment on glass that potentially can be used for large areas. It describes a method for a high-throughput treatment that results in a textured glass surface consisting of a distribution of islands and a superimposed porified layer. While relatively cost effective compared to vacuum deposited thin films, such acid etched solutions are limited to rigid glass substrates only and therefore the final product lacks flexibility.
Another class of inexpensive solutions, with potential cost reductions beyond even the acid etching techniques, involves replication of a texture into a plastic. Maffitt et al. U.S. Pat. No. 4,114,983 describes a method for production of a polymeric element with antireflective microstructured surface comprising a four-step process. Those steps include (1) creation of a master surface relief via a two step etch process in glass, (2) galvanic replication on the glass surface to create a durable metal stamper, (3) stamping into a heated thermoplastic material to transfer the surface relief into the plastic, and (4) release of the plastic element from the stamper. Essentially, the Maffitt patent teaches replication of an acid etched antireflective glass texture into a plastic optical element. However, the acid etched porified surface is not ideal for replication because the surface profile may have overhangs and voids that inhibit release, or cusps that break off during release, resulting in loss of fidelity with each replication. This leads to a reduction in the antireflective performance of the replicated polymer.
Polymeric materials not only serve the requirement of cost-effectiveness, but may also be employed to provide flexible antireflective solutions. Allen et al. U.S. Pat. No. 4,333,983 discloses the use of a thin layer of aluminum oxide to form the adhesion layer between a pliable polymer substrate and a thin dielectric optical coating. The result is a flexible antireflective film for applications that do not require very high performance optical coatings. The Allen patent asserts that such a polymer antireflective film can be inexpensively distributed, since a manufacturer wishing to add an antireflection coating to an optical element can simply purchase the film, cut it to desired geometry, and then apply it to the article. With the advent of dual magnetron sputtering technology, as described by J. Strümpfel et al. (40th Annual Tech. Conf. Soc. of Vacuum Coaters, New Orleans, 1997), large area uniform coatings on polymer webs are possible. However, this technology attains antireflectivity in the same manner as thin film optical coatings, and therefore is still subject to limitations in band performance and angular acceptance. In addition, mechanical integrity due to cracking and separation of layers remains an issue, as well as the cost of manufacturing.
Rather than providing a deposited or sputtered optical coating, the polymer film may be provided with a microtextured surface to achieve the antireflective properties. Schroeder et al. U.S. Pat. No. 5,820,957 discloses an optically transparent polymeric film with textured surface, and an adhesive on the backside. The textured surface functions to diffuse incident light to a degree sufficient to reduce specular gloss. This patent describes a process of very inexpensive replication, potentially much cheaper than magnetron sputtering. To be specific, the Shroeder patent describes an antiglare texture, but the described replication principle can also be applied to antireflective surfaces. That is, the textured film of the patent receives the texturing by casting, imprinting, or embossing from a previously textured master. Thus the properties of the master texture are essential to the optical behavior of the replicated film. This leads back to the problem inherent in the Maffitt patent, i.e. what is a desirable surface profile for the antireflective master to obtain high optical quality and efficient replication?
Clapham and Hutley U.S. Pat. No. 4,013,465 describes a method to produce antireflective textured surfaces that are broadband with large angular acceptance. The microtexture is characterized by a surface covered with a regular array of conical protuberances, where the feature sizes of the tapered protuberances are in general sub-wavelength. Such surface profiles are known in the art as “moth-eye” antireflective surfaces, since Bernhard (Endeavor 16, p. 76-84, 1967) first noticed that the eyes of night flying moths were covered with an array of sub-wavelength protuberances, and hypothesized that the function of this profile was precisely to reduce the reflectivity of the eyes of these moths making them less detectable to predators. The moth-eye microtexture acts effectively as a gradient index layer, and therefore has excellent antireflective properties when compared to multilayer thin-film coatings.
The moth-eye profile has an advantage over other textured surfaces, such as those produced by acid etching, in that it possesses a very smooth profile free of overhangs, voids, or cusps that could lead to degradation during the release phase of polymer replication. Thus a single moth-eye master can generate a multitude of daughter surfaces with very little loss of fidelity. Despite all the benefits of the moth-eye antireflective surface, a reliable and cost effective method for producing moth-eye textures over large areas with high uniformity has not been developed.
The Clapham and Hutley patent suggests a photo-exposure method to produce the moth-eye microtexture. The patent further discloses the specific technique of interference lithography that involves interfering multiple beams of coherent light, to create the moth-eye profile. The distinct benefit of this technique is that it yields relatively high contrast sub-wavelength intensity variations. However, it is known that interference lithography has some drawbacks. For example, the optical system that generates the interference pattern must be very stable in space and time. Difficulty in meeting the requirement of stability leads to reduction in the reproducible yield of high quality exposures. A more serious drawback is the difficulty with achieving large areas of spatial uniformity in the pattern, as any non-uniformity in the spatial distribution of the light intensity of the laser beams will be recorded in the pattern. Therefore, there is a need for another technique that is capable of fabricating microtextured surfaces which are similar to the moth-eye patterns produced by interference lithography, but have greater uniformity and are more amenable for scale-up to large areas.
Another limitation of interference lithography is the strict periodicity of the pattern generated by this technique. In order to add arbitrary non-periodic features to the surface profile, additional fabrication steps must be introduced to the process. Gombert et al. U.S. Pat. No. 6,359,735 describes a two-step process that combines a periodic moth-eye pattern with a randomized rough surface. In this patent, the periodic moth-eye pattern is written using interference lithography, while the non-periodic portion is achieved with a separate step, such as sand blasting, mechanical grinding, or exposure of photoresist to a laser speckle pattern. A new method for creating antireflective microtextured patterns that was not limited to strictly periodic patterns would simplify this process. This new method might also enable the fabrication of quasiperiodic patterns whereby the distribution of protuberances do not fit on a perfectly regular grid, but deviate from periodicity in a subtle, but precise way. A quasiperiodic microtextured surface may have desirable optical properties distinct from either periodic or completely random microtextured surfaces.
A new technique is proposed in this invention for the fabrication of antircflective surfaces. This technique enables the production of microtextures that have the following features: effective antireflectivity over a broad wavelength range, wide angular acceptance of incident light, pliability, ease of patterning non-periodic or quasiperiodic features, ease of scalability to large areas, high manufacturing yield, and low production cost.
SUMMARY OF THE INVENTION
The object of this invention is to provide a method for forming antireflective microtextured surfaces that involve exposing a photosensitive material with UV radiation through a photolithography mask, or in short ‘photomask’. The photomask can be a binary screen mask, a phase shift mask, or their combination. The key inventive concept is the use of the photomask to spatially modulate the intensity of the UV radiation. Photomasks have been used extensively in the semiconductor industry to write microelectronic circuits of ever decreasing physical dimension. However, the photomask has thus far been overlooked regarding the fabrication of antireflective microtextures that are effective for visible light. In accordance with the object of this invention, it is shown that the photomask is a tool well suited for the fabrication of a specific class of surface relief profiles that possess excellent antireflective properties and also ease of replication.
The use of the photomask allows good control over the microscopic details of the surface profile since the light intensity distribution depends precisely on the optical properties of the photomask apertures and phase shifters. Further, the photomask provides greater freedom in pattern design since the arrangement of apertures and phase shifters are subject to few constraints. Thus, another object of this invention is to provide a method for patterning that, compared to methods in the prior art, allows greater freedom in the specification of the antireflective profile, yet more control over the actual fabrication of the specified rmicrotextured surface.
It is still another object of this invention to provide a method for creating large-area antireflective microtextured surfaces that are effectively seamless and free of defects. The use of the photomask is particularly suited for scaleup processes that involve step-and-repeat procedures, due to the uniformity and reproducibility of the individual exposure fields that make up the larger pattern. Alternatively, photomasks are routinely manufactured in large-area geometries of high uniformity and quality. Therefore the method of forming large-area surface relief profiles may simply start with procurement of a large-area photomask.
The method of using a photomask for fabricating large-area microtextures enables the production of high quality surfaces profiles that may be efficiently replicated to produce effective and inexpensive antireflective treatments. Additional objects, features and advantages of the invention will become apparent from a consideration of the included drawings and ensuing detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A shows the isometric view of a non-periodic engineered array of protuberances (EAP).
FIG. 1B shows the side view, with a cross-sectional cut, of the non-periodic EAP structure shown in FIG. 1 A.
FIG. 2A shows the isometric view of an ordered EAP arranged in a square lattice.
FIG. 2B shows the side view, with a cross-sectional cut, of the ordered EAP structure presented in FIG. 2 A.
FIG. 3 is a curve showing the simple bright-field modulation transfer function (MTF) for a periodic structure.
FIG. 4 is a schematic drawing of the transformation of a square illumination pattern, defined by a binary mask, into a sinusoidal pattern projected onto an aerial surface.
FIG. 5 is a schematic diagram (plan view) of an example dark field mask with a square array of sub-wavelength apertures.
FIG. 6 is a schematic diagram (plan view) of an example dark field mask with a quasiperiodic array of sub-wavelength apertures.
FIG. 7 is a schematic diagram (plan view) of an example dark field mask with a square array of sub-wavelength apertures coupled to 180 degree phase shift elements.
FIG. 8 is a schematic diagram (cross section) of an example light-coupling mask combined with phase shift elements, for contact sub-wavelength lithography.
FIG. 9 is a schematic diagram (cross section) of an example metal embedded mask with phase shift elements, for contact sub-wavelength lithography.
FIG. 10 is a schematic diagram (cross section) of an example embedded phase shift attenuated mask for contact sub-wavelength lithography.
FIGS. 11 and 12 are curves schematically illustrating the electric field (dashed lines) and light intensity profiles (solid lines) for a simple phase shift mask, and for a phase shift attenuated mask, respectively.
FIG. 13 is a schematic diagram illustrating, in cross section, a contact lithography technique where a sub-wavelength mask itself serves as the substrate for contact lithography, and exposure is performed by illuminating the back side of the mask.
FIG. 14 is a cross sectional schematic diagram illustrating the transfer of an engineered array of protuberances from developed photoresist into an underlying substrate. The photoresist itself acts as an etch screen mask for the substrate.
FIG. 15 is a cross sectional schematic diagram illustrating a two-step process for the transfer of an engineered array of protuberances from developed photoresist into a final underlying substrate, which involves etching an intermediate layer of chrome, silicon dioxide, or other suitable material.
FIGS. 16A , 16 B and 16 C are cross sectional schematic diagrams, which together illustrate a method to shield the surface structure of an antireflective film with a protection layer during the attachment of the film to a substrate.
DETAILED DESCRIPTION OF THE INVENTION
The method of this invention for producing an antireflective treatment may be described as comprising three major steps: (a) mastering, (b) replication, and (c) distribution. In the context of this invention, ‘mastering’ refers to the process of generating a large area defect free microtextured surface relief in an arbitrary substrate. ‘Replication’ refers to the process of transferring the surface profile onto a material with the desired optical and mechanical properties thereby forming an antireflective treatment. ‘Distribution’ refers to the process of applying the replicated microtextured material onto an optical component to create a consumable antireflective product. The inventive method disclosed herein primarily addresses the mastering process. Since all three steps are interrelated, the details of the inventive mastering have ramifications that affect the performance of the final replicated and distributed antireflective treatment.
The inventive mastering process enables production of a microtextured surface that consists of an engineered array of protuberances (EAP) that has excellent antireflective properties. The EAP microtextured surface is characterized by an array of microscopic protuberances arranged in a pattern that may be periodic, quasiperiodic, or arbitrarily non-periodic. FIG. 1 A and FIG. 2A show examples of EAP structures with a non-periodic array and a periodic square array, respectively. The EAP microtexture represents a generalization of prior art antireflective surfaces fabricated by interference lithography, which were limited only to strictly periodic arrangements of protuberances. The increased freedom in pattern geometry afforded by the inventive process may have distinct advantages for antireflective performance. In particular, the use of quasiperiodic microtextured surfaces (QPMS) as antireflective microtextures has not been adequately explored in the prior art. The concept of the EAP microtexture extends to a non-periodic pattern of protuberances, which in general refers to a specific engineered array that may have desirable visual properties impossible with a more ordered array. For instance, the protuberances may be flattened in regions of the surface to draw characters or logos that will appear slightly more reflective than the surrounding area.
The profile of the EAP microtexture must conform to specific design rules to meet the requirements of a high-quality antireflective surface. FIG. 1 B and FIG. 2B show profiles of a non-periodic and a periodic EAP structures. Consider an antireflective texture that is optimized for the waveband from the lower wavelength λ a to upper wavelength λ b with a maximum reflectance in the waveband of R max . The EAP microtexture must act in the regime of the effective index approximation in order to avoid prominence of diffracted beams. Therefore, the distance between neighboring protuberances must be on the order of, or smaller than, λ a divided by the refractive index of the substrate. Further, the protuberances must be tapered such that the EAP can mimic a gradient index material. The protuberances must have a height h that is greater than ⅓ of λ b for the gradient-index to act effectively in suppressing reflectance. According to prior art, such materials are effective to reduce the reflectance over wide angles of incident light. Finally, the shape of the protuberances must be smooth profiles, free of cusps, overhangs, or voids that would inhibit easy release of materials that are coated onto the master. This is essential to facilitate efficient replication of the microtexture. These geometric requirements for an EAP microtexture are achievable by the inventive process that uses a photolithography mask to pattern the microtextured master.
Mastering Using Photolithography Mask
One of the embodiments of this invention is a method of obtaining an engineered array of protuberances (EAP) in photoresist. The first step is to pattern the microtexture into photoresist. The photoresist is exposed through a photomask in such a way that the light intensity profile closely resembles the desired engineered structure, which may be a regular array of protuberances, the QPMS, or a non-periodic structure. The following two) approaches: ( 1 ) projection photolithography or ( 2 ) contact photolithography can be used for mask exposure.
Approach I: Projection Photolithography.
Projection photolithography requires a photolithography projection tool, sometimes called a projection aligner or mask aligner, with a reticle comprised of a binary mask, a phase shift mask, or their combination. The required light intensity profile is formed in photoresist by optimization of the modulation transfer function (MTF). The MTF depends on the numerical aperture (NA) of the aligner lens, illuminating wavelength, and spatial coherence of the light source. An aligner with ultraviolet light below 250 nm, typically referred to as DUV, should be employed in conjunction with a high NA lens to obtain optimal contrast at feature sizes below 300 nm.
The approach described below assumes the general case of a ZX-aligner tool with 1:Z reduction factor. For instance, for a 5X aligner (Z=5), a periodic pattern with period 1250 nm defined in the reticle (the object plane) will be reduced to the period 250 nm in the image plane.
The modulation transfer function of an aligner can be approximated by the bright-field MTF for an optical system with a uniformly illuminated circular aperture:
MTF =( I max −I min )/( I max +I min )=2(φ−cosφ·sinφ)/π,
The dependence is shown on FIG. 3 . Here cosφ=λf i /2NA, where λ is the light wavelength, and f i is a spatial frequency defined as the number of lines per unit length in the image plane. The MTF vanishes at the critical frequency f ic =2NA/λ. In order to take into consideration the reduction factor Z and deal with the dimensions and spatial frequencies, f o , defined in the reticle, i.e. in the object plane, we can modify the latter expressions as cosφ=Z·λ·f o /2NA, where f i =Z·f o , and the critical frequency f oc =2NA/λ·Z).
The point spread function (PSF) is another useful figure of merit to characterize the quality of an optical system, and its Fourier transformation is related to the MTF function. The PSF is defined as an image of a point source. The image of an arbitrary pattern, then, can be presented as a convolution of the PSF and the pattern. FIGS. 1 and 2 show the EAP structures obtained by such an approach. Each protuberance is approximated by a PSF function. When two points in the image plane are closer than the width of the PSF, the intensities overlap significantly leading to a reduction in contrast. The PSF approach is convenient for consideration of the contrast variation in non-periodic patterns. While MTF concept is more convenient for consideration of periodic patterns.
The MTF for a periodic pattern is also called the contrast transfer function. The spatial frequency f o of a periodic structure (grating) defined in the object plane with a period Δ o , FIG. 4 , can be expressed as f o =1/Δ o . The critical grating period in the object plane is defined correspondingly as Δ oc =Z·λ/2NA. And the critical grating period in the image plane is defined as Δ ic =λ/2NA. The aligner optical system is not able to image the grating with the period smaller then Δ oc .
One specific embodiment of the EAP structure consists of a microstructure with sinusoidal profile. Fortunately, this is easily achieved with the projection lithography technique due to the fact that the image of a binary periodic pattern defined in the reticle with the frequency f sq and period Δ sq is sinusoidal, when 0.5 f oc <f sq <f oc , or Δ oc <Δ sq <2·Δ oc , FIG. 4 . Indeed, a periodic square function with some duty cycle and period 1/f sq can be decomposed into a Fourier series with frequencies f sq , 2f sq , 3f sq . . . . All multiple frequencies above f oc will be filtered out by the aligner's optical projection system leaving only one frequency f sq , similar to the effect of a low pass frequency filter. The same can be understood using the PSF approach. The intensity profile of an aperture image has a PSF like shape if the aperture size, d aperture <2·Δ oc . In other words we can say that only one PSF width is required to image the aperture. For a periodic pattern the requirement on the aperture size is more strict: d aperture ·Δ sq , because the aperture size is limited now by the grating period. If the period of the grating of apertures, Δ sq , is so small that each aperture is imaged by only one PSF, then a sinusoidal like profile of the light intensity is formed in the image plane. Indeed, we can see that effect in FIG. 2B , where each protuberance is approximated by a PSF function but their combination appears sinusoidal. In the case of a non-periodic pattern the distance between two close neighbour apertures, d neigh , should be within the following constraints: Δ oc <d neigh <2·Δ oc . This is to insure that there are no flat regions in the intensity profile.
EXAMPLE 1
A typical period of the periodic EAP structure for visible light is 250 nm. By visible light, we mean electromagnetic radiation with wavelength in vacuum in the range from 390 nm to 800 nm. An aligner with NA=0.65 and DUV source wavelength λ=248 nm will give in the image plane Δ ic =191 nm, f i /f ic =0.76, and MTF=0.14. A similar aligner with NA=0.75 gives Δ ic =165 nm, f i /f ic =0.66, and MTF=0.23.
Special contrast enhancement techniques like oblique off-axis illumination, single-sideband technique, and other aligner specific techniques can significantly increase the value of the modulation transfer function. A phase shift mask, or a binary mask combined with phase shift elements can be employed to increase the contrast of the image as well. Examples of phase shift masks are given below in the context of contact lithography.
Another way to increase the modulation transfer function is to reduce the exposure wavelength.
EXAMPLE 2
An aligner with NA=0.65 and DUV light source λ=193 nm gives a critical period in the image plane Δ ic =148 nm. Thus for the 250 nm period EAP structure, we have f i /f ic =0.59, and MTF=0.3 or 30%. That is much better than 14% for the light source with Δ=248 nm (see Example 1).
Some of the contrast enhancing techniques mentioned above may be combined together to further increase the contrast enhancing effect.
The photoresist non-linearity, developer concentration and temperature, and developing time can be used to optimize the resulting profile.
Approach II. Contact Lithography
A subwavelength mask in contact mode can be used with DUV to get the intensity profile of the EAP with a nearest neighbor spacing less than 250 nm. Only light of the zero diffraction order passes through the sub-wavelength aperture. The light has maximum intensity at the center of the aperture provided that incident light is perpendicular to the aperture plane. The intensity of light drops toward the edges. It also decreases forward from the aperture because the light beam quickly diverges with the distance. A smaller aperture creates wider beam divergence, and conversely a larger aperture creates a less divergent beam. An engineered array of sub-wavelength apertures is used to create the intensity profile of the EAP. The type of photoresist (positive or negative), photoresist non-linearity and the developer should be adjusted to obtain the profile of the desired shape. A typical example of a dark field chrome binary mask 20 with square array of sub-wavelength circular apertures 21 is presented on FIG. 5 . Additionally, non-periodic or quasi-periodic patterns (as in FIG. 6 ) of sub-wavelength apertures 22 in a binary mask 23 can be used to get corresponding non-periodic patterns of conical protrusions in the photoresist.
To increase the contrast one can employ a phase shift mask (PSM), or a binary. mask combined with a phase shift mask. An example of such a composite mask 24 is presented on FIG. 7 . It shows a dark field mask with a square array of circular sub-wavelength apertures 25 and 26 , where open circles do not introduce any phase shift 25 , and where the shaded circles introduce 180 degrees phase shift 26 . Apertures might have an arbitrary form, for instance: square, elliptical, or other. Other examples of composite phase shift masks include light-coupling masks (LCM) as in FIG. 8 , which comprises a metal-embedded mask 27 and a phase shift mask 28 . Another example is a metal-embedded mask (MEM) 29 with phase shift elements 30 as in FIG. 9 . FIG. 10 presents an example of an embedded attenuated phase shift mask (AttPSM) 31 with phase shift elements made of molybdenum silicide 32 .
The effect of a phase shift mask that employs 180 degrees phase shift elements is shown schematically in FIGS. 11 and 12 . The electric field distributions are indicated by dashed lines, and the light intensity distributions are indicated by solid lines. A phase shift metal mask corresponds to FIG. 11 and an attenuated phase shift mask corresponds to FIG. 12. A sub-wavelength mask thus includes a binary mask, a phase shift mask, or a combination of a binary mask with a phase shift mask
Contact lithography can employ a flexible mask made of a polydimethylsiloxane (PDMS) flexible membrane or similar membrane with a shorter cut-off transparency wavelength. With a flexible mask, contact between the mask and photoresist over the entire substrate is achieved by applying air pressure to the flexible mask. Therefore the mask conforms to any gentle undulations or other deviations from planarity of the surface of the photoresist.
Another way to employ the contact mode technique is to use back side exposure, where the photomask itself serves as a substrate, as in FIG. 13 . Photoresist 33 is spun on the front surface of the mask 34 . An embedded mask is necessary to ensure that the front surface of the mask is flat. Such masks are suited for coating with a photoresist. Chrome or phase shift elements, like molybdenum silicide, can be used for forming dark fields 35 . The exposure is performed by illuminating 36 the back side of the mask 34 . Here the sub-wavelength apertures 37 are in intimate contact with the photoresist 33 . This geometry leads to reduction of the wavelength by a factor of the refractive index of the photoresist, which in turn allows reduction of the sub-wavelength aperture size and distance between apertures. This reduction of the exposure wavelength is an advantage compared to the projection lithography technique.
Photoresist Development
Following exposure, either in projection mode or contact mode, the photosensitive material, i.e. photoresist, is developed to produce the engineered array of protuberances (EAP).
In contact mode with back side exposure, the photoresist is developed to form the EAP structure 38 of the front surface of the photomask.
This backside illumination method assumes multiple uses of the photomask. To re-use the photomask, the photoresist must be removed. To facilitate release of the photoresist from the mask surface a thin release coat 39 can be applied to the mask prior to the original photoresist coat. This release coat must be optically transparent and not so thick as to significantly affect the intensity profile in the photoresist. Another purpose of the release coat is to protect the mask from destruction due to excessive stress in the release step of the subsequent replication process, which is described below.
Pattern Transfer by Etching
In the case that the EAP structure in photoresist 40 ( FIG. 14 ) is difficult or impossible to fabricate with the desired parameters, it may be necessary to a transfer the EAP structure into the underlying substrate 41 by a chemical etch process. The desired parameters include but are not limited to the height of the EAP, and the shape and durability of the protuberances. A chemical etch process, where an etch screen mask comprised of the initial photoresist carrying the EAP structure, is used for the structure transfer. Wet or plasma etch processes can be employed. The resulting EAP structure 42 formed in the underlying substrate has a modified profile compared to the original. The etch rate ratio of the photoresist versus the substrate, i.e. the etch selectivity, must be carefully chosen in order to obtain the desired EAP profile.
It is possible that the desired EAP profile is still not achievable due to inadequate selectivity between the photoresist and the underlying substrate. In this case, to improve the selectivity, an additional etch process is required along with an intermediate etch screen mask (FIG. 15 ). An underlying substrate 43 carries an intermediate layer 44 of chrome, silicone dioxide, or other suitable material from which the intermediate etch mask is made. The first etch process transfers the original EAP pattern 45 (residing in photoresist) into the intermediate layer 46 . The second etch process further transfers the pattern into the underlying substrate 47 . An example of the second etch process was described by H. Toyota et al. (Jpn. J.Applied Physics, 40, L747, 2001), where an antireflective sub-wavelength structure on a fused silica substrate was fabricated using a chrome etch screen mask with a high-density fluorocarbon plasma reactive ion etching process.
Large Area Microtextured Surfaces
One embodiment of the present invention is a large uniform area EAP structure, which can be obtained in projection mode by repetitive exposures of the photoresist using a photomask and a mask aligner stepper with resolution better than 0.5 μm. The same technique can be used in contact photolithography mode, where a micrometer stage, instead of the stepper, can be used to translate either the mask or the substrate. The exposed area is limited only by the size of a substrate and by the travel limitations of the aligner stepper. Commercial aligner steppers may be modified to enlarge the travel. In this context “large area” refers to areas greater than can be uniformly coated in a typical vacuum deposition chamber, which is comparable to the screen size of a big screen TV, or a glass window used for artwork protection.
Using the backside illumination method of contact mode lithography, as described above, a large area EAP pattern is obtained by using a large area photomask. The large area photomask can be produced directly by mask making equipment or by means of assembling an array of smaller sized photomasks and joining them together. In the latter case the pattern should extend to the edge of each individual photomask thus leaving no gaps between masks. The photoresist can be spun directly onto the assembled mask or on each individual small mask before assembly. The photoresist can be developed before of after assembly to form the large area surface relief.
Replication of EAP Microtexture
Replication of the EAP structure formed in photoresist can be attained by the following methods:
a) coating the replicated surface by curable polymer, resin, or other curable material. The curing:mnay be achieved by e-beam, UV radiation, or other means. The coating is cured and then released from the master. b) replication using roller embossing, roller imprinting or roller casting (McGrew U.S. Pat. No. #4,758,296). These techniques can include as an intermediate step the production of a metal replica formed by galvanic replication (Galarneau et al. U.S. Pat. No #5,597,613).
Using the replication techniques described above a thin optically transparent film of large area can be produced carrying a microtextured antireflective surface. If desired, the processes can be extended to provide texturing for both sides of the film. This thin film can be applied to an optically transparent substrate like a glass, plastic, polymer, or other optical material in order to form an antireflective coating. The refractive indices of the film and the substrate must be closely matched for the procedure to work effectively. This technique is especially useful when direct definition of an EAP pattern on the substrate is difficult, expensive or impossible. The replication techniques significantly reduce the cost of production of an antireflective plastic film. Such films are easily distributed as an antireflective treatment for transparent substrates.
Distribution of the Textured Antireflective Film
If necessary, an adhesive may be used to bond the EAP antireflective film to a transparent substrate. The adhesive should be closely index matched to both the substrate and the film. A refractive index matching fluid can be used to fill any air gaps between the film, adhesive, or substrate. Alternatively, the index matching fluid can be used in the absence of adhesive. This may be particularly useful when the substrate is not flat due to surface roughness, scratches, or other damage.
In order to protect the microtextured EAP surface during the attachment of the antireflective film 48 to a substrate 50 , a protection layer 49 is required (see FIG. 16 A and FIG. 16 B). Indeed, during the attachment, the film 48 may be subject to excessive forces 51 that can potentially damage the surface structure (FIG. 16 B). The protection layer 49 may be formed by applying an e-bearn or UV-curable resin, polymer or other suitable material to the surface of the thin film 48 carrying the EAP structure. A composite film consisting of the protection layer 49 and the antireflective thin film 48 , as shown in FIG. 16A , is constructed. The EAP on both surfaces are complimentary thus protecting each other during pressurized application of the film 48 onto the substrate 50 . The protection film 49 is peeled off (denoted by the arrow 52 ) after the composite film is securely attached to a substrate by an adhesive 53 , as in FIG. 16 C.
The invention described in this patent presents an antireflective treatment that possesses the following properties: extremely low reflectance and high transmittance over a broad wavelength band, wide angular acceptance, cost effectiveness, large area, and flexibility. It provides a useful method for producing an easily distributed antireflective treatment on instrument displays, clocks and other time-keeping devices, portable electronic displays, and glazing materials for the picture frame industry. These treatments would also be useful for TV screens, computer monitors, LED screens of portable computers, personal data assistants, GPS units, cellular phones, the windows in storefronts, and other applications. A flexible polymer film carrying an antireflective treatment would find a multitude of uses. Plastic photo-protectors, transparent scotch tape, and novel packaging materials may benefit. In particular, pliable antireflective treatments will be essential for the new generation of flexible polymer electronic “roll-up” displays, manufactured by electrophoretic or polymer LED technologies.
One important antireflective application that requires the described properties, especially low cost and large area, are protective layers for semiconductor solar cells. In addition, an improved flexibility of the protective screen makes it possible to include a whole new class of cutting edge flexible thin-film solar cells. In this realm, any slight increase in efficiency, such as enabled by a properly engineered antireflective treatment, translates into significant added value to the final product.
While the above description contains many specific procedures and features, these should not be taken as limitations on the scope of the invention. Many variations are possible regarding the above methods for fabricating antireflective microtextures. For example, a photomask may be used in proximity photolithography to achieve texturing, especially with a short wavelength exposure source. Alternatively, ultraviolet light with wavelength longer or shorter than DUV may be used to expose the photoresist. Accordingly, the scope of the invention should be determined not by the illustrated embodiments, but by the appended claims and their legal equivalents. | A method employing a photolithography mask for producing microtextured antireflective surfaces is disclosed. The photolithography mask is used during the exposure of photoresist to a pattern of ultraviolet light. The exposed photoresist is subsequently processed to obtain a microtextured surface possessing antireflective properties. The antireflective surface profile comprises an array of sub-micron protuberances that may reside in a periodic arrangement, a quasiperiodic arrangement, or in an arbitrary non-periodic arrangement. The antireflective surface is designed for visible light. It may be scaled-up to large areas, and is suitable for replication into inexpensive polymer materials. | 6 |
BACKGROUND OF THE DISCLOSURE
1. Field of the Disclosure
The invention relates to a system for positioning a restrictor plate within a catch basin throat.
2. Background of the Related Art
Private groups and government bodies, such as the United States Environmental Protection Agency (U.S.E.P.A.), have sought to control unregulated sources of storm water discharge that have the greatest likelihood of causing continued environmental degradation. Such sources include storm water runoff, which picks up and transports harmful pollutants and discharges them, untreated, to waterways via sewer systems. Sediment-laden, contaminated runoff can overwhelm local water bodies, particularly small streams, resulting in streambed scour, stream bank erosion, and destruction of near-stream vegetative cover. The further result is the loss of in-stream habitats for fish and other aquatic species, an increased difficulty in filtering drinking water, the loss of drinking water reservoir storage capacity, and negative impacts on the navigational capacity of waterways.
Introduced regulations limit the size of runoff access points in storm drains to a maximum of seven square inches. Openings defining such access points must be not more than two inches across the smallest dimension. For example, a rectangular opening of two inches by three and a half inches would conform to such regulations. Such regulations have left state and local governments, who have curbside storm water catch basins with large inlets, searching for a solution.
Accordingly, there is a need to provide a novel structure for enabling drain water and allowable sized sediment to enter the sewer system while preventing the access to larger sediment.
SUMMARY OF THE EMBODIMENTS
A restrictor plate assembly is disclosed. The assembly is adapted for being positioned within a catch basin throat so that the throat extends rearward of the assembly. The assembly has a longitudinally extending restrictor plate and a restrictor plate securing system, which includes a first clamp arm, pivotally positioned against the restrictor plate, for engaging a first throat surface of the catch basin; a second clamp arm pivotally positioned against the restrictor plate, for engaging a second throat surface of the catch basin, the second throat surface opposing the first throat surface; and an urging member which simultaneously urges the first and second clamp arms against the first and second throat surfaces, respectively.
BRIEF DESCRIPTION OF THE FIGURES
It is to be understood that the following drawings depict details of only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, and in particular:
FIG. 1 illustrates a catch basin fitted with a restrictor plate according to an embodiment of the invention;
FIG. 2 illustrates details of a restrictor plate provided in FIG. 1 ;
FIG. 3 illustrates details of a second restrictor plate provided in FIG. 1 ;
FIG. 4 illustrates details of a splice plate provided in FIG. 1 ;
FIG. 5 illustrates an alternative embodiment, utilizing three restrictor plates;
FIG. 6 illustrates details of a clamp arm provided in FIG. 2 ; and
FIG. 7 illustrates details of a wedge provided in FIG. 2 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
The Catch Basin
FIG. 1 is a prospective/front view of a restrictor plate 10 , according to an embodiment of the invention, fitted within a Type Five (5) Catch Basin, utilized by the Department of Transportation for the state of Florida, U.S.A. This catch basin 11 is provided herein for illustration purposes only. The catch basin 11 includes a rectangular inlet 12 , in which the restrictor plate 10 is positioned. Further details of the catch basin 11 will be disclosed for providing context for the shape and function of the restrictor plate 10 .
The catch basin 11 , is formed from reinforced concrete and has a rectangular inlet 12 . As illustrated, the width is substantially greater than the height. Specifically, the height is about five inches while the width is almost eleven feet.
With further reference to FIG. 1 , the height of the inlet 12 is defined by opposing top and bottom edges 14 , 16 and the width is defined by opposing side edges 18 , 20 . The top and side inlet edges are chamfered in the location where the edges lead into the basin throat 22 .
Top and bottom throat surfaces 24 , 26 extend rearward from top and bottom inlet edges 14 , 16 , and both pitch downwardly towards the rear 28 of the throat 22 . Similarly, opposing side throat surfaces 32 , 34 extend reward from opposing side inlet edges 18 , 20 and taper inwardly towards the rear of the throat 28 .
In the area of the drain 30 , the catch basin includes a grate 36 . As illustrated, the grate 36 is on one side 38 of the catch basin 11 . The grate 36 allows sediment to drop into a basin cavity 40 , and pass into the drain 30 . Furthermore, the grate 36 is flush with the surface of the basin 11 .
The grate has opposing side edges 42 , 44 defining a width of the grate 36 . The side edges are spaced about five feet from each other. In the illustrated basin 11 , this spacing is less than a half of the width of the inlet 12 .
On the other hand, the grate 36 has a depth defined by opposing front and rear grate edges 46 , 48 . The grate front edge 46 is forward of the inlet 12 . On the other hand, the grate rear edge 48 is rearward of the inlet 12 . In the illustrated basin 11 , the grate rear edge 48 is about a half a foot rear of the basin inlet 12 .
The Restrictor Plate
Turning to FIG. 2 the restrictor plate 10 is illustrated. The restrictor plate 10 is adapted for being retrofitted into the basin throat 22 , flush with or rear of the inlet 12 . The restrictor plate 10 can be manufactured from an appropriately rigid and durable material. One example is strength/low alloy, quarter-inch thick, Cor-Ten brand weathering steel, which is an ASTM A588 grade steel rated to 60,000 psi.
As indicated, the restrictor plate 10 can be positioned reward of the inlet 12 by a distance which allows clear access to the grate 36 . For example, the grate rear edge 48 is rearward by about a half of one foot from the inlet 12 . Accordingly, the restrictor plate 10 is similarly located to allow access to and removal of the grate 36 after the restrictor plate 10 is installed.
The illustrated restrictor plate 10 substantially as wide as the basin grate 36 , which is less than a half of the width of the illustrated basin inlet 12 . The height of the restrictor plate 10 is slightly less than the height of the basin inlet 12 . For example, in the illustration, the restrictor plate 10 has a height of about four and a half inches, which is about one half of an inch less than the height of the inlet 12 .
The height difference between the restrictor plate 10 and the inlet 12 enables floating the restrictor plate 10 above the bottom surface of the catch basin upon installation. Floating enables the restrictor plate 10 to fit within the basin throat 22 , despite random surface contour variations. It also allows small particles to pass under the restrictor plate 10 and into the drain 30 , which is acceptable by regulations.
The restrictor plate 10 includes a main body 52 , which has a bottom edge 54 . Attached to the bottom edge 54 is a stiffening flange 56 . The flange 56 is pitched downwardly to match the pitch of the basin throat 22 . This pitch provide an effective guide for proper insertion of the restrictor plate 10 into the basin throat 22 . The flange 52 , as illustrated, is about three inches deep. However, other depths which provide the proper stiffness are acceptable.
Regarding the guide function, if a job-site worker accidentally inverts the restrictor plate 10 , (e.g., flips the plate 10 about its center, depth-wise axis), the flange pitch will extend in the wrong direction. This would prevent the restrictor plate 10 from being installed in the basin throat 22 . The job-site worker would be required to flip the restrictor plate 10 to the proper orientation to complete instillation.
The flange 56 has opposing side edges 58 , 60 which are cut or formed with a surface contour. This contour matches the inward pitch angle of the side surfaces 32 , 34 of the basin throat 12 . This also enables a proper placement of the restrictor plate 10 within the basin throat 12 .
Along an upper edge 62 of the restrictor plate 10 are plural flanges 64 , 66 , which have the same depth as the bottom flange 56 . The upper flanges 64 , 66 are also parallel with the bottom flange 56 . The upper flanges 64 , 66 are illustrated as being substantially less than the length of the restrictor plate 10 . The flanges 64 , 66 provide additional stiffness in the area at which the securing system (discussed below) interacts with the restrictor plate 10 . As illustrated, the upper flanges 64 , 66 are asymmetrical about their depth-wise centerline and the width of the flanges 64 , 66 is approximately five inches.
Alternatively, if the restrictor plate 10 were longer than that illustrated in FIG. 2 , additional securing system (discussed below) could be used for securing the restrictor plate 10 to the basin throat 22 . Such a longer restrictor plate 67 is illustrated in FIG. 3 , and is provided with flanges 68 , 70 which are offset from the center of the restrictor plate 67 . The flanges 68 , 70 are symmetrical about their depth-wise center and are approximately six inches wide. The actual dimensions of each of the upper flanges 64 - 70 can be modified so long as structural integrity of the restrictor plates 10 , 67 are maintained.
Furthermore, the asymmetric upper flanges 64 , 68 have side edges 72 , 74 , which have the same edge contours as the outer edges 58 , 68 of the bottom flange 56 . The contours serve the same purpose as with the bottom flange, to guide the restrictor plate 10 when being set in a with-wise tapered basin throat 22 .
The restrictor plate 10 has plural drainage openings, e.g., 76 , disposed along its length, which allow for continued drainage while restricting larger floatables. Based on design requirements, the size and shape of the openings is less than seven square inches and has a clear space no greater than two inches across the smallest dimension. It is to be noted that the design requirements for the opening size are identified for illustration purposes only and not to limit the scope of the invention.
According to FIG. 2 , there are nine openings 76 . While eight of the openings are identical, the center opening 78 sized differently and is designed to display a stainless steel badge 80 ( FIG. 1 ), which has been stitch-welded to a rear face 81 of the main body 52 of the restrictor plate 10 . The badge 80 can be used to provide information, such as from a government or private entity which installed, or cause to be installed, the restrictor plate 10 . For example, the message could be from the U.S.E.P.A. It is to be noted that other shapes, sizes and locations for the badge can be implemented.
As illustrated in FIG. 1 , a second restrictor plate 82 is positioned on the right side of the other (first) restrictor plate 10 . Depending on the width of the inlet 12 on the right side of the basin grate 36 , the second restrictor plate 82 may be shorter, longer or the same length as the first restrictor plate 10 . As indicated above, an example of a longer restrictor plate 82 is restrictor plate 67 , illustrated in FIG. 3 .
It should be appreciated from the above discussion that the shape of the restrictor plates are symmetrically designed. This symmetry provides advantages, discussed below.
The second restrictor plate 82 is positioned forward of the first restrictor plate 10 , and is substantially flush with the inlet 12 . This is because the second restrictor plate 82 does not extend over the grate 36 .
The Splice Plate
The aggregate length of the first and second restrictor plates 10 , 82 are intentionally less than the width of the inlet 12 . This enables the two restrictor plates 10 , 82 to be connected by a splice plate 84 , providing end-to-end restricted coverage of the inlet 12 .
The splice plate 84 is formed from the same material as the restrictor plate 10 . As illustrated in FIG. 4 , the splice plate 84 has the same height as the restrictor plate 10 . The splice 84 plate is formed with compound (i.e., two) offset angles 86 , 88 , such as a shifted slide.
As illustrated in FIG. 4 , based on the first offset angle 86 , one side 90 of the splice plate 84 is lower than the other side 92 . Based on the second offset angle 88 , one side 90 of the splice plate terminates rearward of the other side 92 . This compound offset matches the downward pitch of the throat 22 occupied between adjacent restrictor plates 10 , 82 . As a result, the two restrictor plates 10 , 82 engage in a linear connection, across the inlet 12 .
The splice plate 86 is formed with opposing end tabs 94 , 96 . The tabs are parallel with each other and at an angle 99 to a main body portion 98 of the splice plate 86 . This relationship enables the tabs 94 , 96 to be plumb against the main body portions (e.g., 52 ) of adjacent restrictor plates 10 , 82 .
The splice plate tabs 94 , 96 , and connecting ends of at least one of the restrictor plates 10 , 82 have plural mounting holes 98 , 100 . More than one hole in each member is desirable, and two holes are illustrated, to prevent rotation of the splice plate 84 relative to the restrictor plate 82 . The type of bolts which can be used to match the splice plates to the restrictor plates include, e.g., ½-13 button head cap screw made of 10-18 steel which conforms with ASTM F835 standards. However, other such mounting bolts may be applied.
The splice plate 86 includes plural drain holes, e.g., 102 , which are the same shape as the holes 76 in the restrictor plates 10 , 82 . The drain holes 102 are stepped in the direction of the first angle 86 of the compound offset of the splice plate 84 . Stepping the drain holes in this fashion positions the holes in parallel with the holes 76 in the restrictor plate.
Turning to FIG. 5 , another configuration is illustrated. In this configuration, the grate plate (not illustrated) is positioned in the center of a catch basin (not illustrated). In this embodiment, a third restrictor plate 104 can be utilized, along with a second splice plate 106 . In this configuration, the outer restrictor plates are flush with the basin inlet. The center restrictor plate is recessed, down the throat of the basin, to allow for grate access.
As illustrated in FIG. 5 , the outer restrictor plates are longer than the center restrictor plate. This is suitable for a catch basin in which the center grate is smaller than one/third the width of the basin inlet.
The symmetric shape of each discussed restrictor plate allows the plate to be laterally shifted in the inlet opening. As such, in FIG. 5 , the same restrictor plate formation can be used for each outer restrictor plate. The same restrictor plate formation could also serve as the outer plates and the center plate, if conditions warranted such a configuration.
The same formation for the splice plate can provide both splice plates 84 , 106 . A splice plate needs only be flipped about its axis to suit its purpose.
The Clamp Arm of the Securing System
Attention will now be directed to structure for securing the restrictor plate within the throat of the catch basin, which is illustrated in FIGS. 2 , 6 and 7 . There are at least two such structures 108 , 110 , one at each opposing end of the restrictor plate 10 . With reference to FIG. 3 , more such structures, e.g., a total of four structures, can be added depending on the length of the restrictor plate.
The components of each of the securing systems 108 are identical. Each includes plural clamp arms 112 , 114 . That is, a lower clamp arm and an upper clamp arm.
A front edge 116 of the lower clamp 112 arm extends outwardly from a rear face 81 of the main body 52 of the restrictor plate 10 . A fulcrum 118 is located at about the lengthwise midpoint of the clamp arm 112 , at which point the arm pitches downwardly, at an angle 119 , which is illustrated as being about sixty degrees. The angle 119 enables the clamp arm 112 to grip into the concrete surface of the basin throat 22 , but other angles may be substituted.
Rearward of the fulcrum 118 , the clamp extends through an opening 120 in the bottom flange 56 . The opening 120 is required due to the depth of the flanges and the size of the clamp arms. The opening 120 in the flange is illustrated as being just over two inches long (i.e., parallel to the length axis for the flange 56 ) and just over an inch in depth. Furthermore, the opening 120 is spaced by about a quarter of an inch from the depth-wise edge of the flange. However, these dimensions are only exemplarily and can be modified according to the design and placement of the clamp arms.
The upper clamp 114 arm also extends from the rear face 81 of the main body 52 of the restrictor plate 10 . The upper clamp 114 extends through an opening 121 , sized similarly to the other referenced opening 120 , in a respective upper flange 64 .
Each clamp arm includes a serrated end section 122 . The serrated sections are adapted to dig into the concrete basin throat 22 , securing the restrictor plate 10 to the basin. The serrated sections 122 are illustrated as being triangular, saw toothed serrations 124 , spanning the distance of the clamp edge. Further, as illustrated, each tooth is about a quarter of an inch tall and about a third of an inch wide. However, other serration configurations may be equally applicable.
In an unbent state, e.g., during the fabrication process, the clamp is illustrated as having a length of about four inches. The clamp is also illustrated as having a width of about two inches. However, these dimensions are not viewed as limiting the invention.
Each clamp has a compound tab 126 disposed at the front clamp edge 116 . A rearward part 128 of the tab 126 extends from the center of the front clamp edge 116 . The rearward part 128 of the tab 126 projects outwardly from the front clamp edge 116 by the thickness of the restrictor plate 10 . The tab 126 is designed to fit within a complementary positioning slot 132 in the restrictor plate 10 .
Extending from the rearward portion of the tab 126 is a half-moon shaped secondary tab 134 . The secondary tab 134 is connected to the rearward portion 128 of the 126 tab by a narrow connecting extension 136 .
With the compound tab 126 and matching slot 132 , the clamp 112 can be held in a proper configuration against the restrictor plate 10 before instillation is complete. This is done by inserting the tab 126 into the restrictor plate 10 , griping the secondary tab 134 with a wrench, and twisting about the narrow extension 136 by just a few degrees. After instillation is complete, the secondary tab 126 can be torn off by further twisting until the extension 136 factures.
The clamp 112 also has two side edge tabs 138 , 140 , with associated extensions 139 , 141 . This structure is similar in shape, though smaller, than the secondary tab 134 and connecting extension 136 in the compound tab 126 . The side edge tabs 138 , 140 are connected via extensions 139 , 141 directly to respective side edges 142 , 144 of the clamp 112 , forward of the fulcrum 118 .
When the long axis of the restrictor plate is parallel with the horizontal, the positioned clamps 112 , 114 have two pair of vertically aligned side edge tabs. Each pair is joined by a respective stabilizing spring 142 , 144 , which helps prevent misalignment of the clamps during instillation.
The Wedge of the Securing System
A wedge 146 is illustrated in FIG. 7 , which has opposing wedge surfaces 148 , 150 . Each of the surfaces 148 , 150 is double sided 152 , 154 , and each extends substantially perpendicular to an intermediate surface 156 . The pitch angle 158 for each side 152 , 154 of the wedge 146 is about forty degrees, but other suitable angles could be utilized. The wedge is fabricated from the same material as the restrictor plate 10 .
In use, the intermediate wedge surface 156 is pulled towards the rear face 81 of the main body 52 of the restrictor plate 10 . By this operation, the opposing pitched surfaces 152 , 154 of the wedge 146 press against the clamp arms at, e.g., the fulcrum. The clamp arms are thereby advanced through respective upper and lower flange openings and forced to dig into the concrete in the basin throat 22 .
The intermediate wedge surface 156 is widthwise dimensioned to separate the wedge surfaces 148 , 150 against the clamp arm 112 by substantially the width of the clamp arm. The intermediate wedge surface 156 is height-wise dimensioned to separate opposing, outermost tips 159 , 160 of the wedge by about three inches, but other height-wise spacing may be substituted.
The intermediate surface is drawn to the restrictor plate, via a through hole 162 , by a mounting bolt 164 . As illustrated, the mounting bolt 164 is a ½-13 button head cap screw made of 10-18 steel which conforms with ASTM F835 standards. However, other such mounting bolts may be applied. The head of the bolt 166 rests against the front surface 168 of the main body 52 of the restrictor plate 10 . On the other side, a mounting nut 165 is positioned on a rear surface 170 of the intermediate surface 156 .
In use, the wedge is positioned against the clamp arms, which are urged together by the springs. The mounting bolt and nut are introduced and tightened by, e.g., 72+5−0 ft-lbs of torque. This causes the wedge to urge the clamp arms against the concrete basin, thereby centering the restrictor plate in the height of the opening. This also renders the system tamperproof at the completion of instillation. The secondary tabs can be removed, as indicated above, as may be required or desired.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not as restrictive. The scope of the invention is, therefore, indicated by the appended claims and their combination in whole or in part rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope. | A restrictor plate assembly is disclosed. The assembly is adapted for being positioned within a catch basin throat so that the throat extends rearward of the assembly. The assembly has a longitudinally extending restrictor plate and a restrictor plate securing system, which includes a first clamp arm, pivotally positioned against the restrictor plate, for engaging a first throat surface of the catch basin; a second clamp arm pivotally positioned against the restrictor plate, for engaging a second throat surface of the catch basin, the second throat surface opposing the first throat surface; and an urging member which simultaneously urges the first and second clamp arms against the first and second throat surfaces, respectively. | 4 |
BACKGROUND
This invention is directed to a heavy-duty pump jack of the type used in oil well pumping. The pump jack eliminates the usual gear box by employing belt-driven speed reduction and leverage for force multiplication.
The modern oilfield pump jack employs a prime mover such as an electric motor or internal combustion engine as its primary power source. The rotary prime mover is connected to a gear box with an output crank. The gear box reduces the speed and multiplies the torque so that the crank can be coupled through a connecting rod directly to the walking beam. The walking beam carries a horse head from which the pump string depends. Counter weights are applied to the walking beam and/or the crank to attempt to equalize the load on the prime mover.
The modern demand for pumping units has outstripped the supply of gear boxes. As a result, there are wells which could usefully employ a pump jack, but gearboxes are not available for pump jacks for those wells. Consequently, there is need for oil well pump jacks which do not employ a gear box.
SUMMARY
In order to aid in the understanding of this invention, it can be stated in essentially summary form that it is directed to a leverage pump jack wherein a pivotal walking beam is rocked by a lever, and the lever is oscillated by an electric motor driving a crank through a belt reduction. The lever provides force multiplication.
It is, thus, an object of this invention to provide a leverage pump jack which provides the necessary force for pumping without the employment of a gear box. It is a further object to provide a leverage pump jack wherein a leverage beam acts upon the walking beam to multiply the pumping force and reduce pumping stroke, with the leverage beam being oscillated by a crank. It is a further object to provide a leverage pump jack which has adjustability in the interaction between the leverage beam and the walking beam so that adjustment may be made without reconstruction. It is a further object to provide a weight which is picked up by the leverage beam when the walking beam is adjacent its bottom end so that the weight helps counterbalance deceleration at the bottom of the hole.
Other objects and advantages of this invention will become apparent from a study of the following portion of the specification, the claims and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side-elevational view of the leverage pump jack of this invention with the horse head almost in its lowest position.
FIG. 2 is a similar view, showing the horse head in almost its highest position.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The leverage pump jack of this invention is generally indicated at 10 in FIGS. 1 and 2. Base 12 is mounted on the ground or on a suitable foundation adjacent the well to be pumped. Sampson post 14 extends upwardly from base 12 and carries beam bearing 16 at its top. Walking beam 18 is mounted on pivot pin 20 for rotary oscillating motion on the pivot pin axis. Horse head 22 is fixedly mounted on the outer end of walking beam 18. Balance weight 24 of selectable size is mounted on the other end of the walking beam to counterbalance the rod string and the movable parts of the pump down hole in the well. By rocking walking beam 18 on its pivot pin 20, the down hole pump is operated.
Pump jack 10 is capable of producing pumping forces in wells of moderate size with a fairly small prime mover. Thus, the prime mover can be of moderate size. An electric motor 26 is illustrated. Electric motor 26 has a Vee belt pulley or sheave 28 as its mechanical output. Countershaft 30 is rotatably mounted on a suitable bearing support 32. Sheave 33 is fixedly mounted on countershaft 30 and is driven from sheave 28 by belt 34. Adjacent to bearing support 32 is bearing support 36 which rotatably carries shaft 38. Sheave 40 is driven by belt 42 which also engages over sheave 44 which is fixed on shaft 30, together with sheave 33. These sheaves and belts are preferably Vee belts because of the superior transmission capability in small space. If required, multiple parallel belts can be employed. Crank 46 is fixed to shaft 38 and rotates therewith.
Oscillation of walking beam 18 by motor 26 is accomplished by leverage beam 48 interconnected therebetween. Leverage beam 48 is pivotably mounted on leverage bearing 50 which is mounted on Sampson post 14. Leverage bearing 50 has its pivotal axis parallel to the axis of pivot pin 20 so that leverage beam 48 is mounted below walking beam 18. Wrist pin 52 is secured on the underside of leverage beam 48. Connecting rod 54 interconnects crank 46 with the wrist pin so that the leverage beam oscillates on the axis of its bearing 50 when the crank rotates. The throw of crank 46 may be adjustable, either by means of a sliding connecting rod bearing thereon, to change the effective radius, or by several discrete connecting rod bearing fastening devices thereon. Thus, the total oscillatory stroke angle of the leverage beam can be adjusted. As far as oscillatory rate is concerned, the sheaves 28 and 44 can be between 3 and 4 inches in diameter, and the large sheaves 33 and 40 can be up to 36 inches in diameter. With a motor 26 having a full-load speed of 1,100 rpm, by sheave size selection one can achieve a pumping frequency as low as about 8 cycles per minutes. A pumping frequency in the order of 16 cycles per minute is more usual in the size of the structure presently contemplated. Thus, a sufficiently low pumping speed is achievable.
Drive roller 56 is mounted on the outer end of the leverage beam, on the opposite side of bearing 50 from wrist pin 52. Post 58 supports drive roller 56 above the leverage beam 48 both for geometrical purposes and to provide the clearances necessary for the leverage beam to pass through the open center of Sampson post 14 below walking beam bearing 16. Drive plate 60 has a straight lower edge 62, as is illustrated, and is mounted on pivot 64 towards the outer end of walking beam 18. Drive plate 60 is positioned so that when the walking beam 18 and leverage beam 48 are in their most counter clockwise position, close to that shown in FIG. 1, drive roller 56 bears on the lower side of walking beam 18 just to the left of drive plate 60. When leverage beam 48 is moved in the clockwise direction, as shown in FIG. 2, where the beam is almost to its limit position, drive roller 56 rolls up the edge 62 of drive plate 60 to force the walking beam 18 in the clockwise direction, as illustrated.
Lock pin 66 is shown as extending through the walking beam and through the uppermost hole in drive plate 60. There are other holes in drive plate 60, and the lower holes can be selected for other drive kinematics. With the position of the drive plate illustrated in FIG. 2, the kinematic motion can be visualized. With the pin 66 in the lowermost hole, the drive roller 56 would be following the lower surface of walking beam 18 so that less stroke is achieved. Thus, the edge 62 both by its curvature and its angle determine the kinematics. For convenience, a straight edge 16 is shown, although other shapes can be designed to control the acceleration and motor loads at various parts of the stroke.
FIG. 1 illustrates the pump jack nearly in its most counter-clockwise position. In this position, the drive roller 56 bears against the lower surface of walking beam 18 so that the angle of the drive plate 60 can be adjusted without any load thereon. Eyes 68 and 70 are respectively provided at the outer end of leverage beam 48 and base 12 so that a chain, cable or chain hoist may be secured therebetween to support the load on horse head 22 when the balance weight 24 is changed or other structure on the pump jack is being adjusted.
Deceleration of the pump jack and the down hole equipment towards the end of the downwad stroke is often a critical point of the cycle because the weight of the down hole equipment and the deceleration forces are acting in the same direction. Stroke bottom system 72 is employed to add a counterbalancing force at the lower end of the stroke. Cross pin 74 is pivotably mounted on leverage beam 48. It has a cross hole, positioned in the upright direction, through which weight rod 76 extends. Cap 78 is secured to the top of weight rod 76. Compression spring 80 embraces weight rod 76 and is positioned above cross pin 74 and below cap 78. Weights 82, of a selectable total weight, are secured to the bottom of weight rod 76. The length of the weight rod is such that when leverage beam 48 has the walking beam and cross head 22 in the raised position shown in FIG. 2, the weights 82 rest upon base 80. When the rocking structure moves towards the lowermost position of the moving down hole equipment, cross pin 74 rises to the point where spring 80 is engaged and weights 82 are lifted. The position of cap 78 on the weight rod controls the point at which the weights 82 are raised. Thus, adjustment of the cap position and adjustment of the total value of weights 82 helps equalize the load on motor 26 as the pump jack goes through its oscillation cycle. Adjustment of drive plate 60 and the radius of crank 46 control the amount of stroke. Both can be adjusted without large equipment or large work force. The use of leverage beam 48 multiplies the available force and permits the modification of the cyclic kinematics through the adjustment of drive plate 60 and permits the varying of the motor load by adjustment of the stroke bottom system 72.
This invention has been described in its presently contemplated best mode, and it is clear that it is susceptible to numerous modifications, modes and embodiments within the ability of those skilled in the art and without the exercise of the inventive faculty. Accordingly, the scope of this invention is defined by the scope of the following claims. | In a heavy-duty pump jack as used in oil well pumping, a leverage beam is oscillated by a motor-driven crank and the leverage beam acts upon the walking beam through an adjustable stroke controller. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention pertains to typewriters and printer ribbon guidance mechanisms and structures and to ribbon cartridges.
2. Description of the Prior Art
Many forms of factory pre-threaded ribbon cartridges for installation on the travelling print carriage of a typewriter or printer are shown in the prior art but the means employed are not generally applicable to articulated or compliant ribbon-guiding structures of the types shown in my U.S. Pat. Nos. 4,047,607 and 4,047,608 which are incorporated herein by reference. U.S. Pat. Nos. 4,277,187 and 4,284,364 show the application of a spreader bar or bridge to the outer ends of two flexible ribbon-guiding members to maintain a fixed separation and to provide a means of attachment to the print carriage. An early application of one type of spreader bar is shown in U.S. Pat. No. 2,074,778 to locate two loops of ribbon. A structure having a spreader bar attached to the outer ends of two flexible or compliant ribbon guides is not collapsible or foldable to any useful degree and hence requires an additional inordinate amount of packaging space or volume over requirements for the cartridge itself.
SUMMARY OF THE INVENTION
This invention provides two forms of collapsible and foldable ribbon guiding and directing structures which can be applied to disposable ribbon cartridges. The structures can be factory pre-threaded. In both forms the articulated ribbon guiding and associated ribbon directing structures are folded against the sides of the ribbon supply and take-up cartridge for very compact packaging. Further, the pre-threaded structures are designed for easy installation by the printer operator without having to thread or otherwise manually position the ribbon web on the print carriage.
DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic plan view of a printer incorporating a replaceable, frame-supported, ribbon cartridge having twin one-way articulated ribbon guides pivoted to the sides of the cartridge and fitted with a ribbon directing spreader bar.
FIG. 1A is a top view of a printing apparatus carriage.
FIG. 2 is a side elevation of the left articulated ribbon guide showing the straddle link and integral pin structure.
FIG. 3 is a partial elevation detail of the ribbon guiding structures showing the ribbon retention lugs.
FIG. 4 is a front elevation view of the ribbon cartridge of FIG. 1 with the twin articulated ribbon guides and spreader bar collapsed and folded for packaging.
FIG. 5 is a partially sectioned side view of one of the rotary articulated guide pivot blocks.
FIG. 6 is an end view of the rotary pivot block shown in FIG. 5.
FIG. 7 is a schematic plan view of a printer using a different ribbon cartridge and articulated ribbon-guiding structure with an articulated folding ribbon directing structure in lieu of a spreader bar.
FIG. 7A is a top view of the print carriage.
FIG. 8 is a partial elevation view of the articulated ribbon directing structure.
FIG. 9 shows how the articulated ribbon directing structure is folded for packaging.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 of the drawing, a printer is generally indicated by the reference number 10. The left and right side members of the machine frame are indicated at 11 and 12 respectively. The platen 13, journalled in side members 11 and 12, supports a record medium 14. A printing apparatus carriage 15 moves back and forth along the writing line on guide rods 16 and 17 and is positioned and is moved back and forth by any conventional mechanism such as stepping motor 15A actuating through cable 15B. Carriage 15 supports a daisy type print wheel 18, a print hammer 19, an electromagnet 20 for driving the print hammer 19, and a character selection servo or stepping motor 21, as well as other mechanisms as required.
A ribbon supply and take-up cartridge containing co-axially supported ribbon supply and take-up rolls 60, 65 is generally designated by the number 22. A ribbon take-up stepping motor 23 is supported by a frame member 24 and drives a take-up roll 65 through a cogged belt 25. Cartridge 22 supports twin, generally identical articulated ribbon guides generally indicated at 26 and 27, each guiding the ribbon 28 in one direction. The right articulated guide 26, here used for guiding the out-going ribbon 28 from the cartridge 22 to the carriage 15, has a primary arm 30 and a secondary arm 31. The left articulated guide 27, here used for guiding used ribbon 28 from the carriage 15 back to the cartridge 22, also has a primary arm 32 and a secondary arm 33.
The primary arms 30 and 32 are each supported at one end for limited rotation in first and second planes which are perpendicular to each other. The arms 30 and 32 are mounted on pivot blocks 34 and 35, respectively, which are free to rotate in, and retained by, the respective side walls 22A and 22B of the two case halves 45 and 46 of cartridge 22. The secondary arms 31 and 33 are hinged, at respective elbow joints 26A and 27A, to their respective primary arms 30 and 32. The outer ends of the secondary arms 31 and 33 are hinged to a spreader bar 36 by pivot connections 31A and 33A respectively. Pivot connections 31A and 33A are contructed in a manner similar to elbows or articulated ribbon guides 26 and 27 and serve as the ribbon directing means on carriage 15 to guide the ribbon 28 between the print wheel 18 and the record medium 14. The spreader bar 36 is removably retained on carriage 15 by support pins 37 and 38 which project upward from carriage 15. These two pins, 37 and 38, could just as easily be integrally formed on bar 36 and project from the bottom of the bar 36 for retention in respective holes 37A and 38A (see FIG. 1A) in carriage 15.
The twin articulated ribbon guides 26 and 27, spreader bar 36, and pivot blocks 34 and 35 are shown as solid members which would be molded of a suitable low friction plastic material. The articulated ribbon guides 26 and 27, and bar 36 could also be made up of metal links as shown in my referenced U.S. Pat. No. 4,047,607.
Referring now to FIGS. 5 and 6, pivot block 34 is shown in detail. Pivot block 35 is identical in construction. An integral shoulder support 40 has integrally molded pins 41 and 42 which support primary arm 30. Block 34 also has a ribbon guide projection 43 for supporting the ribbon 28 when the twin articulated ribbon guides 26 and 27 are folded as to be later described. Pivot block 34 also has a rectangular slot 44 for the ribbon 28 to pass through. As shown, block 34 is held captive between the two halves 45 and 46 of the cartridge 22 case.
FIG. 2 shows further details as to how the primary and secondary arms 32 and 33 are constructed. Primary arm 32 has two straddle links 47 and 48 with pivot holes 28A and 32A which snap over pins 49 and 50 respectively which are integral with shoulder support 51 on pivot block 35, (shown in FIGS. 1 and 4). The other end of arm 32 has integral pins 52 and 53 which engage the respective straddle links 54 and 55 of the secondary arm 33. The outer end of arm 33 has integral pin 56 (shown in FIGS. 1 and 4), which engages straddle links 36A at the left end of spreader bar 36. Primary arm 30 and secondary arm 31 are constructed in a like manner and the outer end of arm 31 engages straddle links 36B at the right end of bar 36. FIG. 3 shows the detail of the straddle link ends of arms 31 and 33, and of spreader bar 36, and shows the bent-over ends or lugs 58 and 59. The ends of lugs 58 and 59 are slightly separated to permit threading of the ribbon 28 and also serve to keep the ribbon 28 in place when there is no tension on the ribbon 28.
Referring back to FIG. 1, the ribbon 28, here assumed to be of the single-strike or multi-strike carbon variety, comes off the ribbon supply roll 60, passes over stripper roller 61, makes a ninety degree twist before passing through slot 44 in pivot block 34, partially around shoulder support 40 and thence to the elbow joint 26A where secondary arm 31 is hinged to the end of primary arm 30. The ribbon 28 then goes partially around a portion of outer curved surface 26B of elbow joint 26A at the end of primary arm 30 and along the the outer surface of secondary arm 31, partially around a curved surface 31B of pivot connection 31A at the outer end of arm 31, over curved blocks 62 and 63 on spreader bar 36, thence partially around curved surface 33B of pivot connection 33A thence along the surface of arm 33, partially around the radius 32C on the end of primary arm 32, and then partially around the radius 32D and into the cartridge 22, makes another ninety degree twist, passes around take-up roller 64, and on to the take-up roll 65, (see FIG. 4). Roller 64 is supported by bracket 66 which projects from the inside of case half 46.
FIG. 4 shows how the cartridge 22, generally constructed of low friction plastics permitting flexibility in thin sections, is supported by frame member 24 and engages the take-up mechanism 64 and 65. The twin articulated ribbon guides 26 and 27 are shown rotated and folded against the sides 22A and 22B of cartridge 22 with the attached spreader bar 36 against the top 22C of the cartridge 22. This folded and collapsed position of the articulated guides 26 and 27 and spreader bar 36 is the position used for packaging the cartridge 22 and, as can be seen, requires little additional packaging space over that required for just the cartridge 22. Before or after the ribbon cartridge 22 is installed in printer 10, the elbow joints 26A, 27A of articulated guides 26 and 27 are swung outward in the direction of their respective arrows 67 and 68. This raises the spreader bar 36 away from the cartridge 22 and then the guides 26 and 27 can be rotated into position for attaching the spreader bar 36 to the carriage 15. FIG. 4 also shows the use of the ribbon guide projection 43 on pivot block 34 and projection 43A on pivot block 35.
The ribbon supply and take-up rolls 60 and 65 respectively can be clearly seen in FIG. 4 as can the path of the ribbon 28 leaving the supply roll 60 and from take-up roller 64 and onto the take-up roll 65. The take-up mechanism is basically comprised of a stepping motor 23, supported by frame member 24, which drives a spiked wheel 70 supported on the end of a swinging lever 71 by means of the cogged belt 25. The upward rotation of lever 71 is limited by a stop pin 72, (more clearly seen in FIG. 1). Upward rotation of lever 71 is provided by spring 73. As the take-up roll 65 becomes larger, the spiked wheel 70 and lever 71 move downward. The front half 45 of the cartridge 22 has notch 74 formed therein so that cartridge 22 passes over spiked wheel 70 when it is inserted into position in printer 10.
FIG. 7 shows a printer 100 having a movable print carriage 101 slidable along guide bars 102 and 103 for making a line of imprints on a record material 104 supported by a platen 105. Carriage 101 supports a printing element 106 which may be of any type such as that known as a "golf ball" or that prints with individual type chips. Printer 100 is shown here employing a ribbon cartridge 107 supported on printer frame 180. This cartridge 107 is of the type shown in my previously referenced U.S. Pat. No. 4,047,607 but may be of the type employing a metal band for guiding the ribbon as shown in my other referenced U.S. Pat. No. 4,047,608.
Cartridge 107 has a ribbon supply roll 108, a ribbon take-up roll 109, and a take-up mechanism generally designated by the number 110 which may be of the type shown in FIGS. 1 and 4. Pivotally attached to cartridge 107 is an articulated ribbon-guiding structure generally designated by the number 112 having links 113 and 114 for supporting rollers 135, 137, 145 which guide a ribbon 115 from the cartridge 107 to the ribbon directing assembly 139, 146, 148, 149, 150 and 147 on carriage 101 and then back to cartridge 107 for take-up. The ribbon 115 moves along its path in the direction indicated by the various arrowheads placed along the path such as the arrowhead 116.
The foldable ribbon directing assembly 139, 146, 148, 149, 150 and 147, shown in elevation in FIG. 8 and folded in FIG. 9, has articulated links 120, 121 122, and 123 which are hinged together in sequence by pins 124, 125, and 126, and are pivoted between triangular plates 127 and 129 by pins 130 and 131. Triangular plates 127 and 129 are, in turn, pivoted to articulated link 114 by pin 132. As can be seen in FIG. 8, pins 125, 130, and 132 extend downward from their respective linkages 149, 146 and 139 and are placed in their respective holes 124A, 125A, 126A, 130A, 131A and 132A (see FIG. 7A); on carriage 101 to hold the ribbon directing assembly in place after it is installed in printer 100 along with cartridge 107. The outer end of articulated link 114 pivots around pin 132 as the carriage 101 moves back and forth along the guide bars 102 and 103.
For sake of clarity in the schematic views of FIGS. 7 and 9, the various articulated links 113, 114, 121, 122, 123, and 124 are shown as a heavy solid line. They may be constructed as shown in my referenced U.S. Pat. No. 4,047,607 and as shown in FIG. 8 where each link 114, 120, 121 has separate link bars 114a, 114b, 120a, 120b, 121a, and 121b. Thus link 120 is comprised of link bars 120a and 120b, link 121 of bars 121a and 121b, and link 114 of bars 114a and 114b. The articulated ribbon guiding structure has three primary rollers 135, 137, 139. Primary roller 135 is positioned on pivot pin 136 which attaches link 113 to cartridge 107. Primary roller 137 rotates on hinge pin 138 which joins like 113 and 114. Primary roller 139 rotates on pivot attachment pin 132. Supplementary ribbon guiding rollers 140 and 141 supported in cartridge 107, 142 and 143 supported by link 113, 144 and 145 supported by link 114, and 146 and 147 supported between triangular plates 127 and 129, all serve to hold the ribbon 115 in contact with primary rollers 135, 137, and 139 as the carriage 101 moves back and forth along the writing line so as to effectively maintain a constant or practically constant ribbon path length from the cartridge 107 to the carriage 101 and back to the cartridge 107 as the carriage 101 is moved. As in FIG. 1, where the ribbon 28 passes around various radii, if these various radii as well as the diameters of the primary rollers 135, 137, and 139 are, respectively, kept equal, then the ribbon path length is generally constant.
Referring again to FIG. 7, The ribbon 115 leaves supply roll 108, passes around secondary roller 140, over primary rollers 135, 137, and 139, around secondary roller 146, then around rollers 148, 149, and 150 which are supported by links 120, 121, 122, and 123, thence around secondary roller 147, over primary roller 139, around secondary rollers 144 and 145, over primary roller 137, around secondary rollers 142 and 143, over primary roller 139, around secondary roller 141, and thence to the take-up roll 109 passing over cartridge guide rollers 151 and 152 which guide ribbon 115 around the supply roll 108.
FIG. 9 shows how the articulated ribbon directing linkage assembly folds against cartridge 107 for packaging where it may be retained by a clip if desired. The articulated ribbon guiding link 113 folds against the right side of cartridge 107 and link 114 lays along the upper side on the cartridge 107 along with the ribbon directing linkage 120-132 as shown.
The ribbon directing linkage or assembly 120-132 as shown in FIGS. 7, 8, and 9 can also be applied to the compliant ribbon-guiding structure shown and described in my referenced U.S. Pat. No. 4,047,608.
While the cartridge 22 as shown in FIGS. 1 and 4 is installed in a vertical position, this is not a limiting requirement. Indeed, it can be installed, for example, to lay at an angle under the printer keyboard which is tilted forward for access for removal and replacement of cartridge 107.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and detail and in applying the concepts of the invention may be made without departing from the spirit or scope thereof. | A frame-supported disposable ribbon supply and take-up cartridge for typewriters and printers of the type employing a carriage-transported printing device is equipped with a constant path length ribbon guiding and directing structure which can be collapsed and folded for compact packaging and which can also be factory pre-threaded to eliminate any need for the operator to fit a ribbon leader around any guides on the print carriage. One form of the invention uses twin one-way articulated ribbon guides which are connected by a ribbon directing bar and are each orthogonally pivoted to the sides of the cartridge for collapsing, rotating, and folding against the sides of the cartridge. The other form uses a single two-way articulated ribbon-guiding structure pivoted to the cartridge and having a second articulated structure, all of which can be folded against the sides of the cartridge. | 1 |
STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government for governmental purposes without the payment of any royalty thereon.
BACKGROUND OF THE INVENTION
This invention relates generally to connector assemblies, and, more particularly, to a cable connector assembly which provides signal flow integrity between a mobile object such as a projectile or test vehicle and a stationary object such as a data processing facility during lift-off of the projectile. Additionally, the connector assembly permits reliable cable separation to take place at a predetermined point in the projectile trajectory.
There are many occasions when it is highly desirable to provide signal flow integrity between a movable and a stationary object. Generally such occasions arise during the lift-off of a projectile or test vehicle when information must be effectively relayed to a data processing facility. There are currently various systems or methods available for retrieving the test data is to be relayed between the projectile (mobile object) and the data collection or processing facility (stationary object). It is essential in each of these systems or methods to reliably provide communication between the projectile or mobile test vehicle and the stationary data processing facility. These prior techniques and systems have advantages and disadvantages which are directly dictated by one or more of the following factors:
1. the travel distance between the start of the projectile or test vehicle movement and the completion of the test and data acquisition period;
2. the amount of serviceable hardware to be salvaged at the conclusion of the test;
3. the volume of the data to be communicated between the projectile and the stationary data processing facility;
4. the structural integrity of the system and the safety of adjacent personnel;
5. the various stress/load dynamics subjected to the system;
6. the critical event timing requirements; and
7. the project budgeting and scheduling parameters.
Such prior methods and systems for data retrieval can be classified into two basic concepts. The first concept being data acquisition which requires electronic storage devices to be mounted in the projectile or mobile vehicle and the second being data acquisition techniques which involve the direct cabling between the projectile or the mobile test vehicle and a stationary electronic storage device located at the stationary processing facility.
A typical device which exemplifies the first type of method or system of data acquisition relies upon the use of a radio transmitter to relay test data to a stationary receiver located at the data processing facility during the test. Another such technique uses a data storage device which relies on an ejection/parachute mechanism to retrieve the test data after the test has been concluded.
Disadvantages inherent in the above two systems are, for example, the loss of extensive and/or expensive electronic components in the first case as well as problems arising from RF interference. The ejection mechanism and parachute in the second case must both function flawlessly or all the test data may be lost. Both methods or systems are not only expensive and highly vulnerable to various types of failure, but each has a limited capacity in the volume of data they may handle. These systems are therefore used primarily in tests that span great distances and require fewer channels of communication.
The second type of data acquisition techniques or systems involve the use of direct cabling between the projectile and the stationary data processing facility. These type of data retrieval systems overcome much of the problems associated with the first type of techniques described above since the volume of data to be communicated is unrestricted by virtue of the design of the system, require much lower budget impact, and greatly reduces the likelihood of electrical interference. The only drawback of such systems is their limitation to a reasonable travel distance of the mobile projectile between the start of the test and the completion of the test and data acquisition.
In general, however, the second type of data acquisition techniques or systems are preferable for projectile or test vehicle data acquisition. The following analysis of such systems provides information which must be taken into consideration when designing the cable connector of such data acquisition systems. One such cable connector provides release of the cable at the point of the mobile projectile or component. The advantage of such a release includes high salvageability of hardware and low load factors on the projectile. The disadvantages, however, include a high possibility of damage to surrounding objects, high launch dynamic forces at the separation of the connector and a cable arresting system is required.
A more reasonable cable connecting technique would involve release of the cable at the stationary component. The advantages of such a system are that there is little chance of damage to surrounding objects, no launch forces at the connector up to the point of separation, no cable arresting system is required and the overall range and safety factor is substantially increased. The disadvantage would be that there is less salvageable hardware and a slight increase in stationary facility load factors.
Currently there are three methods of release at the stationary component. These are (1) to blow the components apart; (2) to spring or push the components apart; or (3) to pull them apart as the cable becomes taut. The disadvantages in blowing or springing the connector apart is the requirement for explosive devices, compressed gases or springs which are contingent upon an event timing system to accomplish cable separation at a predetermined time. There are several factors, therefore, which make these methods vulnerable to failure and create range safety hazzards.
The pull-apart method represents the cleanest and most advantageous method of cable separation since there are fewer movable and/or stationary objects to entangle the data umbilical cord, potential damage to range structures is substantially reduced, no event timing or pyrotechnic devices are required, the procurement cost and lead time is reduced through in-house fabrication and the overall range safety factor is substantially improved. In view of the above factors, it is clearly evident that a pull-apart separation system or connector assembly would produce an ideal method of cable separation after the acquisition of test data from a projectile at liftoff.
Heretofore, prior attempts at such pull-apart separation systems or connector assemblies left much to be desired in the integrity of the cable connections, the insurance of separation at a proper time, and the salvageability of the greatest amount of hardware. As a result, such pull-apart techniques have generally not been used with past data acquisition procedures.
SUMMARY OF THE INVENTION
The releasable cable connector assembly of this invention overcomes the problems encountered in the past and set forth in detail hereinabove. This cable connector assembly is designed as a high density connector to provide signal integrity between a mobile test vehicle such as a projectile and a stationary data processing facility during static and/or dynamic testing. In addition, the connector assembly of the present invention simply, reliably and cost effectively allows for the separation of the stationary and mobile portions of the data cable interconnecting the projectile or test vehicle with the data processing facility.
The releasable cable connector assembly of this invention is made up of four basic subassemblies; (1) a first large stationary outer shell subassembly, (2) a second large stationary outer shell subassembly, (3) a removably or releasably mounted inner shell subassembly, and (4) a mounting fixture for mounting the first and second subassemblies to a stationary supporting structure.
More specifically, the two large outer shell subassemblies each include a cylindrically or tubular-shaped member, with these members being joined together end to end. The tubular-shaped member of the first shell subassembly has fixedly secured at one end thereof a stationary connector mounting ring and female portion of a conventional cable connector and at the other end thereof a cable clamp for fixedly securing the stationary portion of the data cable in place.
The tubular-shaped member of the second outer shell subassembly houses therein the inner releasable shell subassembly. In addition, this tubular-shaped member has secured to one end thereof a releasable or break-away end cover which includes a cable clamp for securing the releasable portion of the data cable thereto. The other end of the tubular-shaped member is fixedly secured to the tubular-shaped member of the first shell subassembly.
The releasable inner shell subassembly includes a tubular-shaped member which contains therein an inner cable clamp for securing the releasable portion of the data cable in place. In addition, the end of the tubular-shaped member adjacent the first stationary outer shell subassembly has a cable connecter mounting ring and a male portion of the conventional cable connector for securing the releasable portion of the data cable in place. The other end of the tubular-shaped member of the inner shell subassembly is initially open, being closed by the releasable or break-away cover of the second outer shell subassembly.
There is approximately 1/16 inch clearance between the wall of the tubular-shaped member of the inner shell subassembly and the wall of the tubular-shaped member of the second outer shell subassembly. The function of the inner shell subassembly is to mate the stationary portion of the data cable with the mobile or releasable portion of the data cable as well as provide a supporting guide surface of specific mass to ensure alignment of cable connector pins during the cable pull-apart operation at a preselected time after lift-off.
During pre-launch, the releasable portion of the data cable is positioned and secured within the tubular-shaped element of the inner shell subassembly. The conductors of the releasable portion of the data cable are connected to the appropriate pins of the male portion of the cable connector of the inner shell subassembly. The releasable portion of the data cable is then connected to the stationary portion of the data cable by the interconnection between the male portion of the cable connector associated with the inner shell subassembly and the female portion of the cable connector of the first stationary outer shell subassembly, respectively.
During the initial stage (lift off) or launch of the projectile the entire data cable remains intact for appropriate data transmission. At a predetermined time after lift off or launch, such as when the cable is stretched out approximately 150 feet and subjected to approximately 700 pounds force, the releasable or mobile portion of the data cable, together with the inner shell subassembly and break-away cover of the second outer shell subassembly are pulled apart from the stationary portion of the data cable and first and second stationary outer shell subassemblies. This feature of the present invention enables the pull-apart disconnection of the data cable to take place rapidly, reliably, and with a minimal amount of injury to the stationary outer shell subassemblies of the connector assembly. In this manner, the stationary outer shell subassemblies of this invention remain intact for subsequent reuse.
It is therefore an object of this invention to provide a releasable cable connector assembly which releasably secures a data cable in place in order to provide signal integrity between a mobile object and a stationary object.
It is another object of this invention to provide a releasable cable connector assembly which is made of a minimal number of parts, and is highly reliable in operation so as to provide efficient cable disconnect capability.
It is still another object of this invention to provide a releasable cable connector assembly which minimizes damage to surrounding stationary structures and data processing equipment.
It is still a further object of this invention to provide a releasable cable connector assembly which can provide highly reliable signal paths for 900 to 1100 data input points.
It is still a further object of this invention to provide a releasable cable connector assembly which affords great safety to surrounding personnel.
It is an even further object of this invention to provide a releasable cable connector assembly in which a majority of the components are reusable.
It is still another object of this invention to provide a releasable cable connector assembly which is economical to produce and which utilizes conventional, currently available components that lead themselves to standard mass producing manufacturing techniques.
For a better understanding of the present invention, together with other and further objects thereof, reference is made to the following description taken in conjunction with the accompanying drawing and its scope will be pointed out in the appended claims.
DETAILED DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevational view of the releasable cable connector assembly of this invention shown partly in cross-section;
FIG. 2 is an enlarged side elevational view, shown partly in cross-section, of the connector mounting rings and mating connector portions of the releasable cable connector assembly of this invention;
FIG. 3 is an enlarged end view taken along line III--III of FIG. 1 of the releasable cable connector assembly of this invention;
FIG. 4 is an enlarged end view taken along line IV--IV of FIG. 1 of the releasable cable connector assembly of this invention; and
FIG. 5 is an enlarged, detailed view of one of the guide pins utilized with the releasable cable connector assembly of this invention and shown partly in cross-section.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is now made to FIG. 1 of the drawing which shows partially in cross section the releasable cable connector assembly 10 of this invention. The connector assembly 10 of the present invention is made up of four major components which will be set forth in detail hereinbelow. The first two major components are in the form of a first stationary outer shell subassembly 12 and a second stationary outer shell subassembly 14. Outer shell subassemblies 12 and 14 are connected together in an end to end fashion in a manner described in detail hereinbelow to form a stationary outer housing 16 of the releasable cable connector assembly 10 of this invention.
The third major component of the present invention is in the form of a releasable inner shell subassembly 18 which is slidably mounted within the second stationary outer shell subassembly 14 in a manner described in more detail hereinbelow. The fourth major component is in the form of a stationary mounting fixture 20. Mounting fixture 20 secures the stationary outer housing 16 to any fixed member such as part of a data processing facility.
The releasable cable connector assembly 10 of the present invention is utilized to releasably secure a data cable 22 between a stationary object such as a data processing facility (not shown) and a mobile object such as a projectile or test vehicle (not shown). Although the following description refers to a projectile at lift off or launch, the present invention is capable of use with any type of mobile and stationary objects which require releasable cabling therebetween.
Still referring to FIG. 1 of the drawing the data receiving cable 22 is utilized to receive incoming data from a projectile at lift off and for transmitting this data to a stationary data processing facility on the ground or other fixed location. Cable 22 is made up of two portions, a stationary cable portion 24 having numerous conductors 26 extending therefrom and a releasable or mobile cable portion 28 having conductors 30 protruding therefrom. During data transmission, it is necessary to provide extremely reliable interconnection between the conductors 26 and 30 of cable portions 24 and 28. After a predetermined time after lift off, reliable separation of the cable portions 24 and 28 must take place. It is the releasable cable connector assembly 10 of this invention which provides such reliable interconnection and release of cable 22.
More specifically, stationary portion 24 of cable 22 is fixedly secured within the first stationary outer shell subassembly 12 while the mobile, or releasable portion 28 of cable 22 is fixedly secured to the removeable inner shell subassembly 18 in addition to being fixedly secured to a releasable or break-away cover 31 of the second stationary outer shell subassembly 14.
Reference is now made to FIGS. 1 through 5 of the drawing for the detailed description of the various components which make up the releasable cable connector assembly 10 of the present invention. For ease of understanding of the present invention, each specific component will be set forth in detail with the interconnection of the various components being set forth thereafter.
As shown in FIG. 1 of the drawing, the first stationary outer shell subassembly 12 is made up of an elongated, preferably cylindrical, tubular-shaped member 32. Secured to one end of tubular-shaped member 32 is a cover 34. As shown in FIGS. 1 and 3 cover 34 is secured to tubular-shaped member 32 by any suitable securing means such as bolts 35. In addition, mounting fixture 20 is secured to member 32 in a manner described in greater detail hereinbelow.
Centrally located within cover 34 is an opening 36 through which the stationary portion 24 of cable 22 may be inserted. Fixedly securing cable portion 24 to cover 34 is a cable clamp 38 of any suitable design. As shown in FIG. 3, cable clamp 38 is made of a pair of cable holders 39 secured together by bolts 40. Any suitable gasket 41 is fitted between cable portion 24 and holders 39.
The opposite end of the stationary tubular-shaped member 32 has fixedly secured thereto a stationary connector mounting ring 42 (shown in FIGS. 1 and 2). Mounting ring 42 has a centrally located opening 43 therein. Located adjacent opening 43 and fixedly secured to mounting ring 42, is the female portion 44 of a conventional connector 45 commercially available for example, from Hughes Corporation. Female portion 44 of cable connector 45 has a plurality of conductive indentations having conductors 26 of the stationary portion 24 of cable 22 connected thereto in a conventional manner. In this manner approximately 900-1100 conductors 26 of the stationary cable portion 24 are available for subsequent interconnection to the conductors 30 of releasable cable portion 28 in a manner described below.
As clearly shown in FIGS. 1 and 2 of the drawing, the second stationary outer shell subassembly 14 is formed of an elongated, preferably cylindrical, tubular-shaped member 46. Member 46 is fixedly secured at one end thereof to the tubular-shaped member 32 by means of any conventional securing means, such as bolts 48. Interposed between tubular-shaped member 46 and tubular-shaped member 32 is an annular-shaped spacer 50. Spacer 50 is utilized to maintain inner shell subassembly 18 a preselected distance from female connector portion 44 in a manner to be set forth in detail hereinbelow.
Still referring to the makeup of stationary outer shell subassembly 14, the other end thereof contains a break-away or releasable cover 31. Cover 31, as clearly shown in FIG. 4 of the drawing has a centrally located opening 51 for receiving the releasable portion 28 of cable 22 therethrough. Any suitable cable clamp 52 such as described in conjunction with the first outer shell subassembly 12 fixedly secures releasable cable portion 28 to cover 31. Clamp 52 also includes holders 53, bolts 54 and gasket 55.
In addition, cover 31 is releasably secured to outer tubular-shaped member 46 by means of a plurality of brass screws 56 which are capable of shearing under a predetermined amount of force. It should be realized that although brass screws 56 are shown as being used with the present invention, they may be substituted for by any type of securing means which are capable of being rendered ineffective as a securing means under a predetermined amount of force.
Also formed within stationary tubular-shaped member 46 are a plurality of viewing and vacuum relief ports 58. Ports 58 serve the purpose of permitting inspection to take place of the joined together cable portions 24 and 28 as well as allowing the relief of any vacuum which may be built up within the housing 16 during the release of inner subassembly 18. Any vacuum created during the rapid withdrawal of inner subassembly 18 from outer subassembly 14 could adversely affect the disconnect procedure between cable portions 24 and 28 if not eliminated.
Still referring to FIGS. 1 and 2 of the drawing, reference is now made to the inner shell subassembly 18. Inner shell subassembly 18 is made up of an elongated, preferably cylindrical, tubular-shaped member 60 which has a diameter slightly less than the diameter of outer stationary member 46. This enables a clearance of, for example, approximately 1/16 of an inch therebetween. In this manner, inner tubular-shaped member 60 may be inserted and be slidable within outer tubular-shaped member 46. Also situated within tubular-shaped member 60 are a plurality of openings 59 which operate in conjunction with ports 58 in the manner described above.
As clearly shown in FIG. 2, at one end of tubular-shaped element 60 is secured a cable connector mounting ring 62. Mounting ring 62 is held in place by a plurality of retaining pins 64 as well as a mounting assembly 66 shown in greater detail in FIG. 5 of the drawing. A detailed description of mounting assembly 66 will be set forth in detail hereinbelow.
Still referring to the makeup of inner shell subassembly 18, an inner cable clamp 68 fixedly secures the releasable portion 28 of cable 22 to subassembly 18. Inner cable clamp 68 is situated substantially midway between the ends of member 60 and within the interior thereof. Clamp 68 includes the same elements as clamps 38 and 52 and therefore is not described in detail. Clamp 68 fixedly secures releasable cable portion 28 to tubular-shaped member 60 so that upon the withdrawal or release of the releasable cable portion 28 the entire releasable or mobile inner shell subassembly 18 can be removed therewith.
Still referring to FIGS. 1 and 2 of the drawing, connector mounting ring 62 is shown having a centrally located opening 69 therein. A male portion 70 of conventional, commercially available mating cable connector 45 is fixedly secured to mounting ring 62 over opening 69. The conductors 30 of the releasable portion 28 of cable 22 are fixedly secured to conductive pins (not shown) of male connector portion 70. The conductive pins of male portion 70 of connector 45 are capable of mating within the conductive indentations (not shown) of female portion 44 of connector 45. The proper alignment and spacing between inner shell subassembly 18 and the first outer stationary shell subassembly 12 is accomplished by guide ring 50 which is interposed between members 46 and 32 as well as a plurality of guide pins 72 found as part of mounting assembly 66 shown more clearly in FIG. 5 of the drawing.
Reference is now made to the plurality of mounting assemblies 66, only one of which is in FIG. 5. Each mounting assembly 66 includes guide pins 72 which are fixedly secured, preferably by welding, to connector mounting ring 62 of inner shell subassembly 18. Pins 72 are of sufficient length to protrude through mounting ring 62 and be inserted within openings 73 located within the stationary connector mounting ring 42. This arrangement prevents any misalignment from occurring between inner shell subassembly 18 and stationary outer shell subassembly 12.
In addition, each mounting assembly 66 has a plurality of elongated guide elements 74 fixedly attached to member 60 of inner shell subassembly 18. A guide rod 76 passes through each guide element 74. Each guide rod 76 has a threaded bottom end 78 which threadably mates within an internally threaded portion 79 of each of the plurality guide pins 72. The other or upper end 81 of guide rod 76 has a washer-type element 80 fixedly secured thereto. Therefore, as each guide rod 76 is threaded into a respective guide pin 72, cable connector mounting ring 62 is drawn tightly against the tubular-shaped member 46. This tightening can be accomplished through an opening 83 formed within the releasable cover 31 by the use of any type of screw driver-like device which can be inserted within the bifurcated upper end 81 of guide rod 76.
The entire stationary housing 16 is rigidly positioned by the pair of mounting fixtures 20. Mounting fixtures 20 secure the first outer shell subassembly 12 and the second outer shell subassembly 14 to a stationary structure 82 which may be formed as part of a stationary data processing facility. Furthermore, if additional support may be required, another mounting fixture may encompass the central portion of housing 16 thereby providing additional structural support to the releasable cable connector assembly 10 of this invention.
OPERATION OF THE PREFERRED EMBODIMENT OF THIS INVENTION
As clearly depicted in FIG. 1 of the drawing, in its stationary position, the stationary and releasable portions 24 and 28 of data cable 22 are joined together by means of cable connector assembly 10 of the present invention. More specifically, the connection takes place by the interconnection and mating relationship between male and female portions 44 and 70 of commercially available cable connector 45. With appropriate tightening of clamps 38, 68 and 52, cable 22 is formed into a reliable, high integrity, transmitting path for data from a mobile object such as a projectile to a stationary object such as a data processing facility.
During liftoff of the projectile, data is continually being transmitted through cable 22 between the projectile and the data processing facility. This data transmission takes place generally within less than 0.1 seconds during projectile lift off before separation of cable 22 takes place. In general, there are between 900 and 1000 contact points between male and female connector portions 44 and 70. It is essential that these contact points remain connected to each other during the data transmission period.
As lift off takes place, under approximately 125 pounds pressure, each of the brass screws 56 securing cover 31 to the second outer stationary shell subassembly 14 fractures. The total applied force (depending upon the number of screws 56) is approximately 700 pounds of force. Upon fracture of screws 56, continual rapid movement of releasable portion 28 of cable 22 removes cover 31 along with inner shell subassembly 18. The withdrawal of inner shell subassembly 16 from the second outer stationary shell subassembly 14 takes place at a rate of approximately 180 feet per second. As a result of the stability and the added guiding ability of the present invention, minimal damage will occur at connector 45 and to surrounding personnel as the releasable portion 28 of cable 22 is rapidly withdrawn from stationary housing 16.
With the use of the present invention, the next projectile need merely have its cable portion 28 connected to a new inner shell subassembly 18. This new inner shell subassembly 18 can once again be inserted within the second stationary outer shell subassembly 14 for subsequent interconnection between portions 24 and 28 of cable 22. This allows for rapid reuse of the connector assembly 10 of this invention for further projectile data transmission.
The stationary components of the present invention, that is, outer shell subassemblies 12 and 14, remain completely intact during projectile lift off and are therefore completely reusable. Only the inner shell subassembly 18 need be replaced with the present invention. In addition, all components of the present invention can be manufactured independently of each other and are completely interchangeable. Consequently, the efficiency and economic gains attained by the use of this invention are immense. It is therefore clearly evident that data acquisition can be rapidly and effectively obtained at a minimal expense by the use of the releasable cable connector assembly 10 of this invention.
Although this invention has been described with reference to a particular embodiment, it will be understood that this invention is also capable of further and other embodiments within the spirit and scope of the appended claims. | A cable connector assembly for releasably securing a pair of cable portions of a cable together, the cable connector assembly having a stationary housing made up of two outer shell subassemblies, a movable inner shell subassembly slidable within one of the two outer shell subassemblies, and a mounting fixture for securing the stationary subassemblies to a fixed object. One of the cable portions has one end secured to a movable object and the other end secured to the inner shell subassembly. The other cable portion has one end secured to a fixed object and the other end secured to the other of the outer shell assemblies. During normal conditions, the cable portions are securly connected together. Upon the application of a predetermined amount of force to the movable portion of the cable, the inner shell subassembly withdraws from the one outer shell subassembly in order for disconnection of the cable portions to take place in a reliable, safe and efficient manner. | 7 |
BACKGROUND OF THE INVENTION
[0001] As the availability of potable drinking water diminishes, it is becoming more and more necessary to utilize alternate sources of water to supply the needs of a household. One readily available and easy to collect alternate source of water is rainwater. Using appropriately configured gutters, the water shed off of a roof can be directed into water storage tanks to collect many gallons of water over a short period of time. For example, 1 inch of rain over a 1000 ft 2 of roof surface corresponds to over 600 gallons. On a rainy day, a light rain of 0.1 inches per hour might fill a 1000-gallon tank.
[0002] There are various means for storing water, but a preferred method for residential water storage is the use of a polyethylene tank. All polyethylene tanks are made from virgin polyethylene has been approved by the United States Food & Drug Administration for use with drinking water. They are also durable, relatively inexpensive, and available in a wide variety of colors. These properties make them an ideal choice for many residential users.
[0003] Proper use of a water storage tank includes addressing the problem of algae growth, which is a common problem associated with standing water. If left unchecked, algae growth may make the stored water unsuitable for its intended purpose. Thus, there is a need to prevent algae growth within water storage tanks. The growth rate of algae can be inhibited by limiting the water's exposure to ultraviolet radiation. Because most water storage tanks are placed outdoors, this generally means being exposed to sunlight.
[0004] The ability of a polyethylene tank to block ultraviolet radiation is dependent on the color of the tank. The darker the color of the tank, the more ultraviolet radiation that is blocked. Therefore, a black polyethylene tank would provide the best ultraviolet radiation protection and best inhibit the growth of algae. However, for a variety of reasons, a user might find that a black water storage tank is unacceptable. In some cases, a home owner's association limits the color of storage tanks. In some situations, the user just insists on having a non-black storage tank. Regardless of the reason, using a single-layer non-black polyethylene storage tank will result in accelerated algae growth. Thus, there is a need to provide water tanks of a variety of colors that still inhibit the growth of algae. By providing a polyethylene tank with a black inner layer and a non-black outer layer, a user can select a water storage tank color and still obtain improved algae inhibiting properties.
SUMMARY OF INVENTION
[0005] Using a modified molding process, a multi-layered storage tank can be produced with different colored external layers with an internal layer of black polyethylene. By combining layers of different materials, the properties of these materials can be combined into a single storage tank with advantages corresponding to the chosen materials.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is an example of multi-layered water storage tank
[0007] FIG. 2 is an illustration of the wall of a two layer water storage tank.
[0008] FIG. 3 is an illustration of the wall of a three-layer water storage tank.
[0009] FIG. 4 is a diagram illustrating the steps necessary to manufacture a two-layer storage tank.
[0010] FIG. 5 is a diagram illustrating the steps necessary to manufacture a three-layer storage tank.
[0011] FIG. 6A is a diagram of a single-port dropbox.
[0012] FIG. 6B is a diagram illustrating a single-port dropbox attached to a mold.
[0013] FIGS. 7A and 7B are diagrams of a dual-port dropbox.
DETAILED DESCRIPTION
[0014] This disclosure can be understood in the context of the following examples. However, what follows is merely exemplar and not intended to define the scope of this patent, which is defined by the claims.
[0015] At a very high level, producing a rotation-molded plastic structure involves heating and rotating polyethylene resin within a mold until the resin heats up and coats the interior of the mold. The mold is then cooled until the plastic structure is ready for extraction. If the process works correctly, the resulting structure should have the shape of the mold with a thickness and color determined by the mold design and material weight.
[0016] One of the important steps in creating a rotation-molded structure is calculating the proper length of time to leave the mold in the oven (i.e., “curing time”). The proper curing time depends on a number of factors including, but not limited to, the shape of the mold, the quantity of resin, the type of resin, and the color of the resin.
[0017] In the absence of pigment, the natural color of polyethylene resin is an off-white color. In order to change the color of the resulting plastic structure, pigmented resin can be used. It may be possible to obtain resin that already contains a particular pigment color. Alternatively, pigment can be added to natural resin using a high-speed mixer. In either case, pigmented resin will change the color of a resulting plastic structure in accordance with its pigmentation. In addition to affecting the color of the resulting structure, resin color also changes the curing time. Darker pigmented resin cures faster than lighter pigmented resin.
[0018] The wall thickness of a plastic structure depends on the quantity of resin used, which is usually measured in pounds. Generally, adding more resin results in thicker walls and removing resin results in thinner walls. In addition to affecting wall thickness, increasing the quantity of resin also increases the curing time and vice versa
[0019] Resins are provided in what are commonly called “powder” for use in molding processes. Powder sizes are measured in terms of mesh. A lower mesh number means larger particles. For example, 35 mesh powder has larger particles than 50 mesh powder. Using a higher mesh results in a shorter curing time as compared to using lower mesh.
[0020] Different materials have different curing times. For example, nylon generally takes longer to cure than a similar amount of polyethylene. The specific properties of the material used will affect the curing time as well as the dependency of the other factors discussed above.
[0021] The process of forming a rotation-molded plastic structure requires the use of a mold with an interior surface corresponding to the outer surface of the desired plastic structure. The mold should be constructed of a material that will maintain a constant shape with minimal expansion during the curing process. The mold should also be sufficiently durable for repeated use in the production of identical plastic structures. In order to shape and cure the contents of the mold, the mold should also be comprised of a heat conductive material.
[0022] During the rotational-molding process, the mold should be rotated from the beginning of the curing time until the completed plastic structure is ready to be removed. During the curing process, the resin powder softens and then spreads over the inner surface of the mold. The rotation of the mold keeps the resin from settling into one spot. The precise curing time is determined by a number of factors including, but not limited to, the quantity of resin, the pigmentation of the resin, the shape of the mold, and the temperature of the oven.
[0023] After the curing process has completed, the mold is put in a cooling phase to lock the melted resin into the shape of the mold. Because the resin is still soft upon exiting the oven, it must continue to be rotated during the cooling process. Using air circulation and possibly a water mist, the mold can be cooled to a workable temperature in a relatively short amount of time.
[0024] Once the mold has sufficiently cooled, the plastic structure can be removed from the mold. If performed properly, the resulting structure should have the same shape as the interior of the mold and possess a thickness and color consistent with the pigmentation and quantity of resin. The process described above is effective for producing a rotation-molded structure with a single layer
[0025] The above process can be modified by adding additional resin to the mold during the curing process using a dropbox, which is an insulated resin container with a release valve. The release valve may be spring loaded for ease of opening. The dropbox can be attached to the mold via an access port in the mold structure. The dropbox and the mold are connected in such a manner that when the release valve on the drop box is opened, resin within the dropbox can flow into the mold. The dropbox is sufficiently insulated that its resin contents will not cure within the dropbox even when the dropbox is within an oven and attached to the mold.
[0026] As discussed above, curing time is inversely proportional to the darkness of the pigmented resin. Accordingly, by beginning the curing process with lightly-pigmented resin and adding darkly-pigmented resin via a drop box, the curing times of the colors can be matched such that the entire structure cures by the end of the cycle. Moreover, because the lightly-colored resin has been partially cured within the mold prior to introduction of the darkly-pigmented resin, it has had the opportunity to coat the inner surface of the mold. When the darkly-pigmented resin is added to the mold, the lightly-pigmented resin acts as a mold for this new layer.
[0027] FIG. 1 illustrates a polyethylene storage tank comprising multiple layers. Storage tank 100 is one possible shape of a multilayer polyethylene water tank. Tank 100 contains a black polyethylene inner layer and one or more outer layers. The inner layer contacts any stored water or other consumable fluid. The outer layers are isolated from the stored water and can serve any number of other purposes including, but not limited to aesthetic coloring and insulation.
[0028] FIG. 2 illustrates a cross-section of a two-layer plastic wall, such as the wall of storage tank 100 . Layer 201 is the outer layer and 202 is the inner layer. In this embodiment, layer 201 is comprised of a white-pigmented polyethylene and layer 202 is comprised of black-pigmented polyethylene. However, layer 201 can also be comprised of different colors and materials including, but not limited to, nylon, polypropylene, or crosslink materials in addition to white-pigmented polyethylene. The resistance to ultraviolet penetration is determined by the combination of layers 201 and 202 . However, the visual appearance of a corresponding tank, such as tank 101 is largely controlled by the color of exterior layer 201 . Accordingly, a two-layer plastic storage tank can provide ultraviolet protection greater than that of a wall comprised solely of layer 201 while providing the outward appearance of layer 201
[0029] FIG. 3 illustrates a cross-section of a three-layer plastic wall, such as the wall of storage tank 100 . Layer 301 is the outer layer, layer 302 is the inner layer, and layer 303 is the middle layer. In this embodiment, layer 301 is comprised of a white-pigmented polyethylene and layer 302 is comprised of black-pigmented polyethylene. Layer 301 can also be comprised of different colors and materials including, but not limited to, nylon, polypropylene, or crosslink materials in addition to white-pigmented polyethylene. In this embodiment, layer 303 is comprised of closed cell white-pigmented polyethylene foam. In addition to the properties of the wall illustrated in FIG. 2 , the addition of layer 303 provides additional ultraviolet protection as well as insulation.
[0030] FIG. 4 illustrates a process that can be used to construct a multi-layer storage tank such as 100 . Specifically, FIG. 4 describes steps in the process of producing a two-layer water tank. By way of example and not limitation, the steps shown in FIG. 4 will be discussed in the context of a specific embodiment for producing a 100-gallon tank of the type of shown in FIG. 1 with a white-pigmented polyethylene outer layer and a black polyethylene inner layer. The values, equipment, configurations and materials discussed below are examples and do not define the scope of this patent, which is defined by the claims. Based on this disclosure, a skilled artisan could apply this technique to different colors of resin, different resin powder size, different tank shapes, different tank sizes, and different layer compositions without undue experimentation.
[0031] Step 401 includes preparing the mold and dropbox. In this embodiment, the mold corresponds to the shape of the storage tank shown in FIG. 1 . This may involve using a water hose, air hose, or other mechanism to remove any residual plastic or other containments that might the adversely affect the rotational molding process. The dropbox is also prepared in a similar manner for use in the disclosed rotational molding process.
[0032] Step 402 involves adding a first resin to the mold. This first resin will form the outer layer of the resulting structure and will correspond to layer 201 in FIG. 2 . If the outer layer is polyethylene, then step 402 involves adding pigmented polyethylene resin powder. Step 402 also includes closing the mold with the first resin inside. The quantity of resin comprising the first resin is based on the characteristics of the mold, and the desired thickness of the resulting plastic structure. In this embodiment, the first resin comprises 44 pounds of white-pigmented 35 mesh resin, which would be added to the mold in step 402 .
[0033] Step 403 involves adding a second pigmented resin to the dropbox. The second pigmented resin corresponds to layer 202 in FIG. 2 . When the second resin is added to the dropbox, the port on the dropbox should be closed so that the second resin will stay within the dropbox until deployed. Step 403 also includes closing any other openings in the dropbox. The overall thickness of a resulting plastic structure depends on the quantity of the second resin as well as the quantity of the first resin. In this embodiment, the second resin comprises 16 pounds of black-pigmented 35 mesh resin, which would be added to the dropbox in step 403 .
[0034] Step 404 involves attaching the dropbox to the mold. The drop box port is attached to an access port on the mold. The access port on the mold may have a cover that needs to be removed or slid away to expose the access port. However, the port on the dropbox remains closed during this step.
[0035] Step 405 is the first curing phase. This step involves setting the rotational parameters and placing the mold in an oven. In this specific embodiment, the mold is rotated continuously along two axes using a 4:1 ratio or other as needed, meaning that for every 4 times that the mold is rotated around its central axis, it has flipped once end-over-end. This rotational configuration is maintained while the mold is the oven. In this specific embodiment, the mold is placed within a gas oven set to 600° F. The duration of curing phase one is based on the properties of the mold, and the resin properties including, but not limited to, pigmentation and weight. In a specific embodiment, curing phase one has a duration of approximately 16 minutes. During curing phase one, the first resin should soften and coat the inner surface of the mold. The second resin inside the dropbox should remain relatively cool because of the insulation of the dropbox.
[0036] Step 406 involves opening the release mechanism on the dropbox, which opens the port on the dropbox. Once the dropbox is opened, the second resin will begin to flow from the dropbox through the access port on the mold into the interior of the developing plastic structure. Step 406 may involve briefly slowing down the rotation and/or removing the mold from the oven just long enough to open the dropbox port. In some cases, the dropbox release is spring-loaded or air opened to minimize any interruption of the normal curing process. Once Step 406 is complete, the second curing phase can begin.
[0037] Step 407 is the second curing phase and involves curing the plastic structure to completion. In the case of the first resin, curing phase two is a continuation of the first curing phase. In the case of the second resin, the second curing phase is the continuation. In this embodiment, the same parameters as the first curing phase are maintained, which means rotating with a 4:1 ratio at a temperature of roughly 600° F. The duration of curing phase two also is based on the properties of the first and second resins. In this embodiment, the second resin comprises of 16 pounds of black resin which translates to a second curing phase lasting approximately 15 minutes. Once the second curing phase has completed, the first resin and second resin should have formed a two-layer wall like the one illustrated in FIG. 2 . In this specific embodiment, the durations of curing phase one and curing phase two are roughly the same. However, this may not be the case when different resin or mold configurations are used.
[0038] Step 408 involves removing the mold from the oven and cooling it to a temperature where the polyethylene resin will cease to flow. Until the mold has sufficiently cooled, its rotational parameters will be maintained. Step 408 may involve the use of fans and water mist to accelerate the cooling of the mold.
[0039] Step 409 involves removing the plastic structure from the mold. The mold is opened and a two-layer tank is extracted from the mold. In this embodiment, the extracted tank should roughly resemble FIG. 1 . The actual thickness of the wall layers is based on the quantity of resin used to form each layer. In this embodiment, 44 pounds of white-pigmented resin was used for the outer layer and 16 pounds of black-pigmented resin was used for the inner layer. Accordingly, the outer layer should be thicker than the inner layer.
[0040] FIG. 5 illustrates a process that can be used to construct a multi-layer storage tank such as 100 . Specifically, FIG. 5 describes steps in the process of producing a three-layer water tank. The process used in the three-layer process is similar to the process used in the two-layer process, so it will discussed in terms of differences from the two-layer process discussed above and illustrated in FIG. 4 . By way of example and not limitation, the steps shown in FIG. 5 will be discussed in the context of producing a 100-gallon tank of the type of shown in FIG. 1 with a white-pigmented polyethylene outer layer, a pigmented polyethylene foam middle layer, and a black-pigmented polyethylene inner layer. The values, equipment, configurations and materials discussed below are examples and do not define the scope of this patent, which is defined by the claims. Based on this disclosure, a skilled artisan could apply this technique to different colors of resin, different resin powder size, different tank shapes, different tank sizes, and different layer compositions without undue experimentation.
[0041] Step 501 is very similar to step 401 . However, the dropbox used in the process of three-layer process contains two compartments as opposed to the dropbox used in the two-layer process which may contain only one compartment. Therefore, step 501 includes preparing both compartments of the dropbox.
[0042] Step 502 is similar to step 402 in that the resin that will form the outer layer is added directly to the mold. In this specific embodiment, the first resin comprises of 44 pounds of white-pigmented 35 mesh polyethylene resin.
[0043] Steps 503 and 504 are similar to step 403 in that resin will be added to a dropbox. However, it is important to note that the second resin referenced in step 503 is the resin that will form the middle layer of the resulting water tank and not the inner layer as in step 403 . In this specific embodiment, the second resin comprises 10 pounds of white-pigmented polyethylene foam resin. By “foam resin”, this means that the resin contains a foaming (blowing) agent that will cause this resin to produce polyethylene foam during the curing process. The resin added in step 504 corresponds to the resin added in step 403 of the two-layer process in that they both involve the resin that will form the inner layer. Of course, step 504 involves a second compartment that may not be present in the two-layer process. In this specific embodiment, the third resin comprises 10 pounds of black-pigmented polyethylene resin.
[0044] Step 505 is similar to Step 404 in that they both involve attaching a dropbox to a mold. However, the dropbox used in step 505 contains two ports, so the attachment process may involve the use of multiple access ports on the mold.
[0045] Steps 506 , 507 , and 508 roughly correspond to steps 405 , 406 , and 407 . Because the dropbox used step 505 has two ports, only a single port is opened in step 507 . Steps 509 and 510 are additional steps that relate to adding the third resin and utilizing a third curing phase. Step 509 , where the second dropbox compartment is opened, should be substantially similar to step 507 , where the first dropbox compartment is opened. Steps 506 , 508 , 510 are curing periods separated by the addition of resin to the mold. In this specific embodiment, all curing phases occur at 600° F. or other needed temperature, wherein the first curing phase 506 has a duration of 16 minutes, the second curing phase 508 has a duration of 10 minutes, and the third curing phase 510 also has a duration of 10 minutes. As with the two-layer variation, the three layers should cure together.
[0046] Steps 511 and 512 are essentially the same as steps 408 and 409 in that the mold should be cooled before removing the completed plastic structure. In this specific embodiment, the result should be a water tank which resembles water tank 100 in FIG. 1 , with a three-layer wall structure similar to what is shown in FIG. 3 .
[0047] The various curing times and rotational parameters can be altered by a skilled artisan to account for the use of different materials that may have different curing times. The principles discussed above apply when using other plastic materials. For example, a nylon outer layer takes longer time to cure than an equivalent polyethylene outer layer. Accordingly, the duration of curing phase one would need to be extended to account for this property of nylon. A skilled artisan could make the adjustment necessary to account for different materials, different pigments, different powder sizes, and different molds.
[0048] FIG. 6A illustrates a single port dropbox 600 that might be used in producing a two-layer tank. Dropbox 600 has an outer surface 601 and an inner surface 602 . Between the outer surface 601 and inner surface 602 is layer of insulation, which may include, but is not limited to Teflon. The surfaces themselves may also have insulating properties. The overall insulation needs to be sufficient to keep the contents of dropbox 600 from curing within the dropbox. Dropbox 600 contains a port 603 that will connect to a corresponding access port on a mold 101 (shown in FIG. 6B ). Port 603 contains a plug which is connected to release handle 604 . The plug in port 603 will remain closed until such time as release handle 604 is activated. In some embodiments, release handle 604 is spring loaded, such that it need only be pulled to activate.
[0049] FIG. 6B illustrates a dropbox 600 that has been attached to mold 101 . The dropbox is attached securely to mold 101 because it will stay attached to the mold throughout the entire curing process. Release mechanism 604 is readily accessible so that it can be activated with as little disruption to the curing process as possible or by other means like pneumatic release.
[0050] FIGS. 7A and 7B illustrate a dual port dropbox 700 that might be used in producing a three-layer tank. Dropbox 700 has an outer surface 701 and two inner surfaces 702 and 704 , two ports 703 and 705 , and two release mechanism 706 and 707 . Dropbox 700 contains two compartments 708 and 709 . Inner surface 704 , port 705 and release mechanism 706 correspond to compartment 708 . Inner surface 702 , port 703 and release mechanism 707 corresponding to compartment 709 . Similar to dropbox 600 , dropbox 700 should have insulation between its outer surface 701 and its two inner surfaces 702 and 704 . In addition, surfaces 702 and 704 should be insulated from each other because one compartment may be opened for a substantial period of time before the other compartment is opened.
[0051] Dropbox 700 can be attached to a mold 101 in a similar manner as dropbox 600 . However, mold 101 will need to have dual access ports to take full advantage of the dual port capability of dropbox 700 . The presence of multiple access ports on mold 101 does not preclude the use of dropbox 600 as additional access ports can remain unused. Although dropbox 700 has two compartments, if can be still be used to produce a two-layer structure if only one compartment is used or if both compartments are used in tandem.
[0052] Although the above example is described in the context of a water storage tank which inhibits algae growth, a resulting two-layer tank may be used for other purposes or in other applications.
[0053] 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 to the embodiments described 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. | Black polyethylene storage tanks are an inexpensive and effective way to store water and simultaneously inhibit algae growth. However, based on other considerations, it may be desirable to use a storage tank with a non-black color. By producing a polyethylene water storage tank with a black inner layer and a non-black outer layer, the desire to inhibit algae growth and the desire to have a non-black exterior can both be met. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to a fleece funnel downstream of and at a distance from the output rollers of a set of drafting rollers, where one long side of a funnel area is constituted by a guiding surface, said guiding surface delimiting an impact surface, said impact surface being concave, with a funnel opening with funnel channel being located at the lowest point of the concavity, and with a ramp surface outside the funnel area.
Although the fleece funnel is also called a fleece nozzle in practice, only a fleece funnel shall be referred to hereinafter for the sake of uniformity.
The delivery speed of the drafted fiber sliver, such as it is delivered at the output of the drafting equipment by a pair of output rollers, is a criterium for the economic soundness of a draw frame.
In the technical development of the draw frame, the increase of delivery speed has been a major requirement. Below are some basic remarks concerning this:
As a rule, several fiber slivers which are united into one fiber sliver are presented to the drafting rollers of the draw frame. The combined fiber sliver is drafted in the drafting rollers. The pair of delivery rollers is the pair of output rollers of the drafting equipment and delivers a spread-out fiber sliver. The spread-out fiber sliver is called a fiber fleece. This fiber fleece is conveyed at delivery speed into the fleece funnel. The fiber fleece is imparted its delivery speed by the circumferential speed of the pair of delivery rollers. The fleece funnel must collect this fiber fleece, must roll it up, remove the air at the same time from the fiber fleece and deflect it into the funnel outlet, introducing it into same. With the introduction of the fiber fleece into the funnel outlet, a compressed fiber fleece is again created. Different designs are found in past developments of the fleece funnel.
A solution for a fleece funnel according to DE-OS 26-23-400 from 1976 shows a design such as it was used successfully at delivery speeds of approximately 350 meters/minute. From today's point of view, this is a slow delivery speed with other technological requirements. At this slow delivery speed, a well-known folding of the fleece across its width still takes place (a wedge-like folding as in an accordion).
As the delivery speed increased to around 950 meters/minute, the fleece funnel was given a different configuration. Such a configuration is shown in EP 593 884. This new, different form resulted from a different behavior of the fiber fleece as it impacts the fleece funnel, due to the higher delivery speed. The fiber fleece is no longer folded but becomes similar to a balloon being rolled up. At the previous delivery speed of up to 950 m/min, no difficulties were encountered with the known fleece funnel because the rolling-up process could be carried out reliably with the existing form of the fleece funnel and the optimal positioning of the pair of delivery rollers and of the fleece funnel. In practice, an arrangement emerged such as is still considered advantageous today at delivery speeds up to 950 m/min. Such an arrangement is also used in the RSB 951 draw frame of Rieter Ingolstadt Spinnereimaschinenbau AG.
The present development of the fleece funnel is due to the additional requirement for the automation of the introduction of a sliver end into the funnel outlet of the fleece funnel, up to the sliver funnel. For this reason, changes were made recently in the fleece funnel. DE-PS 36 12 133 shows a funnel-shaped inlet corresponding to a fleece funnel.
The document contains no statements concerning a fleece funnel, but in the automatic introduction of a sliver end it refers to the problem of air back-up in the sliver funnel (see column 1, 53rd to 62nd line). In order to remove the air carried by the fiber sliver on its way from the fleece funnel to and into the sliver funnel, the cross-section of the sliver funnel must be enlarged briefly in that area. This is necessary for the automatic introduction of the fiber fleece up to the sliver funnel. It is furthermore a disadvantage that the calender disks must be opened for the automatic introduction of the sliver end in order to manage the large air mass, i.e. to avoid air back-up which has a detrimental influence on the movement of the fiber sliver.
The problem of air mass in the automatic introduction of the sliver end into the fleece funnel, through the sliver funnel, and into the nip of the calender disks has been solved by the technical solution according to the European application 95114975.6. Therein, the fleece funnel was given a considerably greater role than the known fleece funnels. The result was a modified form of the fleece funnel. These modifications of the fleece funnel are described in detail in the above-mentioned, not yet published European application 95114975.6.
When attempting to increase the present high delivery speed of 950 m/min significantly to around 1200 m/min and more, it appears that the fleece funnel, in addition to other operating elements of the draw frame, plays an essential role in achieving the desired delivery speed. The fleece funnel must be able in this case to roll up the fiber fleece reliably and without affecting the quality at the considerably faster delivery speeds of the fiber fleece conveyed by the delivery rollers and must be able to move it on in the form of a fiber sliver. In this connection the automatic introduction of a spread-out fiber sliver (called a fiber fleece) beginning at the fleece funnel, must also be ensured.
The fleece funnels mentioned in the state of the art are not ensuring the desired success at delivery speeds of 1200 m/min and more. This also applies to the solution of the unpublished European application 95114975.6. The fiber fleece is either backed up, or the quality of the fiber sliver is adversely affected.
No information was disclosed in the state of the art on the configuration of a fiber funnel which would be necessary at delivery speeds of 1200 m/min and more, while preserving its functions for the automatic threading of a fiber fleece.
Further considerations were therefore concentrated on the fiber funnel described in the as yet unpublished European application 95114975.6 and concerning the placement of the fiber funnel across from the output roller pair (constituted by the delivery roller and a deflection roller). In operating such a fleece funnel at a fiber fleece delivery speed above 950 m/min, it has been shown that a considerably greater mass of fiber fleece is conveyed within the same time unit than at lower delivery speeds. Thus much more air caught in the fiber fleece is also conveyed.
The fiber fleece impacts the impact surface of the fiber funnel. A person schooled in the art knows that the fiber fleece forms a balloon as it impacts the impact surface because of the high delivery speed. The balloon rolls itself up and is conveyed into the outlet of the fleece funnel. When the delivery speed is increased to more than approximately 950 m/min, the balloon becomes larger. This may result in a change of the balloon configuration and may eventually impair its stability.
Another difficulty arises because of the greater circumferential speed of the pair of output rollers. This produces a stronger air flow in the fixed gaps between the fleece funnel and the pair of output rollers. This concerns the gap between lower drafting delivery roller and ramp surface of the fleece funnel. This stronger air flow has a detrimental effect. It affects the position of the balloon. Part of the balloon can be steered into the gap between fleece funnel and deflection roller. Damage to the balloon or backing up of the fleece is possible.
OBJECTS AND SUMMARY OF THE INVENTION
It is a principal object of the present invention to create a fleece funnel allowing for substantially higher delivery speeds than 950 m/min, without affecting the quality of the fiber sliver and without disturbing the movement of the fiber fleece, making also possible the additional function of automatic insertion of the fiber sliver end.
The fleece funnel according to the invention has the advantage that the fiber funnel operates without affecting the quality of the fiber sliver at delivery speeds of 1200 m/min and more. It also functions without interfering with the conveying of the fiber sliver. The form of the balloon is not disturbed with the fiber funnel according to the invention and the air can be removed more efficiently. An additional advantage is an improved cleaning effect of the fiber fleece.
The guiding surface and impact surface of the fiber funnel form a right angle with each other. The longitudinal axis of the funnel channel is in an imagined plane perpendicular to the impact surface and parallel to the guiding surface. The fiber fleece, which is also in a plane, makes contact with the impact surface. Between the imagined plane of the fiber fleece and the imagined surface of the longitudinal axis an angle is formed. This angle is called the impact angle α. It has been found that the impact angle α has a value which is advantageously comprised between 15° and 19°. Ensuring this impact angle α optimizes trouble-free rolling up of the fiber fleece.
Another embodiment of the invention is achieved in which the distance D1 between the imagined plane of the longitudinal axis of the funnel channel and the guiding surface has a value within the range of 10 mm and 14 mm. This makes it possible for the balloon to take on an optimal form.
Another design consists in forming the impact surface from surface segments. A surface segment of the impact surface is located on either side of the funnel outlet, whereby its contour is substantially linear. The funnel outlet is located in this surface segment. The surface segments on either side of this surface segment are domed and constitute a tangential connection.
With the surface segment of a linear contour, the presentation of a wide fiber fleece end at the fleece funnel is possible, so that this end can be introduced automatically into the funnel outlet. With the surface segment of the linear contour, the convexity radius of the adjacent segments necessarily becomes smaller if the original width of the fleece funnel is to be maintained. This makes possible an offset grasping of the end of the fiber fleece. The portion of the fiber fleece lying on the linear surface segment is seized earlier by the suction air stream than that portion of the adjacent, convex surface segments. It is not necessary to shorten the width of the end of the fiber fleece for automatic introduction.
The new contour of the impact surface is an advantageous design and also improves the effect of the rolling up of the fiber fleece in that the centering force for the fiber fleece (mainly for the edges of the fiber fleece) has been strengthened.
Another advantageous design consists in reducing the guiding surface delimiting the funnel area in the area of the linear surface segment of the impact surface to a lower height than the original height of the guiding surface. The possibility also exists of reducing the height preferably in a central area of the guiding surface. This central area is approximately equal to the width of the fiber fleece. This creates a recess at the upper edge or a lowering of the upper edge of the guiding surface. The length of this recess is approximately equal to the width of the fiber fleece.
Furthermore the distance between the upper edge Ho of the guiding surface, i.e. the upper edge which was not lowered to a reduced height, and the upper roller (e.g. in form of a deflection roller) of the drafting equipment is basically from 0.5 to 6.5 mm. As a result, the edge fibers standing out from the fiber fleece are incorporated more efficiently into the fiber fleece.
However there also exists the possibility of omitting the recess at the upper edge of the guiding surface. This makes for a less advantageous embodiment. In that case the upper edge of the guiding surface should also be at a distance from the upper roller that is basically 0.5 to 6.5 mm.
An example of an embodiment of the invention is shown in the drawing and is described in further detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a fleece funnel according to the state of the art;
FIG. 2 shows a sliver guiding apparatus with fleece funnel according to the European application 95114975.6;
FIG. 3 shows the fleece funnel with details from FIG. 2;
FIG. 4 is a three-dimensional representation of the fleece funnel according to the European application 95114975.6;
FIG. 5 shows a fleece funnel with characteristics according to the invention;
FIG. 6 is a three-dimensional representation of the fleece funnel according to the invention as in FIG. 5;
FIG. 7 is a representation of the distances between the fleece funnel according to the invention and the pair of output rollers;
FIGS. 8 and 8a show a fleece funnel with partially reduced height of the guiding surface; and
FIG. 9 shows the angle of impact at the fleece funnel.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the presently preferred embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used with another embodiment to yield still a further embodiment. It is intended that the present invention cover such modifications and variations.
FIG. 1 shows the arrangement of a fleece funnel (1), such as is used for example on the draw frame model RSB 951 of Rieter Ingolstadt Spinnereimaschinenbau AG. Based on the direction of movement of the fiber sliver FB, the fleece funnel (1) is located after the drafting equipment S. A 3-over-3 drafting equipment is shown. The pair of input rollers consists of rollers 5, 5'. The central pair of rollers is constituted by the rollers 6, 6' and the pair of output rollers is constituted by the delivery rollers 7, 7'.
The fiber sliver spread out after the pair of delivery rollers is conveyed into the fleece funnel in form of fiber fleece FV. The fleece funnel (1) is provided with a nozzle insert 2. Following the fleece funnel (1), a sliver guiding pipe 3 is installed which lets out into a sliver funnel 4. The sliver funnel 4 compresses the fiber sliver FB' and deflects it into the nip of the pair of calender rollers 8, 9. The calender rollers 8, 9 convey the fiber sliver FB" into a depositing device of the draw frame. This depositing device is not shown. The fiber fleece FV is securely seized by the fleece funnel (1) shown in FIG. 1, is folded, and formed into a skein fiber sliver FB'. The fleece funnel used on the RSB 951 reliably carries out this function for fiber fleece FV delivery speeds of 950 m/min. This delivery speed is imparted to the fiber fleece FV by the output rollers, constituted by the pair of delivery rollers 7, 7'.
A further development is shown in FIG. 2. Here the arrangement of a fleece funnel 100 is shown as described in detail in the European application 95114975.6. This fleece funnel can also be used reliably at delivery speeds of up to 950 m/min and in addition makes an automatic insertion of the end of a fiber fleece possible. The following are details of its operation.
The fiber sliver FB is presented to the drafting equipment SW. The fiber sliver FB may be a single fiber sliver or a single, doubled fibers sliver. This fiber sliver FB is drawn in by the pair of input rollers 50, 50'. These are followed by the central pair of rollers 60, 60'. There follows the pair of delivery rollers delivery rollers 70, 70', whereby the delivery roller 70 and the deflection roller 80 constitute the pair of output rollers. The pair of output rollers may also be constituted by a delivery roller 70 and its upper roller 80, for instance.
FIG. 2 shows the fleece funnel in its operating position. The fleece funnel 100 is provided with a plug-in, attachable nozzle insert 101 with a funnel channel 104. The funnel channel 104 is provided at its outlet with an articulated surface 105. The nozzle insert 101 can be swivelled together with the fleece funnel 100 on the side of the conical segment 204 of a sliver funnel insert 202 by means of this articulated surface 105. The sliver funnel insert 202 is received by a sliver funnel seat 201. The sliver funnel seat 201 is inserted in a holder 200. The sliver funnel insert 202 is provided with a cylindrical channel 203. Injector bores 205, 206 which are connected to an external compressed-air system (not shown) let out in the cylindrical channel 203. Guiding prongs which adapt themselves to the radius of the calender disks 90, 91 and extend into proximity of the nip, as shown by a guiding prong 207, are located on either side of the outlet of the cylindrical channel 203. FIG. 2 furthermore shows that in its operating position of the fleece funnel 100, a narrow space exists between the fleece funnel 100 and the deflection roller 80, this being the distance A o . During the operation of the drafting equipment and especially under the action of the deflection roller 80, an air current LS (in the direction shown by the arrow) is conveyed through this gap with distance A o .
Below the lower rollers of the drafting equipment SW constituted by the input roller 50, the central roller 60 and the delivery roller 70, a suction air stream AR acts in the direction indicated by an arrow. The suction air stream AR is produced by a suction system (not shown) below the drafting equipment SW. An air current moving through the gap with distance B o is included in the suction air stream AR.
C o characterizes the distance between nip KL of the pair of output rollers and the funnel outlet.
FIG. 3 shows additional details concerning the fleece funnel 100 such as it is used in the European application 95114975.6. The fleece funnel 100 is constituted with an essentially rectangular opening edge of the fleece funnel. Each of the long sides of the funnel area 103 is formed by -a guiding surface 110 and a delimiting surface 111. Between them an impact surface 109 is located. The impact surface 109, following a radius, is inclined in a concave manner, whereby the funnel outlet is at the lowest point of the concavity. The funnel outlet is constituted by a nozzle insert 101 which can be inserted into the fleece funnel 100 and can be fixed by means of stopping device 108. On the impact surface the nozzle insert 101 constitutes the funnel outlet which is connected to a funnel channel 104. The funnel channel 104 constitutes an articulated surface 105 in proximity of its channel outlet. Outside the funnel area 103 a ramp surface 102 is provided and leads to the delimiting surface 111. The fleece funnel 100 is swivelled manually by means of the handle 106 which is also stopped by means of the stopping device 108.
FIG. 4 shows the fleece funnel 100 without the handle 106 and without swivel bearing in a three-dimensional drawing. The reference numbers of FIG. 4 match those of FIG. 3.
The fiber fleece impacts the impact surface 109 at higher delivery speed and with greater force. The fleece is diverted from the impact surface 109 to the guiding surface 110. At the same time the fleece constitutes a balloon-like formation, called a balloon. When this balloon comes into contact with the guiding surface 110 the balloon is caused to roll up upon itself and is guided into the funnel channel 104. As the delivery speed increases beyond 950 m/min, the balloon grows in size. At the same time, the air current LS at the distance A increases in force as shown in FIG. 2. Because of the increased air current LS, the fleece balloon can be deflected into the space with the width A o . This has a detrimental effect on the rolling up of the fiber fleece. In the worst case the fiber fleece is backed up and the delivery of the fiber fleece must be stopped.
FIG. 5 shows a fleece funnel 300 with characteristics according to the invention. This embodiment is characterized in that the impact surface 309 is widened to such an extent in the direction of the ramp surface 302 that the contour of the impact surface forms a common intersection line SL with the contour of the ramp surface (FIGS. 5, 6). No delimiting surface 111 as in FIG. 3 is used in this case. A contour is formed by a contour line relative to a surface.
Surprisingly, this embodiment has the advantage that the air carried along with the fiber fleece can be removed much better. The air to be removed can be incorporated into the suction air stream AR (shown in FIG. 2) of the lower drafting equipment suction system without having to overcome any obstacles (originally the delimiting surface) and thereby without resistance. This results in an improved configuration of the balloon. Aspiration of the balloon against the space between the upper roller and the guiding surface is avoided. Another effect of this measure has been shown in an improved cleaning effect. The pollution (dust, foreign particles) developed during the impact of the fiber fleece and not again taken up by the fiber fleece as before, but are incorporated directly together with the air to be removed into the suction air stream and are removed.
The guiding surface 310 and the impact surface 309 of the fleece funnel form together a right angle. The longitudinal axis LA of the funnel channel 304 lies in a plane which is perpendicular to the impact surface and parallel to the guiding surface 310. This plane is not shown, but can be reconstructed in theory through FIG. 9. The fiber fleece FV which is also in a plane, impacts the impact surface 309. This plane is not shown in the drawing, but can also be reconstructed by using FIG. 9.
Between the imagined plane of the fiber fleece FV and the imagined plane of the longitudinal axis LA an angle is formed which is called the impact angle α (see FIG. 9). It has been found that the impact angle α is advantageously comprised between 15° and 19°. Ensuring this impact angle α optimizes the trouble-free rolling up of the fiber fleece.
In another embodiment the distance D 1 between the imagined plane of the longitudinal axis LA of the funnel channel 304 and the guiding surface 310 lies between 10 mm and 14 mm. This enables the balloon to form in an optimal manner.
In another embodiment (FIG. 6) the impact surface 309 consists of surface segments (F1, F2, F3). A surface segment Fl of the impact surface 309 is formed which is located on either side of the funnel outlet and has an essentially linear contour. On either side of the surface segment Fl are the surface segments F2 and F3. The surface segments F2, F3 have a smaller radius than the radius of the impact surface 109 of FIG. 3 surface segment Fl. The new contour of the impact surface 309 makes an offset seizing of the end of the fiber fleece possible. The fiber fleece located in the surface segment Fl is seized from the funnel outlet with funnel channel 304 earlier by the suction air stream than the same fiber fleece located in the surface segments F2, F3. Thereby, a fiber fleece tip is formed and seized automatically. This facilitates the automatic introduction of an end of a fiber fleece. No portion reduced from the total width of the fiber fleece need be presented to the fleece funnel. The fiber fleece can be presented to the fleece funnel in its full width. This is an improvement. Surprisingly the centering force for the fiber fleece could be increased so that the rolling up effect of the yarn fleece could also be optimized at high speeds. For better understanding FIG. 6 shows several characteristics in a three-dimensional representation which were already explained through FIG. 5.
In another embodiment (FIGS. 8, 8a) the guiding surface 310 delimiting the funnel area 303 is reduced in height as compared with the impact surface to a height H 1 from the original height H o of the guiding surface. Such a reduction of the original height of the guiding surface is made at least in the area of the linear surface segment Fl of the impact surface 309.
Another possibility consists in reducing the height of the guiding surface to a height H 1 in a central area MA of its width B (FIG. 8a). The central area MA has approximately the width of the presented fiber fleece. The height H 1 is reduced by at least 1 mm from the original height H o .
In another modification, the upper edge of the guiding surface 309 in the area of the remaining original height H o is placed at a distance A 1 from the upper roller 80 (FIGS. 7 and 9), whereby the distance A 1 has a value from 0.5 mm to 6.5 mm. With this recess of the upper edge caused by height H 1 (according to FIG. 8a) an aimed air stream coming from the funnel area can be directed to behind the guiding surface, causing spread-out border fibers to be incorporated more efficiently into the fiber fleece.
The invention has the further advantage that the automatic introduction of a fiber fleece could be improved. The improvement reveals itself in that now the beginning of a fiber fleece can be presented to the fleece funnel in its entire width. It is no longer necessary to present a portion of the fiber fleece with reduced width to the fleece funnel.
It will be appreciated by those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope and spirit of the invention. It is intended that the invention cover such modifications and variations as come within the scope of the appended claims and their equivalents. | A fleece funnel is provided for use in textile drafting equipment to receive a fiber fleece conveyed by a pair of delivery rollers. The fleece funnel includes a long side disposed adjacent to the delivery rollers. A funnel area is defined in the long side for receiving the fiber fleece. The funnel area defines a planar guiding surface in a planar substantially concave impact surface. A funnel opening is defined in the impact surface and a funnel channel is in communication with the funnel opening. A ramp surface is defined on the long side outside of the funnel area. The ramp surface meets the impact surface and defines a common contour line with the impact surface so that air forced out of the fiber fleece balloon formed as the fiber fleece is conveyed into the funnel opening is drawn away from the funnel area towards the ramp surface unimpeded by planar components of the fleece funnel. | 3 |
This is a continuation, of application Ser. No. 08/404,662, filled Mar. 15, 1995, New U.S. Pat. No. 5,601,573 which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates to sterile surgical fasteners, used to occlude bodily tissue structures, and the methods and instruments for applying such fasteners. More particularly, this invention relates to sterile clips, and instruments and methods for placement of such clips, that are used to ligate tubular structures within the body, such as blood vessels, to impede the flow of bodily fluid therethrough.
In order to prevent excessive fluid loss or bleeding during a surgical procedure, a surgeon will typically have to ligate or close various fluid ducts and/or blood vessels before severing those vessels. There are many types of mechanisms or devices for shutting off the vessels such as ligating clips, hemostatic clips and the like. In some instances the surgeon will tie a ligature or suture about a vessel to close or shut the vessel. Ligating clips are well known in the art. Many of the clips are metal and comprise a pair of legs which are connected at one end. The vessel to be ligated is placed between the legs and the legs forced together about the vessel to close the vessel. Clips have also been developed from plastic materials. However, since plastics do not have the same strength and malleability characteristics as metals, the plastic clips typically include some type of locking mechanism so that when the legs are urged together about the vessel Whey are locked in a closed position.
Ligating clips should ensure closure of the vessel. That is, they should completely shut off blood flow or other fluid flow and not allow leakage. Also, the clips should remain closed, should not open or break and should not slip or slide out of position or off the vessel. While it doesn't take much force to collapse and close a vessel, the clips that are now typically used require substantial force to close or change configuration so that once closed, the clip will remain in its closed position.
In minimally invasive surgery, in particular, endoscopic surgery, it has become desirable to provide smaller instruments capable of reaching surgical sites through smaller access ports. Smaller incisions cause less damage in accessing the surgical site and the access wounds from such incisions heal faster. In presently known clip appliers, the size of the instrument is dictated, in general, by the size of the clip as it is passed through the clip applying instrument to its business end, and the size of the jaws used to crush the clips closed. Clips are passed through the clip applying instrument in an open position so as to allow the clip to capture a tissue structure to be ligated before the jaws crush the clip closed over the structure.
It is therefore an object of the invention to provide a clip which is contained in a space-efficient, closed position until it reaches the structure to be ligated, thus enabling the use of smaller access ports.
In endoscopic surgery, the business end of the instrument is placed within the body through an appropriate cannula, body canal or small incision. The manipulation of that business end by the surgeon is accomplished outside the body. As a result, it becomes more difficult to control the business end of the instrument since it is further removed from the actual operation of the instrument. Any slight movement in the manipulation of the instrument outside the body is magnified at the business end of the instrument. Therefore, there is a greater chance in an endoscopic procedure that a slight movement of a clip applier as a clip is being closed will-cause clip misplacement. This is, particularly true considering that conventionally available clips require high force to effectively form over a tissue structure.
It is therefore another object of the present invention to substantially reduce the forces required to endoscopically apply a clip to ligate a structure such as a blood vessel. The less force required to place a clip, the greater the chance of accurate clip placement and therefore of positive vessel closure throughout the surgical procedure. Further, the force used to crush the clip also crushes the tissue and making the clip hard to remove, if so desired. Also, the less force required to place a clip on a vessel the less likely the vessel will be cut or lacerated.
It is a further object of the present invention to provide a clip and clip applier which allow a user to close off a vessel and determine whether the positioning is appropriate before applying the ligating clip.
Clips now typically used are applied with a clip applier which crushes the clip to a preset dimension. Although a range of clip sizes exist to provide for ligation of a variety of tissue structure sizes, frequently, the preset dimension is too large for a smaller structure or too small for a larger structure. If the structure is too small or too large, or conversely stated, if the clip gap of the closed gap is too large or too small, the clip has a greater chance of being misplaced, of providing inadequate ligation force or of slipping off the vessel.
Furthermore, the presently used clips typically comprise two legs attached at one end. Therefore, the closure force varies along the length of the clip, the greater force being closer to where the legs are attached. Thus with such a clip configuration, the chances are greater that the clip will slip from the closure site, particularly if the tissue is slightly misplaced towards the clip opening.
It is therefore an object of the invention to provide a clip and applier which reduce the chances of the clip slipping from the ligated vessel site or of providing insufficient ligation. It is an object of the invention to provide a clip and a method of applying the clip to a wider range of vessel sizes. It is also an object of the invention to provide a clip which provides substantially uniform ligating force along the length of the clip.
Though the novel clip, instrument and methods of the present invention are most appropriate for use in endoscopic procedures and will be so described in the following, it should be pointed out that the clip and/or the instrument could also be used quite capably in traditional open type surgical procedures.
SUMMARY OF THE PRESENT INVENTION
In accordance with the present invention, a new sterile clip, clip applier and method for ligating a tissue structure is provided.
One embodiment of the invention provides compression members at the distal end of a clip applying instrument which compress and/or occlude a tissue structure just prior to applying a ligating clip.
One feature of a preferred embodiment provides a clip applier which ligates or compresses a tissue structure to a predetermined force as opposed to a specific gap size or range before advancing a ligating clip to the structure.
Another feature of a preferred embodiment provides an efficiently sized clip, which may be passed to the distal end of the clip applier in a closed position. When the clip reaches the distal end of the instrument, it may be slightly opened, sufficiently to capture tissue which has been compressed and/or occluded. Then, the clip is released from the business end of the device, and, because the material of which it is constructed retains its resiliency and yields very little, the clip tends to return to its original shape, thereby keeping the ligated structure occluded.
The clip and instrument of the present invention may be used in smaller diameter cannula than prior art clips used to close the same size vessels. Since the clip of the present invention is already in its closed configuration and no jaws are necessary to contact the clip in order to close the clip, the overall diameter of the instrument may be reduced when compared to prior art instruments used for the same function. This allows the instrument to be used in smaller size access channels, incisions and/or cannulas and reduces the size of the incision in the patient. For example, currently used endoscopic clip appliers are about 10 mm in outside shaft diameter. A 5 mm outside shaft diameter clip applier and clip of the present invention may be used to apply clips presently only capable of being used only with a 10 mm or larger size access tube and clip applier, for example, clips of a 8-9 mm closed length size.
Ideally, the ratio of the diameter of the clip applier shaft to the final clip configuration height is as near unity as possible, taking into consideration various design constraints. The final clip configuration height is defined herein to mean the height of the clip measured in a plane perpendicular to the ligating surfaces when the clip is closed over a tissue structure. The present invention more specifically provides a clip applier and a clip wherein the ratio of the outer diameter of the clip applier shaft to the final clip configuration height is less than 5.2, preferably less than about 3.0 and most preferably less than 2.6. These preferred ratios have been determined based on conventional clip sizes and conventional instrument and access tube sizes.
The clip applier of the present invention may be adapted to receive clips of various sizes. However, the clip of a preferred embodiment, itself, is adapted to receive a range of various vessel sizes. This clip tends to size itself as it is placed on the Vessel. This feature provides a clip having a preloaded force which will not yield when the clip is deflected slightly, but sufficiently to capture a tissue structure.
The clip as such is formed of a resilient (as opposed to malleable) material and has tissue occluding leg members biased to spring back to a near zero gap size. The legs of the clips are biased together with a given force and the force increases at increasing deflection. The leg members include opposing ligating surfaces.
One embodiment of the invention provides a clip which is deflected from multiple clip elements, so as to divide the deflection force between multiple opposing springs, among other reasons, to reduce the likelihood of the clip yielding. For example, the clip may be deflected from two ends so as to divide the deflection force between two springs. The springs are arranged with respect to the ligating surfaces to permit deflection and closure of opposing ligating surfaces away from and towards each other, respectively. The springs are arranged so that opposite ligating surfaces provide sufficiently uniform force to close off a tissue structure placed therebetween. Preferably, the ligating surfaces of the clip are biased towards each other but from directionally opposite ends, so as to provide more uniform force between surfaces over the length of the clip.
In one embodiment, a one piece clip is provided with a plurality of opposing springs or spring force directions associated with opposing ligating surfaces.
In a preferred embodiment the clip comprises two leg members disposed in close proximity and substantially parallel to one another, at least along the portion of their lengths where a tissue structure is to be captured and ligated. The leg members are connected to each other by a connecting element which restricts separation of the leg members. The connecting element and leg members provide an opening at the distal end of the leg members, for capturing a tissue structure between ligating surfaces associated with the leg members. The connecting element, with which the springs are associated, allows the distal ends of the leg members to be slightly pushed apart by forces applied to the clip. Once those forces are removed the leg members return toward their original position.
In one embodiment, two opposing parallel leg members are joined by a connecting element having at least two springs acting from different directions on directionally opposed leg members. Preferably, two diametrically opposing spring members provide substantially parallel uniform deflection of the leg members from each other. A first spring member permits a first parallel leg to deflect away from a second parallel leg at the distal end of the clip. The second spring member permits the second parallel leg to deflect from the first parallel leg member proximal of the distal end of the clip. Preferably one of the two spring members is on a distal end of the clip while the other spring member is located at or towards the proximal end. The parallel legs provide an opening on the distal end of the clip for receiving tissue to be ligated. The opening may be angled to gather or "funnel" tissue between leg members, or, when being applied, may be opened by the applying mechanism to funnel tissue.
In a preferred embodiment, each leg member has at least one free end associated with it, such that the free ends of each leg member are opposed, irrespective of where connected. Preferably, the leg members are cantilevered from both the distal and proximal ends of the clip, one leg member from one end and the other leg member from the other end, so that the free end of one leg member resides at a restricted end of the other leg member, and vice versa. The connecting element restricts and connects each leg member at the leg member's restricted end. In this embodiment, the leg members are oriented so that their distal and proximal ends directionally correspond to the distal and proximal ends of a clip applying instrument wherein the distal end of the instrument includes the business end of the device.
The present invention also includes an instrument and method for applying the sterile clip to a vessel to be ligated. The instrument includes a handle having an actuating trigger and an elongated shaft with jaw members at its distal end. The jaw members comprise a pair of occluding surfaces diverging from each other from their proximal end to their distal end. These surfaces accept a vessel to be ligated. The surfaces may be placed on opposite sides of the vessel to be ligated and the surfaces occlude the vessel.
In operation, jaws of the instrument are placed through an access channel or port such as a cannula. The jaws of the instrument are positioned about the tissue or structure to be ligated. The jaws of the instrument may be rotated using a knob accessible by the instrument user, to rotate up to 360 degrees in either direction, to assist in positioning the jaws about the tissue or structure to be ligated, and to provide operative site visibility and accessibility. The jaws are preferably biased apart by a spring having a predetermined force. The spring loaded jaw closing mechanism closes the jaws to a predetermined force. The jaws may be locked in their closed position before the clip is placed over the tissue structure.
Once the jaws are positioned, the trigger may be actuated to close the jaws over the tissue or structure and thereby temporarily occlude the tissue. At this point, the user may examine: whether the appropriate tissue is compressed; whether sufficient or excessive tissue is compressed; and whether or not there is sufficient compression, all accomplished before applying the clip to the tissue. If the user is not satisfied, the trigger may be released to open the jaws of the instrument disengaging it from the tissue or structure without having applied a clip. If the user is satisfied, the ratcheted trigger is squeezed further. The clip is passed to the end of the instrument which spreads the legs of the clip slightly so that the opening at the distal end of the clip can accept the tissue structure at or near where the diverging surfaces have compressed and occluded the tissue structure. The clip is advanced over the tissue and then is disassociated from the jaws of the instrument. Following release of the trigger, the jaws may be removed from the tissue while the clip remains on the ligated vessel.
One embodiment of the invention provides an applier having a single-trigger, two stage actuation stroke for; 1) grasping and positioning of the tissue into the instrument to find the appropriate clip position and compressing tissue; and 2) locking the device and advancing the clip onto the tissue.
Another embodiment may include a plurality of triggers used to actuate the functions of the instrument described herein. For example, a first trigger is associated with a tissue compressing means and a second trigger is associated with a feed means. The first trigger is actuated causing the tissue compressing means to compress tissue at the distal end. Then, the feed means feeds a fastener to the distal end of the instrument where the fastener is placed over the pre-compressed tissue and dissociated from the instrument.
An alternative embodiment provides an instrument which applies a clip to a pre-compressed tissue structure. The clip may be shaped like a conventional clip but in a semi-formed state so as to reduce the size of the clip as it is passed to the end effector of the instrument. A compression means of the end effector pre-compresses the tissue structure prior to closing the ligating clip over the tissue. The tissue may be released from the compression means of the end effector prior to applying the clip. The clip has an opening just large enough to fit over the pre-compressed tissue. After advancing the clip over the pre-compressed tissue, the end effector then crushes the clip closed, thereby ligating the tissue structure.
The invention will be more fully described in conjunction with the specific embodiments given in the following drawings and description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a clip applier of the present invention.
FIGS. 2A and 2B are an exploded perspective view of a preloaded clip applier of a preferred embodiment of the invention.
FIG. 3A is an enlarged cross sectional side view of the clip applier of FIGS. 2A and 2B in a resting position.
FIG. 3B is an enlarged cross sectional view of the clip applier of FIGS. 2A and 2B in a tissue grasping position at the end of a tissue grasping and compressing stage, and at the beginning of the clip advancement and placement stage of trigger actuation.
FIG. 3C is an enlarged cross sectional view of the clip applier of FIGS. 2A and 2B at the end of the clip advancement stage of trigger actuation.
FIG. 4A is a side cross sectional view of a portion of the shaft of the present invention in a resting position.
FIG. 4B is side cross sectional view the portion of the shaft of FIG. 4A with a feed bar advancing a stack of clips.
FIG. 4C is a side cross sectional view of the portion of the shaft of FIG. 4B with the feed bar returning to its original resting position.
FIGS. 5A is a side cross sectional view of the distal end of the clip applier with jaws initially placed over a tissue structure to be ligated.
FIG. 5B is a side cross sectional view of the distal end of the clip applier with a tissue structure compressed between the jaws.
FIG. 5C is a side cross sectional view of the distal end of the clip applier with a clip advancing towards a compressed tissue structure.
FIG. 5D is a side cross sectional view of the distal end of the clip applier with a clip placed over a tissue structure.
FIG. 5E is a side cross sectional view of the distal end of the clip applier with a clip placed over a tissue structure and the clip being disengaged from the clip applier.
FIG. 6 is a side cross sectional view of the housing of the clip applier.
FIG. 7 is a side cross sectional view of the coupling mechanism of the clip applier.
FIG. 8 is a top cross sectional view of the coupling mechanism of the clip applier.
FIG. 9 is a perspective view of the lower jaw.
FIG. 10 is a perspective view of the top jaw.
FIG. 11 is a perspective view of the clip of a preferred embodiment.
FIG. 12 is a top view of the clip of FIG. 11 prior to being preformed.
FIG. 13 is a partial breakaway side cross-sectional view of an end effector of an alternative embodiment of the present invention in its initial position.
FIG. 14 is a cross section of the end effector of FIG. 13 along the lines 14--14.
FIG. 15 is a partial breakaway side cross-sectional view of the end effector of FIG. 13 in a tissue compressing mode.
FIG. 16 is a partial breakaway side cross-sectional view of the end effector of FIG. 13 illustrating closure of a clip.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 11 there is illustrated a clip 34 of the present invention. The clip 34 comprises a top leg member 62, a connector portion 64, and a second leg member 63. The connector portion 64 comprises an elongated portion 77 and two spring members 65,66. The first spring member 65 is located at the proximal end of the clip 34 and is coupled to the proximal end of the first leg member 62. The second spring member 66 is located at the distal end of the clip 34 and is coupled to the distal end of the second leg member 63. The first leg member 62 and the second leg member 63 are substantially parallel to each other along substantially their entire length. Each leg member 62,63 has a tissue engaging surface 78,79 respectively. Each tissue engaging surface interfaces with the tissue engaging surface of the other leg member. The tissue engaging surfaces 73,79 include scored surfaces 98 for holding tissue between the interfacing surfaces and preventing tissue from slipping out. The surfaces 78,79 may also have dimples 97 or the like to ensure closure and prevent movement of the clip 34 once it is placed on the tissue structure. The proximal ends of the leg members 62,63 form an opening 85 for capturing a tissue structure 99 (FIG. 5) such as a tubular vessel. The top leg member 62 includes two upper transverse tabs 75 located at the distal end of the top leg member 62. The connector portion 64 includes two lower transverse tabs 76 located towards the distal end of the connector portion 64. The clip has a height, h. The height is measured in a plane perpendicular to the ligating surfaces when the clip is passed through the shaft 5, prior to placement over a tissue structure. As depicted in FIG. 11, the proximal end of the clip 34 has a proximal end height h 1 and the distal end of the clip 34 has a distal end height h 2 wherein the proximal end height h 1 is about equal in height to the distal end height h 2 .
The clips of the present invention are preferably made from various well-known materials or alloys of materials, for example, of titanium, tantalum, stainless steel, memory metals having super elastic characteristics or the various plastic materials that have some resiliency such as polyolefins, glycolide-lactide polymers and similar plastic materials. The yield strength of the material should sufficient to allow opening by the instrument of the clip, to place it over tissue and resiliently return to its original closed configuration. Preferably, the material used is a titanium alloy, such as for example, titanium 3Al-2.5V.
FIG. 12 illustrates a titanium strip 34a prior to performing the clip 34 from the strip 34a. Transverse tabs 75,76 are formed in the titanium strip 34a by coining or other known manufacturing methods. The strip 34a is subsequently bent twice to form three substantially parallel portions, i.e., the leg members 62,63 and connector portion 64, and two bent portions, i.e., the springs 65,66. The bent portions act as springs biasing the respective ends of the attached leg member towards the opposite leg member, thus providing substantially uniform or substantially symmetrical biasing of the leg members towards each other.
Referring now to FIGS. 1-10, there is illustrated a clip applier 1 of the present invention. A housing 4 includes a stationary handle 10, a trigger 11 pivotally mounted to the housing 4, and a knob 59 rotatably attached to the distal end of the housing 4. The knob 59 and housing 4 are coupled to the proximal end of an elongated shaft 5. The shaft 5 includes a stationary elongated lower jaw portion 41 terminating in jaw 9, a grasper bar 31, a feed bar 32, a support tube 33, a stack 35 of clips 34, a feeder shoe 70 and, at its distal end 40, a pair of jaws 8, 9 for grasping and compressing a tissue structure 99 to be ligated.
The outer diameter of the shaft 5 comprises the support tube 33 having a lumen through which extend the lower jaw portion 41, grasper bar 31, and feed bar 32. The support tube 33 terminates just proximally of jaws 8,9 to permit pivotal action of jaws 8,9. The support tube 33 is constructed to resist excessive torquing to and/or deflection of the various parts of shaft 5.
The support tube 33 and the lower jaw portion 41 are rotatably attached to the housing 4 by way of rotating knob 59. The knob 59 is attached to the support tube 33 by a press fit between the opening inner diameter of the knob 59 and the outer diameter of the proximal end of the support tube 33. Inwardly protruding lugs 48 of the knob 59 are rotatably engaged with outwardly protruding lugs 49 of the lower jaw portion 41. The knob 59 permits 360 degree rotation of the shaft 5 with respect to the housing 4.
The trigger 11 includes a trigger arm 18 extending from the housing 4 so that the user may hold the handle 10 and actuate the trigger 11 by grasping the trigger arm 18 with the same hand. Posts 12 molded into trigger 11 fit into bosses 13 molded into housing 4, so as to permit pivotal movement of trigger 11 with respect to handle 10.
Housing 4 further includes a feed cam 16 pivotally attached to the housing 4 and slidably coupled to the trigger 11. The feed cam 16 is coupled on one end to a coupling mechanism 17. The coupling mechanism 17 couples the force applied to the trigger 11 to the tissue grasping/compressing and clip advancing/placing functions of the device. The trigger 11 includes a trigger post 19 which moves within a slot 20 in the feed cam 16. The trigger 11 is actuated by applying a force to the trigger arm 18 to rotate the trigger arm 18 towards the handle 10. This force causes: the trigger 11 to pivot about posts 12; and the post 19 to move within the slot 20 to pivotally rotate the feed cam 16 with respect to the housing 4. The rotation of the feed cam 16 multiplies the trigger force translating it into longitudinal movement of the coupling mechanism 17 as described in more detail below.
The coupling mechanism 17 is arranged longitudinally with respect to the longitudinal axis of the shaft 5. The coupling mechanism 17 is comprised of a grasper coupling 21, a feeder coupling 22, an in-line spring 23 and a return spring 24. The proximal end of the feeder coupling 22 includes a rearward extending post 26, and a radially extending circular surface 27. The feed cam 16 has two radially extending arms 25 which straddle a proximal or rearward extending post 26 of the feeder coupling 22, and are slidably mounted between radially extending circular surface 27 and rearward extending post 26. The radially extending arms 25 translate the rotational movement of the feed cam 16 to longitudinal movement of the coupling mechanism 17.
Longitudinal movement of the coupling mechanism 17 comprises two distinct steps. The first step comprises compression of the return spring 24 which has a lower spring preload and/or a lower spring constant than the in-line spring 23, and therefore compresses with less force. The first step corresponds to the tissue grasping and compression step of the trigger actuation. The second step comprises the compression of the in line spring 23, in general, for the most part, after the return spring 24 has compressed. The second step corresponds to the clip advancement and placement step of the trigger actuation.
The distal end of the feeder coupling 22 is slidably fitted and longitudinally moveable within the proximal end of the grasper coupling 21. The grasper coupling 21 includes a radially extending circular surface 28. The in-line spring 23 is situated over the feeder coupling 22 and grasper coupling 21, and between circular surface 27 and circular surface 28. The in-line spring 23 acts on circular surface 27 and circular surface 28 to longitudinally bias feeder coupling 22 and grasper coupling 21 away from each other. The grasper coupling 21 includes a second radially extending circular surface 29 on its distal end. The proximal end of the return spring 24 abuts against the distal end of the second circular surface 29. The lower jaw portion 41 includes a circular surface 36 on its proximal end enclosed within rotation knob 59 of housing 4. The distal end of the return spring 24 abuts against the circular surface 36. Thus, the return spring 24 biases the grasper coupling 21 in a proximal direction away from the proximal end of the shaft 5, i.e., away from the circular surface 36 of the lower jaw portion.
As an initial force is applied to the trigger arm 18, the feed cam 16 advances the coupling mechanism 17, the return spring 24 compresses, and the grasper coupling 21 longitudinally advances. Upon application of an appropriate additional amount of force, the feeder coupling 22 will slide towards the grasper coupling 21 as the in line spring 23 compresses.
Tissue is grasped and compressed by the top jaw 8 closing towards the jaw 9 of the stationary lower jaw portion 41. An elongated portion 37 of the lower jaw member 41 extends through an aperture 30 in the housing 4 and an aperture 96 in the knob 59, and along the longitudinal axis of the shaft 5. The elongated portion 37 is formed in a u-shape by side walls 38 and floor 39. The elongated portion 37 ends in a lower jaw 9.
The grasper bar 31 is attached at its proximal end to the grasper coupling 21 and extends longitudinally through an opening 47 circular surface 36 and the elongated portion 37 of the lower jaw portion 41. The grasper bar 31 includes a ceiling 69 and two side walls 68. The two side walls 68 fit inside and adjacent side walls 38 of lower jaw portion 41. The grasper bar side walls 68 have series of slots 67 which expose a series of notched surfaces 61 on the inside of the lower jaw portion side walls 38 Forward longitudinal motion of the grasper coupling 21 is transferred to the grasper bar 31.
The top jaw 8 is located at the distal end of the grasper bar 31. Downwardly extending posts 55 on the distal end of the grasper bar 31 are inserted into corresponding slots 56 of top jaw 8 to movably attach the grasper bar 31 to the top jaw 8. The top jaw 8 includes a pair of hooks 51 on each side of the proximal end of the jaw 8. The hooks 51 pivotally engage the lower jaw 9 at indentations 52 in lower jaw 9. The top jaw 8 and lower jaw 9 include interfacing tissue contacting surfaces 53,54, respectively. Jaw 8 includes a window 87 through which compressed tissue may be viewed during the tissue compressing stage, and where a clip may be viewed during the clip advancing stage.
Advancement of the grasper bar 31 pivots the top jaw 8 closed towards the lower jaw 9 so that the interfacing surfaces 53, 54 move together to compress any tissue structure engaged between jaws 8,9. When the top jaw 8 is closed towards the lower jaw 9, the engaged tissue is forced into a tissue channel 57 in the lower jaw 9. The tissue channel 57 helps to ensure that the tissue does not extrude distally out of the jaws 8,9 when the clip is advanced onto the tissue. The tissue channel 57 also assists in properly positioning the tissue for disengagement of the clip 34 from the instrument. A pair of upwardly extending tabs 58 at the distal end of the lower jaw 9 also assist in tissue placement between the jaws 8,9 by acting as a distal tissue stop. A pair of proximal tissue stops 100 incorporated into fronts of hooks 51, prevent tissue from going into the device proximally of jaw 8. The tissue channel 57, tabs 58 and tissue stops 100 properly place the tissue in the amount to be ligated, where the clip disengages from the device. This is particularly important as the clip 34 in this embodiment does not extend as long as the jaws 8,9. Release of the trigger 11 releases the return spring 24, which causes the grasper bar 31 to retract and the top jaw 8 to open.
After the jaws 8, 9 close over a tissue structure 99 to be ligated, the trigger arm 18 is squeezed further initiate the second step, i.e., clip advancement and placement. As the trigger is squeezed, a step force arm 2 on the trigger 11 contacts a corresponding step force rib 6 on the housing 4. When the return spring 24 is compressed and the jaws 8,9 closed to the force of the return spring 24, a protrusion 3 on the step force arm 2 contacts the corresponding step force rib 6 which imparts an increase in the tactile force felt on the trigger arm 18 by the user. This increase in force denotes the separation between the jaw closing mode and the clip advancement mode in the two-stage, single stroke actuation. Similarly, the feed cam 16 has an anti back-up arm 14 with a protrusion 15 at its distal end. Anti back-up arm 14 contacts a corresponding backup rib 7 on the housing 4 to prohibit the reversal of the feed cam rotational motion. This occurs at the transition between the jaw closing mode and the clip advancement mode of the trigger stroke. The back-up rib 7 measures a complete stroke of the trigger before it permits the anti back-up arm 14 to disengage therefrom, thus ensuring the clip 34 is properly advanced all the way onto the tissue, as described in more detail below.
Two engagement arms 44 with inwardly protruding tabs 45, extend from the proximal end of the feed bar 32. The engagement arms 44 extend through an opening in the distal end of the grasper coupling 21 into the feeder coupling 22. Feeder coupling 22 has a center rib section 46 which is straddled by the engagement arms 44 of the feed bar 32 and is engageably coupled by tabs 45. The feed bar 32 is advanced by the forward motion of the feeder coupling 22.
In the second mode, i.e., the clip advancement and placement mode, trigger arm 18 advances the feeder coupler 22 which advances the feed bar 32. The feed bar 32 extends through the opening 47 in circular surface 36 and longitudinally between the elongated portion 37 of the lower jaw portion 41 and the grasper bar 31, ending in a slightly bent heel portion 43. During the second trigger step, the heel portion 43 advances the distal most clip into the jaws 8,9 and over an engaged compressed tissue structure 99.
A stack 35 of clips 34 is preloaded into the clip applier in an end to end configuration along the longitudinal axis of the shaft 5. The feed bar 32 also advances the stack 35.
The feed bar 32 sits on top of the floor 39 of the lower jaw portion 41. The stack 35 of clips 34 sits on top of the feed bar 32 between the feed bar 32 and the ceiling 69 of the grasper bar 21. The distal most clip 34 in the stack 35 is positioned beyond the heel 43 at the distal end of the feed bar 32 and just proximal of the lower jaw 9. The stack 35 of clips 34 with a feeder shoe 70 positioned proximal of the last clip in the stack 35, is advanced distally through the shaft 5 by the feed bar 32.
The feeder shoe 70 has a main body 71 and a cantilevered lower arm 72 biased away from the main body. A tab 73 extends downward from the lower arm 72 and engages in one of a longitudinal series of slots 60 in the feed bar 32, i.e., so that the feed shoe 70 is positioned just proximal of the last clip in the stack 35. The feed shoe 70 further comprises transversely biased arms 74 extending from the sides of the feed shoe 70.
During the resting stage and when the grasper bar 31 is advanced, the arms 74 are in contact with the notched surfaces 61 of the lower jaw sides walls 38. The notched surfaces 61 are then exposed by slots 67 in the grasper bar 31 side walls 68. The arms 74 are biased outward to impede proximal movement of the feed shoe 70. The arms 74 permit distal movement of the feed shoe 70. The feed bar 32 is advanced, and the arms 74 of the feed shoe 70 pass over the walls 68 of the grasper bar 31. The arms 74 then engage exposed notched surfaces 61 again, this time distally by one clip length.
When the feed bar 32 is advanced, the feed shoe 70 is advanced because the tab 73 is engaged in one of the feed bar slots 60. The distal end of the feed shoe 70 advances the stack 35 of clips 24 towards the distal end of the instrument. Each time the trigger 11 advances the feed bar 31, the feed shoe 70 advances by one clip length. The grasper bar 31 has a cantilevered lifter spring 86 located towards its distal end. The cantilevered lifter spring 86 extends down from the ceiling 69 of the grasper bar 31.
During the initial advancement of the grasper bar 31, the distal most clip is moved from the longitudinal plane of the stack 35 into the longitudinal plane of the feed bar 32. During the second step of the trigger stroke, distal end of the feed bar advances the distal clip 34 into the jaws 8,9 which have closed over, compressed and temporarily occluded a tissue structure 99. After the first clip is placed, the next distal most clip is moved downward from the feed bar 32 by the cantilevered spring 86, as the feed bar 22 is retracted at the end of the trigger stroke. The cantilevered spring 86 prevents the distal most clip from retracting with the feed bar 32. Thus, the distal most clip in the stack 35 is transferred by the cantilevered lifter spring 86 after the second stage of the trigger stroke is completed.
A longitudinal channel 93 is formed in the lower jaw 9 through which a downwardly extending depression 88 of the feed bar 32 rides to ensure the proper placement of the distal end of the feed bar 32 with respect to the distal clip throughout clip advancement and placement. When the distal clip is lowered to the plane of the feed bar, the lower transverse tabs 76 ride on shelves 90 formed in the side walls 38 of the lower jaw 9. The shelves 90 interface with the inner surface of the lower transverse tabs 76. The upper transverse tabs 75 ride along ramps 91 which engage the inner surfaces of the upper tabs 75 and angle the upper tabs 75 towards the top jaw 8, causing the inner tissue engaging surfaces 78, 79 of the biased leg members 62, 63 to separate from each other to provide the opening 85. At the end of the ramps 91 the upper transverse tabs make a transition from the lower jaw 9 to rails 92 in the top jaw 8. The rails 92 engage the inner surface of the upper transverse tabs 75. Thus, the first tissue engaging surface 78 of the first leg member 62 is advanced into the top jaw 8 above the compressed tissue structure 99. The second tissue engaging surface 79 of the second leg member 63 is advanced into the lower jaw 9 below the compressed tissue structure 99.
Throughout the advancement of the clip, the body of the clip is contained within longitudinal channels 93 and 94 in the top jaw 8 and lower jaw 9, respectively. Upper transverse tabs 75 advance to openings 95 towards the distal end of the top jaw 8. The width of the opening 95 is greater that the inner width of the rails 92 and closely corresponds to the outside width of the upper transverse tabs 75. The tabs 75 disengage from the top jaw 8 as they are advanced through the opening 95, allowing the upper leg member 62 to resiliently move toward the lower leg member 63 and contact tissue structure 99 with the tissue engaging surface 78.
Likewise, at approximately the same time, lower transverse tabs 76 reach opening 96 towards the distal end of the lower jaw 9. The width of the opening 96 is greater that the inner width of the shelves 90, and closely corresponds to the outside width of the lower transverse tabs 76. This allows the tabs 76 to disengage from the lower jaw 9 through the opening 96, allowing the lower leg member 63 to resiliently move toward the upper leg member 62 and contact tissue with the tissue engaging surface 79. The position of the tabs 75,76 corresponds to the timing of leg member disengagement from the jaws 8,9 of the instrument, to correctly place the clip on the tissue. Although an upper and lower set of transverse tabs are shown, a number of combinations, including a single tab alone, are possible for disengaging a clip from the instrument.
In addition, the channel 94 in the lower jaw 9 curves upward at its distal end to urge the clip 34 upward as it is disengaged from the lower jaw 9. Also, a kickoff spring 101 having a free end 102 extends from distal end of floor 39 of lower jaw portion 41 through channel 94 of lower jaw 9. Free end 102 is biased upward towards top jaw 8. The kickoff spring 101 is compressed downward as the clip 24 is advanced distally into jaws 8,9. As top jaw 8 opens, the force holding the clip against the kickoff spring 101 is released and the spring 101 urges the clip out of the jaws 8,9.
The stack 35 of clips 34 is moved sequentially until all clips have been dispensed. The shaft 5 includes a clip indicator 80 which allows the user to identify when there are approximately two unused clips remaining in the instrument 1. The clip indicator 80 comprises two longitudinally positioned holes 81, 82 in the support tube 33 located towards the distal end of the support tube 33 and two corresponding holes 83, 84 in the grasper bar 31. The feeder shoe 70 has a colored marker 89 which shows through the holes 81, 82, 83, 84 when the feeder shoe 70 passes underneath the holes 81, 82, 83, 84 as it is advanced distally. When the feeder shoe 70 passes the first hole 81 and corresponding hole 83, two clips remain and when the feeder shoe 70 passes under the second hole 82 and corresponding hole 84, one clip remains.
A track plug 50 is positioned within the opening 47 of the lower jaw 41 and within the proximal end of the grasper bar 31, to reduce the outward flow of body cavity gases through the opening 47. The plug 50 is held in place and motionless with respect to the longitudinal motion of the grasper bar 31 and feed bar 32 by return spring 24.
Although the instrument is shown to have one moveable and one stationary jaw, the instrument may have both jaws moving to close over tissue to be occluded.
FIG. 3A illustrates a preferred embodiment of the clip applier 1 prior to actuation. At this stage, as further illustrated in FIG. 5A, the jaws 8,9 are open and may be placed about a tissue structure 99. FIG. 4A illustrates an enlarged cross section of the shaft 5 corresponding to the initial position of the device as illustrated in FIG. 3A. The transverse arms 74 of the feeder shoe 70 extend through slots 67 in side walls 68 of grasper bar 31 and are engaged against the notched surfaces 61 of the lower jaw walls 68. The tab 73 extends downward from the lower arm 72 and engages in one of a longitudinal series of slots 60 in the feed bar 32.
FIG. 3B illustrates the clip applier of FIG. 3A as it completes the tissue grasping stage of the trigger actuation. The protrusion 15 on the anti back-up arm 14 of the feed cam 16 has just engaged with the rib 7 of the housing. Thus, until this point (see FIG. 3A) the user can release the trigger 11 to open and reposition jaws 8,9. Just prior to locking, the protrusion 15 reaches the rib 7 and an increased tactile force is perceived by the user in actuating the trigger arm 18. The increased tactile force is a result of protrusions 3 on an arm 2 contacting rib 6 in housing 4. This indicates to the user that any additional force applied to the trigger arm 18 will require the user to complete the clip placement in order to release the jaws 8,9.
FIG. 4B corresponds to the stage just prior to locking. The jaws 8,9 are closed and the distal most clip has not been significantly advanced. Once the protrusion 15 engages with the rib 7 of the housing as shown in FIG. 3B, the trigger stroke must be completed.
FIG. 3B illustrates the end of the first stage and the initiation of the second stage of the trigger actuation. The protrusion has engaged with the rib 7 and the clip placement stage has been initiated (FIG. 3B). FIG. 4B corresponds to the clip advancing stage of the trigger actuation also illustrated in FIGS. 3B, 3C, SC, SD, and 5E. The feed bar 32 is advanced distally along with the feed shoe 70 which correspondingly advances the clip stack 35 the distance of one clip. Transversely biased arms 74 move across walls 68 of grasper bar 31.
As shown in FIG. 5C, the distal clip sits distally of the feed bar 32. The upper transverse tabs 75 of the first leg member 62 ride up ramps 91 to the top jaw 8, separating the inner tissue engaging surfaces 78, 79 of the biased leg members 62, 63 from each other to provide the opening 85.
In FIG. 5D, the clip 34 is advanced over the tissue structure. In FIG. 5E, the clip is disengaged from the shelves 90, rails 92, jaws 8,9 at the distal end 40. This corresponds to the end of the trigger stroke, as illustrated in FIG. 3C. When the clip 34 is disengaged and the trigger arm 18 is released, the trigger 11 will return to its original position illustrated in FIG. 3A.
FIG. 4C illustrates the shaft of the instrument when the trigger is released after the end of the trigger stroke. The in line spring 23 causes the feed bar 32 to retract. The biased arms 74 of the feed shoe 70, however, remain engaged against the walls 38 of the lower jaw portion 41 so that the feed shoe 70 remains stationary. The lower arm 72 of the feed shoe 70 ramps out of the slot 60a in feed bar 32 in which it was positioned and into the slot 60b distal of slot 60a. Also, the next distal most clip is moved downward from the feed bar 32 as the feed bar 32 is retracted at the end of the trigger stroke. The cantilevered spring 86 prevents the clip from retracting into the feed bar 32. Thus, feed shoe 70 and feed bar 32 are positioned to advance the next clip upon a subsequent actuation of the trigger 11.
The clips may be loaded and stored in the shaft as illustrated or, alternatively, in the handle, or, both shaft and handle. The applier may be capable of applying a plurality of clips as shown or a single clip. Also multiple clips may be simultaneously applied by adapting the device to accommodate multiple rows of clips and multiple disengagement means at the business end. A cutting means made be included in this embodiment, for cutting a ligated structure between two of the clips.
Referring now to FIGS. 13-16 there is illustrated an alternative embodiment of the present invention. An end effector 111 of a clip applying instrument is illustrated having: a shaft 105; a clip advancing fork 114 extending longitudinally through the lumen of a shaft 105; and a pair of pivotally attached hollow jaws 108, 109 coupled to the distal end of the shaft 105. The fork 114 has an upper prong 112 and a lower prong 113, respectively. Each prong 112,113 has a protrusion 116, 117 extending transversely from the prongs 112, 113. Each protrusion 116, 117 has a camming surface 118,119, respectively. The prongs 112,113 are respectively slidable within lumens 120,121 of jaws 108,109. The lumens 120, 121 of the jaws 108, 109 include camming surfaces 128,129 corresponding to camming surfaces 118, 119 of protrusions 116, 117.
A partially formed deformable clip 122 is situated within the fork 114. The clip 122 has legs 123, 124 connected on their proximal end by a connecting member 125 and forming a narrow opening 126 on their distal end. The clip 122 is held by the legs 123,124 between the prongs 112, 113 of the fork 114.
The jaws 108, 109 are initially biased away from each other. As the clip fork 114 is advanced, the prongs 112, 113 are advanced through the lumens 120, 121. As the fork 114 is advanced, the clip leg 123 slides within the lumen 120 of the top jaw 108 and the clip leg 124 slides within the lumen 121 of the bottom jaw 109.
In use, a tissue structure to be ligated is placed between the jaws 108, 109. The clip fork 114 is advanced, closing the jaws 108,109 together and pre-compressing the tissue structure between the jaws 108,109. The fork 114 simultaneously advances the clip 122 over the pre-compressed tissue structure so that the tissue structure lies between the legs 123, 124 of the clip 122. The opening 126 of the semi-formed clip 122 is just sufficiently large enough to fit over a pre-compressed tissue structure and is small enough to fit within the shaft 105. Prior to any contact between camming surfaces 118, 119 and camming surfaces 128,129, the fork may be retracted, releasing the jaws 108, 109 from the tissue structure before the clip 122 is closed over the tissue structure.
As the clip fork 114 advances further, the camming surfaces 118,119 contact camming surfaces 128, 129 which force the prongs 112,113 to close together. As the prongs close, they in turn force the legs 123,124 of the clip 122 to close together over the pre-compressed tissue. The clip 122 is made of a deformable material. Thus when the clip 122 is closed, it is formed into its final shape and remains closed.
The clip fork 114 may be retracted, thereby opening the jaws 108,109, leaving the clip in place, ligating the tissue structure.
Ligating clips may be applied to blood vessels during a surgical procedure either as a single clip using a single clip applier or utilizing a multiple clip applier. The instrument may be inserted through a cannula during an endoscopic procedure and if a multiple clip applier is being used, the instrument may ligate or place clips on a number of vessels at a number of locations.
The instrument may be made from various materials such as metals, plastic preferably a polycarbonate resin and the like. Usually if the instrument is made from stainless steel the instrument will be reusable while if the instrument is made from plastic materials the instrument will be disposable. In certain embodiments of the instrument of the present invention, the instrument may be designed to accept a replaceable cartridge of clips. This may be accomplished with either a reusable instrument or semi-disposable instrument which is meant to be used a number of times on a single patient.
Having now described the present invention, it will be readily apparent to Whose skilled in the art that various modifications and alterations may be made to the present invention without departing from the spirit and scope thereof. | A clip, clip applier and method for ligating a tissue structure is provided. The applier has a two stage actuation. In the first stage, a tissue structure is positioned into the jaws of the clip applier The jaws close and lock to a preset force to compress and temporarily occlude the tissue structure. If satisfactorily positioned, the second stage is initiated in which a clip is advanced through the shaft of the clip applier in a closed position. At the distal end of the clip applier, the clip is opened slightly to capture the pre-compressed tissue structure, and is placed over the structure. The clip is then dissociated from the business end of the instrument. Preferably the clip comprises two leg members disposed in close proximity to one another joined from opposing directions by a connecting element. The connecting element restricts separation of the leg members with opposing spring members so as to provide substantially uniform parallel deflection of the leg members from each other. | 8 |
TECHNICAL FIELD
The present disclosure relates to clutch systems.
BACKGROUND
In motorized vehicles, the clutch enables the engine drive train to be disconnected from the axels during changes in the drive ratio. Often, the clutch provides a friction coupling between the drive train and the axels. This friction coupling (for example, contact between two fiber-compound discs) may be prone to slipping as the drive train rotations per minute (RPM) increase. To alleviate this condition, a clutch cover may be employed.
FIGS. 1 and 2 are front and back view illustrations, respectively, of a prior art clutch cover 100 . The cover 100 may be employed in two and four stroke engine systems, such as Honda™ and Banshee™ motors for all terrain vehicles (ATVs). Bolts may be inserted through the holes 118 in the posts 106 to mount the cover 100 to a clutch flywheel of the engine. Heads of the bolts may recess into the counter-sink holes 120 . The shaft of the bolts may pass througb springs. As the bolts are tightened to the clutch flywheel, the springs come under tension, recessing the heads of the bolts into the holes 120 , and bringing the posts 106 into contact with a clutch pressure plate.
FIG. 3 is a side view illustration of a clutch finger 300 . The finger 300 has an arm 306 and a cam 304 . A bolt may be inserted through the hole 308 and secured with a nut to add weight to the end of the arm 306 . A pivot may be inserted through the hole 302 at the juncture of the arm 306 and the cam 304 . Fingers 300 may be inserted into the slots 110 of the cover 100 and the pivot may be recessed into the slots 112 . Retaining screws may be threaded into the holes 114 , and tightened until their heads are recessed into the countersink holes 116 , thus securing the finger pivots in the slots 112 .
Forming a hole 102 in the cover 100 lessens the weight and may accommodate possible protrusions of the transmission system. Forming bays 108 also lessens the weight of the cover 100 .
As engine RPMs increase, the arms 306 of the fingers 300 are drawn outward by centrifugal force, rotating the cam 304 against a pressure plate mounted behind the cover 100 . Rotation of the cams 304 against the pressure plate increases the force of the frictional coupling between the engine drive train and the axels, reducing slipping of the clutch at higher engine RPMs.
Weight and durability of system components are crucial factors in the performance of engine systems. An improved cover would benefit from further reductions in weight, while either improving or without compromising the durability of the cover.
SUMMARY
The following summary is intended to highlight and introduce some aspects of the disclosed embodiments, but not to limit the scope of the invention. Thereafter, a detailed description of illustrated embodiments is presented, which will permit one skilled in the relevant art to make and use aspects of the invention. One skilled in the relevant art can obtain a full appreciation of aspects of the invention from the subsequent detailed description, read together with the figures, and from the claims (which follow the detailed description).
A clutch cover includes posts to receive bolts to retain the cover to a clutch flywheel and retaining screw holes to retain clutch fingers mounted on the cover. At least one indent in each post accommodates the retaining screw holes and/or countersinks thereof. At least one edge of the cover is formed to create lips around slots to receive the clutch fingers. The lips may have a width narrower than the diameter of the retaining screw holes and/or the countersinks thereof. The cover may comprise two retaining screw holes for each clutch finger.
BRIEF DESCRIPTION OF THE DRAWINGS
The headings provided herein are for convenience only and do not necessarily affect the scope or meaning of the claimed invention.
In the drawings, the same reference numbers and acronyms identify elements or acts with the same or similar functionality for ease of understanding and convenience. To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.
FIG. 1 is a front view illustration of a prior art clutch cover.
FIG. 2 is a back view illustration of a prior art clutch cover.
FIG. 3 is a side view illustration of a clutch finger.
FIG. 4 is a front view illustration of an embodiment of a clutch cover.
FIG. 5 is a back view illustration of an embodiment of a clutch cover.
FIG. 6 is a side view illustration of an embodiment of a clutch cover.
DETAILED DESCRIPTION
The invention will now be described with respect to various embodiments. The following description provides specific details for a thorough understanding of, and enabling description for, these embodiments of the invention. However, one skilled in the art will understand that the invention may be practiced without these details. In other instances, well known structures and functions have not been shown or described in detail to avoid unnecessarily obscuring the description of the embodiments of the invention. References to “one embodiment” or “an embodiment” do not necessarily refer to the same embodiment, although they may.
Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise,” “comprising,” and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to.” Words using the singular or plural number also include the plural or singular number respectively. Additionally, the words “herein,” “above,” “below” and words of similar import, when used in this application, shall refer to this application as a whole and not to any particular portions of this application. When the claims use the word “or” in reference to a list of two or more items, that word covers all of the following interpretations of the word: any of the items in the list, all of the items in the list and any combination of
FIGS. 4–6 are front, back, and side view illustrations, respectively, of an embodiment of a clutch cover 400 . Posts 410 are formed with indents 411 . The posts 410 include holes 412 to receive bolts to mount the cover 400 to the clutch flywheel. Countersink holes 414 receive heads of the tightened bolts.
Fingers 300 may be inserted into the slots 402 of the cover 400 and a finger pivot (e.g. the pivot through finger holes 302 ) may be recessed into the slots 404 . Retaining screws may be threaded into the holes 420 , and tightened until their heads are recessed into the countersinks 418 , which may overlap the slots 402 , thus securing the finger pivots in the slots 404 . The indents 411 in the posts 410 accommodate the holes 420 and/or the countersinks 418 of the holes 420 , and enable positioning the holes 420 back from the edges 406 , 408 of the cover 400 . Positioning the holes 420 back from the edges 406 , 408 enables the removal of a substantial amount of material, forming lips 416 around the slots 402 , without compromising the durability of the cover 400 . Material may be removed from the cover 400 to form the edges 406 , 408 , and to create lips 416 having a width narrower than the diameter of the countersinks 418 of the holes 420 to receive the retaining screws. The lips 416 may even have a width narrower than the diameter of the holes 420 themselves. The edges 406 , 408 may form lips 416 having two portions 602 , 604 , one portion narrower than the other. Two holes 420 and countersinks 418 may be provided per finger pivot, securing the finger pivots at two positions of the slots 404 and further improving durability.
Further weight reductions are achieved by forming a hole 422 and bays 424 in the cover 400 .
Other embodiments may comprise additional or fewer posts 410 , and additional or fewer slots 402 , 404 for fingers 300 and pivots, respectively. In light of this disclosure, these and other modifications will now become apparent to those skilled in the art. | A clutch lockout includes posts to receive bolts to retain the lockout to a clutch boss and retaining screw holes to retain lockout fingers mounted on the lockout. At least one indent in each post accommodates the retaining screw holes. | 5 |
FIELD OF THE INVENTION
The present invention relates to ladders and, more particularly, to protective caps that secure over the ends of the rails of a ladder to protect the surface upon which the ladder leans when in use.
BACKGROUND OF THE INVENTION
Ladders have been used for decades by homeowners and commercial entities. Without a doubt, ladders provide great utility to those that use them. In decades past, most ladders were made of wood, but that has changed. Most ladders today are made of aluminum or fiberglass. Aluminum or fiberglass is desirable because the materials are lightweight and durable. Nonetheless, the rails that form the sides of the ladder have a tendency to cause damage to the surface upon which they are leaning. Further, hard plastic end pieces are often times used to protect the ends of the rails and are prone to damage the surface upon which they rest. It is not uncommon for the ladders to leave scratches and marks on, for example, vinyl siding.
Industry recognized this problem and, for a number of years, has offered protective caps that fit over the ends of the ladder rails. The caps are typically made from a pliable plastic. The caps serve to protect the surface upon which the ladder leans.
A problem, however, not addressed by the prior art is that ladder rails are not all sized the same. Thus, a protective cap designed to fit on one ladder rail will not fit on all ladder rails. If a user attempts to place a protective cap that is larger than the ladder rail cross-section, the cap will not fit securely on the ladder and can easily fall off the ladder rail. If a user attempts to place a protective cap on the ladder rail that is too small, it may not fit at all, or, if forced over the ladder rail, it may split after some time or during use. Further, the user often times does not know the size of the ladder rail. It is therefore much easier to buy a product that is adapted to fit over a broader range of varying sized side rails
SUMMARY OF THE INVENTION
This invention is directed to a protective ladder cap for fitting over the end of a rail of a ladder. The cap has an open end for fitting over the rail and a closed end. The cap has at least one elongated internal rib that tapers from a lower rib height closer to the open end than the closed end to a higher rib height closer to the closed end than the open end. In the preferred embodiment, the cap includes a plurality of internal ribs. The internal ribs also preferably comprise an indent portion adjacent the closed end of the rail to secure the cap on the ladder rail.
In the preferred embodiment, the protective ladder cap has two wide internal faces and two narrow internal faces. The internal ribs are on at least one of the wide internal faces, and preferably both. In an even more preferred embodiment, the internal ribs are on the narrow faces as well.
Because the internal ribs taper from a lower height to a higher height, the ladder cap is adapted to receive ladder rails of varying cross-section. Further, the tapered ribs ensure that the ladder cap is secured to the ladder, thus minimizing the ability of the ladder cap to fall off of the ladder rail. Because the ladder cap of the present invention is able to securely fit on ladder rails having varying cross-sections, consumers purchasing ladder caps are not required to know the cross-section size of their ladder rails. Thus, the ladder cap of the present invention also makes it much easier for consumers to purchase a ladder cap that fits snugly on the consumer's ladder.
These and other aspects of the invention are described more fully below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the ladder cap of the present invention shown as attached to the ends of the side rails of the ladder;
FIG. 2 is a perspective view of the ladder cap of the present invention;
FIG. 3 is a cross-sectional view of the ladder cap, taken along the plane parallel to the side face of the ladder cap and represented by section line 3 — 3 in FIG. 5;
FIG. 4 is a cross-sectional view of the ladder cap, taken along the plane parallel to the side face of the ladder cap and represented by section line 4 — 4 in FIG. 5; and
FIG. 5 is a cross-sectional view of the ladder cap, looking directly into the ladder cap and taken along the plane represented by section line 5 — 5 in FIG. 3 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the present invention is directed to a protective ladder cap 10 that is adapted to fit on a ladder 12 . The ladder, as is well known, typically includes two side rails 14 and a plurality of rungs 16 (only one shown) that are spaced apart to provide steps for the user. The ladder cap 10 is sized to fit over the ends of the side rails 14 to protect the surface upon which the ladder is resting.
As shown in FIG. 2, the protective ladder cap 10 comprises a cap 18 that has an open end 20 and a closed end 22 . The open end 20 is sized to fit over the end of the side rails. The opening is defined by the length from point 24 to point 26 , which is preferably about 3.5 inches and the length from point 28 to point 30 , which is preferably about 1.25 inches. The dimensions are sized to allow the ladder cap 10 to be easily slid over the ends of the side rails 14 . Referring to FIGS. 3 and 4, the inner surface 32 of the closed end 22 typically abuts against the ends of the side rails when the ladder cap is pushed onto the ladder side rails 14 . The cap 18 includes two wide sidewalls 34 and two narrow sidewalls 36 , which together with the top or closed end 22 form the cap 18 .
As shown best in FIG. 3, the ladder cap 10 includes two opposed side detents 38 that protrude inwardly to engage the side rails. From the detents 38 , the two wide sidewalls extend outwardly to the closed end 22 at approximately six degrees and the two narrow sidewalls extend outwardly to the closed end 22 at approximately fourteen degrees (i.e., both walls are angled outwardly slightly). The total height of the ladder cap 10 from the open end 20 to the closed end 22 is approximately 5.5 inches. The total height from the open end 20 to the middle of the detents 38 is approximately 2 inches.
The two wide sidewalls 34 of the ladder cap 10 have internal wide faces 40 and the two narrow sidewalls have internal narrow faces 42 . In the preferred embodiment, the ladder cap 10 includes a plurality of elongated internal wide face ribs 43 on the internal wide faces 40 , as shown in FIGS. 3 and 5. Referring to FIG. 4, the length of each wide face rib 43 is approximately 3 inches, and the height tapers from point 44 to a height of approximately 0.094 inches at point 46 . The taper from point 44 to point 48 is less than the taper from point 48 to point 50 . At point 48 , the height of the rib is approximately 0.219 inches and at point 50 the height of the rib is approximately 0.344 inches. The height at point 51 is approximately 0.438 inches. The internal wide ribs 43 preferably include a height of at least 0.250 inches and the rib is preferably tapered from a lower height of around zero inches to the maximum height, as shown in FIG. 4 at point 51 . Nonetheless, it is appreciated that the lower height could be more than zero. The lower the height, however, the easier to facilitate a smooth engagement by the end of the ladder rail onto the surface of the internal rib. It should also be understood that the terms “narrow” and “wide” as used herein are used simply as descriptive terms to distinguish between the various sides; the terms should not be construed to be limited to a particular dimension or size.
The wide face ribs 43 also include an indent portion 52 in the preferred embodiment. The indent portion together with the closed end 22 forms a u-shaped channel. The depth from point 51 to the bottom 54 of the indent portion 52 is approximately 0.344 inches. The width of each wide face rib 43 is approximately 0.100 inches and the distance between each rib is approximately 0.210 inches. As shown in FIG. 5, wide face ribs 43 extend inwardly beyond the open end 20 such that when the ladder cap 10 is slid on the end of a side rail 14 through open end 20 , the side rail 14 engages the tapered internal wide face ribs 43 . If the ladder cap 10 is pushed onto the side rail 14 sufficiently, the side rail lodges into the indent portion 52 , further holding the ladder cap 10 on the side rail.
In the preferred embodiment, the ladder cap 10 also has narrow face ribs 60 on the internal narrow faces 42 , as shown in FIGS. 3 and 5. The narrow face ribs 60 are approximately the same length as the wide face ribs 43 . The rib height tapers from point 62 to a height of approximately 0.438 inches at point 64 to a height of approximately 0.750 inches at point 66 . The width of each narrow face rib 43 is approximately 0.100 inches and the distance between each rib is approximately 0.210 inches.
It should be understood that the dimensions are only illustrative. One skilled in the art can readily appreciate how to alter the dimensions provided without departing from the spirit and scope of the invention. The same is true with respect to the number of internal ribs. In fact, the present invention would work, although not preferably, with only one thicker internal rib that engages the side rail when it is inserted into the ladder cap 10 . Also, the product will perform well with ribs on only the internal wide faces 40 and will work adequately if the ribs are located only on the side faces 42 . By placing ribs on opposed faces, the ladder cap 10 slides over the side rail 14 more evenly and increases the surface area of frictional engagement. In the preferred embodiment, the ladder cap 10 includes at least 5 internal wide face ribs on each wide face 40 and at least two narrow face ribs.
In use, the ladder cap 10 is slid over the end of a side rail 14 through open end 20 . The side rail 14 engages the internal ribs 43 and 60 . To the extent the ladder cap 10 is slid over a side rail 14 all the way, the side rail 14 should become lodged in not only the detents 38 but also the unshaped channel formed by the indent portions 52 and the closed end 22 , thus further securing the ladder cap 10 to the side rail 14 . The wide sides 34 and the narrow sides 36 that extend upwardly beyond the detents 38 to form the closed end 22 are approximately 0.250 inches thick.
The ladder cap is preferably made out of a PVC plastic that is a dielectric material. In the preferred embodiment, the material is plastisol.
While a preferred protective ladder cap has been described in detail, various modifications, alterations, and changes may be made without departing from the spirit and scope of the ladder cap according to the present invention as defined in the appended claims. | A protective ladder cap for fitting over the end of a rail of a ladder is provided. The cap has an open end for fitting over the rail and a closed end. The ladder cap has tapered internal ribs for engaging the end of a side rail of a ladder. The ladder caps prevent the ladder side rails from damaging the surface upon which the ladder leans when in use. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation-In-Part of, now abandoned, U.S. Patent Application Ser. No. 12/585,517, filed on Sep. 17, 2009 and published under Publication No. U.S. 2010/0126113 A1, which claimed benefit of U.S. Provisional Application for Patent Ser. No. 61/136,595, filed on Sep. 18, 2008, both of which being incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to wall construction, and in particular to a method and an apparatus for anchoring wall mounted furniture such as handrails, grab bars, cupboards and other items.
BACKGROUND OF THE INVENTION
[0003] U.S. Pat. Nos. 6,705,056 and 7,133,149 disclose a method and an apparatus of anchoring in which backing members are provided for positive location in between successive spatially disposed U-shaped metal studs forming a wall structure, the backing members being interlinked by a hinge. The backing members are provided with grooves which selectively register with overturned edges of the stud flanges thereby giving a positive location for the backing members with hinges affording continuity longitudinally of the wall structure formed by the studding. The backing members, which may be of plywood, are marketed together with the hinge in suitable lengths such as to present an integral combination, which in use constitutes a continuous strapping lengthwise of the studding thus providing flexibility during installation, but rigidity when properly fixed in position by the use of suitable fasteners.
[0004] Although the prior art recited supra represents a valuable contribution in the building trade giving time-saving installation advantages together with the structural integrity demanded by appropriate codes, the combination of the backing members and the hinge is cumbersome in terms of packaging, storage and to some extent in handling.
[0005] Accordingly, there is a need for an improved system for the installation of metal studding and the provision of the requisite heavy-duty backing members for the attachment of wall-mounted furniture normally to be found in commercial and residential premises.
SUMMARY OF THE INVENTION
[0006] It is therefore a general object of the present invention to provide an improved apparatus for and method of providing backing members interstitially between successive studding in a wall structure composed of metal studs.
[0007] An advantage of the present invention is to facilitate installation of the backing members to the studding.
[0008] A further advantage of the present invention is that the apparatus can be installed horizontally and transversally between successive face-to-back wall studs, vertically and longitudinally along any one wall stud, and horizontally and transversally between successive face-to-face wall studs.
[0009] Another advantage of the present invention is to provide apparatus which, when installed correctly, confers on the assembled studding a rigidity, straightness and strength that enable the application of plasterboard sheeting in a uniform plane.
[0010] A still further advantage of the present invention is that the apparatus now proposed provides elements that can be easily packaged, stored, handled, and secured to metallic wall studs, for reliable attachment thereto.
[0011] Another advantage of the present invention is to provide a kit of parts that can be marketed for both the commercial and DIY (Do-It-Yourself) sectors.
[0012] According to a first aspect of the present invention there is provided a backing member for horizontal or vertical installation in-between successive U-shaped metal studs forming part of a wall structure, the backing member comprising a generally planar first bridging limb having at a free first end thereof a first groove for registration with at least a flange of the metal stud, the first groove extending across a face of the first limb substantially parallel to and adjacent an edge of the free end of the first limb, and a second limb in the form of a bracing block extending orthogonally from the first limb at a second end thereof opposite the first end and secured to the second end, the second limb being dimensioned to engage a web of the stud internally or externally thereof, the first and second limbs in use extending in-between successive metal studs and being securable thereto by fasteners, wherein a second groove extending across said face of the first limb orthogonally with respect to the first groove and in parallel with another edge of the first limb extending between the first and second ends thereof, said second groove further extending across a second face of the second limb being in a coplanar relationship to said face of the first limb.
[0013] The primary intention of the backing member is to extend horizontally in-between and brace successive metal studs. However, in an alternative usage of the backing member, it may be disposed vertically at a marginal part of a single stud for securement to a flange thereof and for this purpose the backing member is provided with the second groove for registration with said flange, the second groove being arrayed orthogonally to the first-mentioned groove. This alternative usage may be of advantage for the fixing of certain room or office wall furniture.
[0014] A third registration groove may be provided on the backing member and extends parallel to the first-mentioned formation, the first and third formations being spaced apart a distance corresponding to the spacing of the flanges of successive studs facing each other. The third registration formation may be formed in the second limb. The backing member may conveniently be produced from wood, which may be of laminated form.
[0015] The studs are provided with flanges having turned-over edges which in use present detents to engage one or more of the said formations to afford positive location of the backing member in relation to the studs.
[0016] The formations are conveniently in the form of grooves for registration with and reception of turned-over edges or lips of the stud flanges.
[0017] It is to be understood that the backing members are securely fastened to the studs by the use of approved fasteners, generally threaded fasteners.
[0018] According to a second aspect of the present invention there is provided a kit of parts including a plurality of backing members each produced according to the first aspect of the present invention.
[0019] According to a third aspect of the present invention there is provided a method of providing at least one backing member between two successive vertically erected U-shaped metal studs constituting studding in a wall structure, each said stud being installed with the web thereof secured to an end abutment and its front and back flanges forming the open mouth of the stud facing along the studding, with said two studs being oriented in a wall direction with the flanges of a first one of the studs being oriented toward a second one of the studs, each flange of each stud being turned-over to provide marginal lips in the form of detents, each backing member employed being made in accordance with the first aspect of the present invention, the method including the steps of:
a—inserting the backing member in-between the two successive studs with the second limb abutting the external surface of the web of the second stud and a free end of the first limb abutting the internal surface of the front flange of the first stud, the at least one formation registering with the detent of the front flange of the first stud; and b—securing the backing member to both the first and second studs by the use of fasteners passing through the front flange of the first stud into the backing member and through the web of the second stud into the backing member.
[0022] Conveniently, the studding includes a third vertically erected U-shaped metal stud adjacent the second stud and being oriented in the opposite sense relative to the first and second studs with the flanges of the third studs being oriented toward the second stud, the at least one backing member being a first backing member and the at least one registration being a first registration adjacent the free end of the first limb thereof, a second backing member having a third registration formation being generally parallel to the first formation and located adjacent the second limb, the method further including the steps of:
c—inserting the second backing member in-between the second stud and the third stud with the free end of the first limb abutting the internal surface of the front flange of the second stud with the first formation registering with the detent of the front flange of the second stud and the second limb abutting the front flange of the third stud with the third formation registering with the detent of the front flange of the third stud; and d—securing the second backing member to both the second and third studs by the use of fasteners passing through the front flange of the second and third studs into the second backing member.
[0025] The invention also includes a wall structure produced by the method and incorporating a plurality of backing members secured to a plurality of studs, the combination constituting studding to which a plasterboard is secured.
[0026] Other objects and advantages of the present invention will become apparent from a careful reading of the detailed description provided herein, with appropriate reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] Further aspects and advantages of the present invention will become better understood with reference to the description in association with the following Figures, in which similar references used in different Figures denote similar components, wherein:
[0028] FIG. 1 is a perspective front elevation of a section of studding in a wall structure showing backing members in accordance with an embodiment of the present invention emplaced in-between successive studs;
[0029] FIG. 2 is a partially broken plan view of the studding shown in FIG. 1 ; and
[0030] FIG. 3 is a perspective front elevation of the embodiment of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] With reference to the annexed drawings the preferred embodiment of the present invention will be herein described for indicative purpose and by no means as of limitation.
[0032] FIG. 1 illustrates a section 1 of studding 2 forming part of a wall structure (not shown), the studding 2 being comprised of a plurality of metal U-shaped studs 4 each having a web 6 with flanges 8 extending orthogonally therefrom with overturned edges or lips 10 essentially parallel to the web 6 . Whilst the internal surface of the web 6 is substantially flat, its corresponding external surface 11 is slightly recessed in its central portion as at 12 . The proximal stud 4 a is typically secured to an end abutment 13 ( FIG. 2 ) with its surface 11 interfacing therewith and the open mouth of the stud facing along the length of the studding 2 , the successive studs 4 being oriented as shown in the opposite sense, up to a last and final distal stud (not shown) of the wall construction. Backing members 20 extend between and are positively located in relation to the studs 4 in a manner to be described below.
[0033] Referring now to FIG. 3 , a backing member 20 is depicted and comprises a first limb 22 and a second limb 24 extending substantially orthogonally therefrom at one end of the first limb 22 to give a generally L-shaped appearance of its cross-section. The first limb 22 has a first registration formation or groove 26 (or channel) extending across its width and opening into both edges and a second groove 28 extending lengthwise and intersecting the first groove 26 and a third groove 30 formed in the second limb, the first and third grooves being parallel one to the other or substantially so. The second groove 28 extends across both first 22 and second 24 limbs, and typically intersects both first 26 and third 30 grooves. The backing member 20 in this example of the present invention is of laminated form and is of the appropriate ply to comply with building codes, including its length dimension to substantially fit standard construction stud spacing(s) S (see FIG. 2 ), between successive face-to-back studs. The first and second limbs of the backing member 20 are typically securely attached to one another by staples or the like attachment, optionally with an adhesive there between. The backing member is conveniently produced from wood, which may be of laminated form of typically ¼ inch thick (as illustrated in FIGS. 2 and 3 ), and could preferably be pre-treated with afire-retardant. The second limb 24 provides for a relatively wider surface to abut the web 6 of the adjacent stud 4 than the thickness of the first limb 22 . Furthermore, the presence of the second limb 24 prevents a possible delamination, and therefore unreliable securing, that could occur if a screw would directly penetrates into the edge surface of the first limb 22 , within the plane thereof, in between adjacent layers of the laminate.
[0034] As shown in FIG. 3 , typically, the overall length A of the backing member 20 is, in English units, an eighth of an inch (⅛″) smaller than the stud spacing S. for example 15⅞ inches for a stud spacing S of 16 inches. The distances B, C, D of the center of the respective first 26 , second 28 and third 30 grooves to the corresponding close edge of the backing member 20 are typically 11/8″, ⅝″, and 1⅛″, respectively, while the typical groove width is about ⅛″. The width dimension of the backing member 20 may considerably vary depending of the intended use and expected load support. To this end, a substantially square shape backing member 20 s is illustrated in FIG. 1 .
[0035] Although a different and less convenient installation order could be considered, the first backing member 20 to be installed is typically the leftmost one 20 c, in the present case of FIG. 1 , simply for ease of installation. Then the following backing members 20 are successively installed the same way in-between successive studs 4 .
[0036] For the last but one backing member 20 b, the second limb 24 abuts the external surface 11 of the second stud 4 b as can be seen in FIG. 2 , typically in register with the front flange 8 thereof, and is secured thereto by means of screws 32 or the like extending through the web 11 into the backing member 20 b, whilst the first limb 22 extends into the open mouth of the third stud 4 c with the lip 10 of the front flange 8 interengaging and registering with the first groove 26 , with the end of the first limb 22 typically abutting the internal surface of the web 6 . The first limb 22 receives a screw 32 ′ or the like extending through the front flange 8 .
[0037] In use with the proximal stud 4 a being oriented as shown (in a face-to-face relationship with the second stud 4 b ), the first backing member 20 a is finally (when other backing members 20 b, 20 c were previously installed) inserted in-between that first proximal stud 4 a and the second, successive stud 4 b in the studding 2 . As can be seen more particularly in FIG. 2 , the third groove 30 is caused to register with the lip 10 of the front flange 8 of the stud 4 a, the lip forming a detent for positively locating the backing member 20 a on the stud 4 a . At the other end of the backing member 20 a, similarly to the installation of previous backing members 20 b, 20 c, the first groove 26 is caused to engage the lip 10 of the front flange 8 of the second stud 4 b with the end of the first limb 22 typically abutting the internal surface of the web 6 of stud 4 b. The limbs 22 and 24 are secured to the respective studs 4 a and 4 b by means of screws 32 or the like extending through the respective flanges 8 into the backing member 20 a.
[0038] As it would be obvious to one skilled in the art, only the first backing member 20 a could be installed between the first and second studs 4 a, 4 b, without having to previously install any other adjacent backing members 20 .
[0039] Typically, at the end, all studs 4 are braced one to the other with the backing members 20 provided for wall furniture fixtures and fittings, placed on a plasterboard 40 ( FIG. 2 ) secured to the studding 2 .
[0040] If it should be desired to provide a backing member 20 v in a vertical orientation as can be seen in FIG. 1 on the proximal stud 4 a, the second groove 28 is caused to engage the lip 10 on the front flange 8 of the stud 4 a and screws 32 are applied through that flange into the backing member 20 v to secure the latter in position as shown.
[0041] The backing member of the present invention is of such dimension as to be easily packaged and thus stored. Accordingly, the invention may be supplied in kit form to the extent that suitable fasteners may be included thereby enabling a user to apply the backing member to pre-erected metal studding in a simple and swift manner, obviating the need for complicated strapping arrangements. The versatility of the invention in terms of its orientability in either the horizontal or the vertical mode is an added advantage.
[0042] Although the present invention has been described with a certain degree of particularity, it is to be understood that the disclosure has been made by way of example only and that the present invention is not limited to the features of the embodiments described and illustrated herein, but includes all variations and modifications within the scope and spirit of the invention as hereinafter claimed. | A drywall backing apparatus for metal studding consists of a two-limb backing member, with one limb extending orthogonal to the other to present a generally L-shaped form. The metal studding comprises a plurality of U-shaped studs, the flanges of which have overturned edges for engagement and registration with grooves in the backing member which bridges and is secured by fasteners to successive studs to provide suitable fixing for wall furniture. | 4 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority benefit of Provisional U.S. Patent Application, Ser. No. 61/733,168, filed on Dec. 4, 2012. This Provisional U.S. Patent Application Ser. No. 61/733,168, in its entirety, is incorporated by reference into this specification and is made a part hereof, including but not limited to those portions which specifically appear hereinafter.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to devices and methods such as for impressing a specifically desired pattern or form into uncured concrete for a sidewalk, floor, barrier, wall, or other selected surface, More specifically, this invention relates to a device with a negative relief for imprinting a texture into uncured concrete to create an appearance of, for example, brick pavers, stone patterns, and hardwood flooring.
2. Description of Related Art
The manufacture or creation of various specifically desired patterns or forms on wet or uncured concrete such as sidewalks, barriers, walls or other selected surfaces can oftentimes be more costly, in terms of either or both time and resources, than may ultimately be desired. As a consequence, alternative techniques for forming or creating such surfaces in actuality or in appearance have been desired and sought.
U.S. Pat. No. 5,228,799 discloses a device for imprinting patterns on concrete is formed of a lightweight cylindrical member with a raised grid pattern thereon for forming the impressions. The device of this invention requires a particular handle and cannot be used with a commonly-owned handle, such as a conventional paint roller, thereby increasing the cost for a user of this device.
U.S. Pat. No. 5,421,670 discloses a roller assembly for imprinting a pattern in a malleable surface wherein a hub is formed with a cylindrical frame that receives a pattern forming shell thereon. The device of this invention requires a motor and is limited to use with a specific handle and roller and cannot be used with a commonly-owned handle, such as a conventional paint roller.
U.S. Pat. No. 6,923,630 discloses an apparatus and a method for impressing three-dimensional patterns in a slip-formed concrete wall. At least one impression roller is provided at the discharge end of a slip form. The impression roller includes an outer periphery, provided with a layer or coating of resilient material. The layer is pre-formed or pre-cast to include an aesthetically pleasing, three-dimensional pattern. The axis of the roller is maintained in parallel relation to the plane of the exposed surface of the wall, with the outer periphery of the roller slightly depressed into the wall surface. As the uncured concrete wall emerges from the slip form, the impression roller places a pattern into the wall surface which corresponds to the pattern on the roller. Movement of the roller along the wall causes the impression roller to rotate, impressing successively formed portions of the wall with the pattern. Additional rollers may be used to impress patterns on the opposing wall surface, as well as the top wall surface.
There is a need and demand for devices and methods of sufficiently low cost and ease of operation and implementation such as to more easily allow or permit individuals to use such devices and methods without requiring extensive training or practice and without requiring costly specialized utensils or tools.
SUMMARY OF THE INVENTION
A general object of the invention is to provide improved devices and/or methods such as for impressing a specifically desired pattern or form onto a sidewalk, barrier, wall, or other selected surface.
A more specific objective of the invention is to overcome one or more of the problems described above.
These and other objects of this invention are addressed by a device for impressing a design into uncured concrete including a hollow cylindrical sleeve which can be paired with a conventional paint roller with a roller applicator with a nap. The hollow cylindrical sleeve preferably includes an inner tubular surface which includes a surface texture to engage the nap of the conventional paint roller and an outer surface which includes a negative relief for imprinting a texture and/or a design in uncured concrete to create an appearance of a variety of materials such as, but not limited to, brick pavers, stones, and hardwood. Alternatively the negative relief can be used to create impressions of logos, characters, nature scenes, trademarks quotes, sayings, and other visual impressions. In a preferred embodiment, the hollow cylindrical sleeve further includes a taper on each end. The taper minimizes or preferably avoid undesired contact of the ends of the hollow cylindrical sleeve to the uncured concrete.
In an alternative embodiment, the hollow cylindrical sleeve can be joined to another type of handle which allows the hollow cylindrical sleeve to rotate without requiring a conventional paint roller.
In a preferred embodiment, the hollow cylindrical sleeve is manufactured from a durable material which stands up to repeated impressions on concrete including, for example, Shore A urethane, Shore D urethane, silicone, latex, plastic, and any other material known to one having skill in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective angled side view of a roller element, in accordance with one embodiment of the invention, for impressing a pattern onto a desired surface.
FIG. 2 is a perspective end view of the surface-impressing roller element shown in FIG. 1 .
FIG. 3 is a perspective angled side view showing a conventional paint roller sleeve partially inserted into the surface-impressing roller element shown in FIG. 1 .
FIG. 4 is a perspective angled side view showing the surface-impressing roller element shown in FIG. 1 and the conventional paint roller sleeve shown in FIG. 3 but now with the conventional paint roller sleeve fully inserted within the surface-impressing roller element.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides an improved device for impressing a specifically desired pattern or form onto uncured concrete such as a sidewalk, floor, barrier, wall, or other selected surface. Also provided are corresponding or associated methods for impressing a specifically desired pattern or form onto a sidewalk, barrier, wall, or other selected surface.
FIGS. 1 and 2 illustrate a surface-impressing roller element, in accordance with one embodiment of the invention and generally designated by the reference numeral 10 . As detailed further below, the surface-impressing roller element 10 is useful for impressing a desired selected pattern onto a chosen surface of uncured or wet concrete.
The surface-impressing roller element 10 can desirably have or be in the form of a hollow cylindrical sleeve such as adapted to fit over and engage with a conventional or standard paint roller element. For example, the surface-impressing roller element 10 can generally include a hollow cylindrical sleeve 12 having opposed ends 14 and 16 , an outer surface 18 with a negative relief 19 formed, shaped or textured to provide a desired surface impression upon application or use, and an inner surface 20 . By way of example and not necessarily limitation, the outer surface 18 can be formed, shaped or textured to provide desired surface impression upon application or use such as in the form or appearance of brick, stone, rock, wood or other materials as may be desired in a specific or particular application. Thus, those skilled in the art and guided by the teachings herein provided will appreciate that the broader practice of the invention is not necessarily limited or restricted by or to the form or appearance of the surface impression resulting from the use of a roller element in accordance with the invention.
As perhaps best seen by reference to FIG. 2 , the surface-impressing roller element 10 and, more specifically the hollow cylindrical sleeve 12 has an inner diameter 22 and an outer diameter 24 . Further, the inner surface 20 may, in accordance with one embodiment of the invention, desirably include appropriate cross hatching or other selected surface texturing, generally designated by the reference numeral 26 , to better ensure desired engagement with an associated conventional or standard paint roller element such as may desirably be inserted or disposed there within, such as described in greater detail below.
Surface-impressing roller elements in accordance with the invention can be desirably fabricated or manufactured from various materials such as known in the art including, for example, Shore A urethane (such as Shore A urethane with a durometer in the range of 25 to 100), Shore D urethane, silicone, latex, or any other material known to one skilled in the art. Further, those skilled in the art and guided by the teachings herein provided will understand and appreciate that surface-impressing roller elements in accordance with the invention can be desirably fabricated or manufactured by various techniques including, for example, injection molding.
Turning now to FIGS. 3 and 4 , there is shown a conventional paint roller sleeve, generally designated by the reference numeral 30 being and then completely inserted into the surface-impressing roller element 10 such as to form a combination designated by the reference numeral 40 . As will be appreciated by those skilled in the art and guided by the teachings herein provided, surface-impressing roller elements in accordance with the invention can be variously sized as may be desired for specific applications. For example, surface-impressing roller elements in accordance with selected preferred embodiments of the invention can be appropriately sized, e.g., have an appropriate inner diameter 22 such as to permit and ensure desired and proper placement and use with standard sized paint roller sleeve such as having ½, ¾, ⅜ inch or other sized nap. In an alternative embodiment, the surface-impressing roller elements in accordance with the invention can be sized to fit directly to the paint roller without a paint roller sleeve.
As shown, the outer surface 18 of the surface-impressing roller element 10 can, if desired, be tapered 28 at or adjacent either or both the ends 14 and 16 , respectively, such as to minimize or preferably avoid undesired contact of the specifically formed, shaped or textured outer surface at such end portions.
Further, the as identified above, the conventional paint roller sleeve 30 includes a nap 32 of such size, shape and/or form to facilitate engagement with the associated surface-impressing roller element 10 . More particularly, the surface-impressing roller element 10 and more specifically the inner surface 20 thereof such as including cross hatching or other selected surface texturing 26 (shown in FIG. 2 ), engages with the paint roller sleeve 30 and, more specifically, the nap 32 to form a stable component effective to impress a desired pattern or form onto a surface upon which the surface-impressing roller element 10 is applied. More specifically, the firm engagement of the paint roller sleeve 30 with the surface-impressing roller element 10 preferably prevents slipping or movement of the surface-impressing roller element 10 relative to the paint roller sleeve 30 .
In a preferred embodiment shown in FIGS. 1-4 such engagement is preferably ensured by a tight press fit of the roller element 10 relative to the paint roller sleeve 30 and particularly the flexible nap of the paint roller sleeve 30 . According to another preferred embodiment of the invention, the surface-impressing roller element 10 may be constructed of latex or similar highly flexible material and may be elastically rolled onto the paint roller sleeve 30 thereby creating a tight engagement between the surface-impressing roller element 10 and the paint roller sleeve 30 .
With the paint roller sleeve 30 appropriately inserted and engaged with the surface-impressing roller element 10 , there is formed the combination 40 such that the surface-impressing roller element 10 can be appropriately rolled over or onto a desired selected surface such as to impress the form, shape or texture of the surface-impressing roller element 10 there onto.
The invention illustratively disclosed herein suitably may be practiced in the absence of any element, part, step, component, or ingredient which is not specifically disclosed herein.
While in the foregoing detailed description this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purposes of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention. | A device for impressing a pattern or design into uncured concrete having a hollow cylindrical sleeve which can be paired with a conventional paint roller with a roller applicator sleeve having a nap. The hollow cylindrical sleeve includes an inner tubular surface which includes a inner surface texture to engage the nap of the conventional paint roller and an outer surface which includes a negative relief for imprinting a texture and/or a design in uncured concrete to create an appearance of a variety of materials such as, but not limited to, brick pavers, stone, rock, and hardwood. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/983,773 filed Oct. 30, 2007, and incorporated herein by reference in its entirety.
[0002] This application claims the benefit of U.S. Provisional Application No. 61/060,946 filed Jun. 12, 2008, and incorporated herein by reference in its entirety.
FIELD OF INVENTION
[0003] The present invention relates to building construction and, more particularly, to a prefabricated building wall section system for use in replacing concrete blocks.
BACKGROUND OF THE INVENTION
[0004] Typical building construction uses concrete blocks that are individually set in mortar to construct walls of a building. These blocks are nominally 8×8×16 inches when measured with the associated mortar joints. Each block weighs about 40 pounds and the laying of the blocks to create a wall is a labor intensive task. Various methods have been proposed to overcome the labor issues involved in laying block, including creating forms and pouring solid concrete walls. Other proposals have used prefabricated wall panels such as foam core panels that can be put in place and then sprayed with a concrete surface. It has also been proposed to prefabricate a foam core panel with outer concrete surfacing that can be lifted in place using lifting apparatus at the job site. However, recent changes in building codes have required that building walls have sufficient strength to withstand winds associated with hurricanes and tornados.
BRIEF DESCRIPTION OF THE INVENTION
[0005] A prefabricated wall system used in constructing a structure is disclosed. The system has a wall segment configured to be lightweight and easily handled manually while constructing the structure. A securing system is disclosed being configured to secure the wall segment in place on the structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] A more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, exemplary embodiments of the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
[0007] FIG. 1 is a composite view of all of the individual elements that are joined together to form a prefabricated wall section;
[0008] FIG. 2 shows the components of the wall section of FIG. 1 as they are assembled to form a wall section;
[0009] FIG. 3A shows an exemplary embodiment of the components of another wall section as components are assembled to form the wall section;
[0010] FIG. 3B shows an exemplary embodiment of additional components of the wall section illustrated in FIG. 3A as components are assembled to form the wall section;
[0011] FIG. 4A shows an exemplary embodiment of the components of another wall section as components are assembled to form the wall section;
[0012] FIG. 4B shows an exemplary embodiment of additional components of the wall section illustrated in FIG. 4A as components are assembled to form the wall section;
[0013] FIG. 5 shows an exemplary embodiment of the components of another wall section as components are assembled to form the wall section;
[0014] FIG. 6 illustrates an assembly of the wall sections to form a wall;
[0015] FIG. 7 illustrated an assembly of the wall section upon a floor;
[0016] FIG. 8 illustrates a final wall assembly;
[0017] FIG. 9 is a partial cutaway and external view of a wall assembly using a concrete post and beam application;
[0018] FIG. 10 is a partial cutaway and external view of a wall assembly using a steel post and beam application;
[0019] FIG. 11 illustrates a wall assembly with a window;
[0020] FIG. 12 illustrates details of a portion of the wall assembly;
[0021] FIG. 13 is a cross-sectional view of the window installation in the wall assembly;
[0022] FIG. 14 illustrates a starter block used to minimize water incursion into a structure;
[0023] FIG. 15 illustrates the use of the starter block in a wall structure;
[0024] FIG. 16 is an enlarged cross-sectional view of the starter block and wall assembly;
[0025] FIG. 17 shows one form of sill board for use in the window structure of FIG. 13 ;
[0026] FIG. 18 is a cross-sectional view of a wall segment arrangement of FIGS. 3A and 3B .
[0027] FIG. 19 is a cross-sectional view of a wall segment arrangement of FIGS. 4A and 4B .
[0028] FIG. 20 is a cross-sectional view of a wall segment arrangement of FIG. 5 .
[0029] FIG. 21 is a cross-sectional view of another exemplary wall segment;
[0030] FIG. 22 is a cross-sectional view of another exemplary wall segment arrangement; and
[0031] FIG. 23 is a cross-sectional view of another exemplary wall segment arrangement.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Reference will now be made in detail to the embodiments consistent with the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals used throughout the drawings refer to the same or like parts.
[0033] Though exemplary embodiments of the present invention are described with respect to concrete post and beam construction, the exemplary embodiments disclosed herein are also applicable for steel post and beam construction. Towards this end, the exemplary embodiments of the present invention is applicable for a plurality of uses, including but not limited to high rise structural construction other uses, where improved wind load tolerances and reduced effects of seismic activity is realized.
[0034] Turning now to FIG. 1 , the various components that make up the inventive wall section are each illustrated as individual items in this figure. Each of the items are previously cut or sized to fit a particular desired dimensional wall section, such as but not limited to a 5×9 or 4×8 section. As shown in FIG. 1 , the individual pieces comprise a metal stud 10 which extends through the longest length of the wall section and a metal track 12 which is used to join the completed sections or panels. The panels use metal channels 16 and angle bars 14 to join the metal studs 10 into a rectangular configuration. The components also include a corrugated galvanized steel panel 18 between the metal studs. The remaining components include a thermal ply layer 20 which is attached to one side of the assembled metal studs. A rib lathe 22 is fastened to the outer exposed area of the thermal ply layer to form a surface for receiving stucco or other outer material such as lightweight concrete. Insulation 24 is placed between the studs 10 . A lightweight concrete drywall panel 26 may be poured in situ over the rib lathe 22 to form the panel.
[0035] Referring to FIG. 2 at 30 there is shown an assembly of the metal studs 10 fastened together at opposite ends by transverse angle bars 14 . In addition, the center studs 10 a and 10 b are fastened together by means of the metal track 12 . The combination of the studs 10 , track 12 , and angle bars 14 forms a skeleton structural unit 30 which is the basis for the wall panel. The bars 14 are fastened to the studs along one edge and then the assembly 30 is inverted to receive the thermal ply outer panel 20 . The panel 20 is attached to the framework 30 by screws or other suitable means well known in the art. The rib lathe 22 is then attached to the thermal ply layer by screws to form a bonding surface for the lightweight concrete panel 26 . The lightweight concrete panel indicated at 26 in FIG. 1 is formed on the assembly 32 by placing the assembly in a form and pouring the concrete over the rib lathe.
[0036] FIGS. 3A and 3B show exemplary embodiment of the components of another wall section as components are assembled to form a wall section. As illustrated in FIG. 5A , a vapor barrier, such as but not limited to Visqueen®, stretched over a mold 99 . The framework 30 is secured to the mold 99 . Foam insulation 100 is inserted into the openings in the framework 30 . Plumbing and electrical conduits 62 , such as but not limited to cold rold channels and electrical chases, are installed into the framework 30 . As illustrated holes 104 , or openings, are formed through the framework 30 to accommodate the conduits 102 .
[0037] Turning to FIG. 3B , a thermal ply layer 108 is attached over the opening where the conduits 102 are visible between the framework 30 . A second layer of foam insulation 110 is attached to the thermal ply layer 108 and the framework 30 . A third piece of foam insulation 112 is installed over the framework 30 . Whereas the first and second layers of foam insulation 100 , 110 are multi-faceted pieces configured to fit within openings in the framework 30 , the third layer of insulation 112 is a solid piece configured to cover the exposed edge of the framework 30 , furthest away from the mold 99 . As further illustrated, a home wrap, Visqueen® or another coating, 114 is stretched and secured to the third layer of foam insulation 112 . A lath 116 is then placed over the home wrap 114 and attached to the framework 30 and/or third layer of insulation 112 , collectively forming a wall segment 118 .
[0038] FIGS. 4A and 4B show exemplary embodiment of the components of another wall section as components are assembled to form the wall section. As illustrated in FIG. 6A , a mold 120 is coated with a lightweight concrete coating 122 , such as but not limited to the lightweight concrete coating disclosed in U.S. patent application Ser. No. 12/166,494, filed Jul. 2, 2008, herein incorporated by reference. A mesh panel 124 is inserted into the poured concrete 122 . The mesh panel 124 may be made of a metal and/or a plastic material. The mesh panel 124 is further covered with the lightweight concrete 122 and the concrete is then leveled off. A framework 30 is fixed within the concrete 122 . The framework 30 has threaded rods 126 , such as but not limited to steel rods, inserted through the framework 30 . The threaded rods 126 are provided to apply tension within the core of the finished wall segment. Application of tension to the rods 126 significantly increases strength and surface impact resistance. A temporary mold 128 is formed by placing a removable material, such as but not limited to Styrofoam® beneath the threaded steel rods 126 . Though Styrofoam® is disclosed, the type of material used is a material to define an area during construction of the wall.
[0039] Turning to FIG. 4B , a second layer of mesh 130 is placed in the openings of the framework 30 , over the threaded rods 126 . Another layer of lightweight concrete 122 is then poured within the openings of the framework 30 . A thermal ply 20 , such as but not limited to a single piece, is secured over the framework 30 . A lathe 132 is fastened to the framework 30 , over the thermal ply. A foam board 134 is installed and then a final layer of the lightweight concrete 122 is applied. After the concrete 122 has set, the formboards 134 and Styrofoam molds 128 are then removed, forming the wall segment 136 . This configuration has no foam insulation. Therefore, toxic fumes are eliminated in case of a fire.
[0040] FIG. 5 shows exemplary embodiment of the components of another wall section as components are assembled to form the wall section. A mold 140 is provided. Either lightweight concrete or another type of board, such as but not limited to a Magnesium Oxide board, 142 is installed in the mold 140 . Foam insulation 144 is attached to the concrete/board 142 . A top surface of the wall segment has a concrete layer and/or the magnesium oxide board 144 . Such a wall segment 150 is lightweight and has a high R-value rating. An R-value rating is based on a measure of thermal resistance used to compare insulating values. The higher the R-value of a material, the better its insulating capability. Additionally, such a wall segment 150 has high impact resistant qualities while being flexible.
[0041] At a construction site, the individual panels indicated at 34 in FIG. 6 are assembled by joining the ends of the panels together using the metal tracks 12 . The tracks 12 are screwed to the studs 10 using conventional metal screws designed for this purpose. As shown at 40 in FIG. 6 , the initial panel stands on end and is positioned over a vertically extending reinforcement bar and then rotated around the rebar and slid into position so that the panel is actually connected to the reinforcing bar indicated at 42 . A plurality of the panels 40 is then sequentially placed adjacent each other and joined together by the metal tracks 12 as indicated at 44 . The corrugated galvanized steel indicated at 18 in FIG. 1 is inserted into the wall panels between each of the pair of parallel studs 10 . Once the corrugated galvanized steel panels 18 are positioned between the studs 10 , a one and one-half inch metal channel is slid through the holes that are conventionally formed in the metal studs and rotated to lock the studs and corrugated steel in place as shown at 46 . As each of the preformed panels is slid into place and attached to an adjacent panel by means of the six inch track 12 , a space is formed between the adjacent panels that can be used to receive concrete so that the wall is joined by formed in place concrete piles between each of the pairs of panels.
[0042] The individuals panels, or wall segments indicated at 34 , in FIG. 2 , 118 in FIG. 3B , 136 in FIG. 4B , and 150 in FIG. 5 can be installed in a similar manner as disclosed above. In another exemplary embodiment, illustrated in FIG. 7 , once a floor 152 is laid for a building structure, the track 156 , such as but not limited to a steel track, is secured to the floor 152 . The steel track 156 is segmented by tenants 158 , such as but not limited to steel tenants. The wall segments 34 , 136 , and 150 are positioned on the tracks 156 therebetween the tenants 158 . A tubing 160 , such as but not limited to a vertical steel tubing, is placed between adjacent wall segments, and a horizontal tubing 162 , such as but not limited to a steel horizontal tubing, is secured above the wall segment.
[0043] Turning now to FIG. 8 , at 50 , in another exemplary embodiment, there is shown upper and lower reinforcing bars 52 extending lengthwise across the top of the assembled panels so that a concrete tie-beam can be poured in place across these panels and joined by the reinforcing bar extending crosswise of the panels. The reinforcing bars 52 are conventional reinforcing bars used in wall construction. At 54 there is shown a further step in the assembly in which the insulation material 24 is pushed in place between the vertical studs 10 . Note that the insulation 24 is in two pieces, one long piece and one short piece to accommodate the joint formed at the top of the studs by the crossing angle bar 14 . Once the insulation has been placed between the studs as indicated at the assembly 56 , the concrete reinforcement can be pumped into the down cells formed between adjacent panels by tracks 12 and into the top area in which the reinforcing bar 52 is located so that the down cells and cross tie-beam are integrally joined. Finally, the wall 58 can be completed by conventional attachment of a drywall panel 60 to the inside of the walls overlaying the insulation material 24 .
[0044] As disclosed herein, the wall segments are utilized with a concrete and/or steel post and beam application. FIG. 9 discloses a wall where a concrete post and beam application is used. Once the walls are in place, such as secured to the track 156 , concrete, reinforced concrete, is poured therebetween adjacent wall segments to form the post 165 . A concrete beam 166 , with reinforced concrete, is poured horizontally across the top of the wall segments. An upper track 157 is provided to define the location where the cement is poured forming the concrete beam 166 .
[0045] FIG. 10 discloses a wall where a steel post and beam application is used. In this embodiment, the steel posts 170 are secured in place after the floor is poured. The wall segments are lifted over the steel posts and are lowed down into position. The walls are then bolted to the steel beam 172 once it is placed on top of the wall segments. Those skilled in the art will readily recognize that a plurality of various wall segments, such as but not limited to those disclosed herein, may be utilized for the wall segments.
[0046] FIG. 11 shows how a window and hurricane shutter assembly can be incorporated in the wall section. In this example, the wall section is formed of two spaced cementious panels 70 and 72 with Styrofoam filler 76 between the panels. A poured concrete tie beam across the top of the wall at 74 provides structural strength. Again, those skilled in the art will readily recognize that a plurality of various wall segments, such as but not limited to those disclosed herein, may be utilized for the wall segments.
[0047] FIG. 12 shows detail of another form of the wall structure in which the wall is made up of multiple segments each defined by a concrete header, footer and side beams. Between these concrete elements, the wall is formed by a corrugated steel panel 78 mounted to the vertically oriented metal studs 80 .
[0048] FIG. 13 is a cross-sectional view of the window arrangement of FIG. 11 illustrating a structure in which the building base is built on a footer 82 and raised to ground level or above by conventional concrete blocks 84 . A starter block 86 is placed on the blocks 84 at the level of the concrete slab 88 . The wall panels 58 are then erected on the starter block 86 with a beveled mud set at 90 . Along the bottom of the window opening there is beveled window sill 92 and a buck strip 94 . Details of the sill 92 are shown in FIG. 17 . The sill forces the penetrating water to drain to the exterior. Details of the starter block 86 are shown in FIG. 14 . This block serves as a formboard and a recessed trap to catch water that penetrates through the outer wall. The starter block is formed of a material that absorbs the water and releases it below ground level. FIG. 15 provides a better view of the arrangement of the starter blocks 86 along a support wall.
[0049] FIG. 16 is an enlarged view of the interface of the wall section 58 with the starter block 86 at slab level. It should be noted that the beveled concrete insert 90 locks the bottom of the wall panel to the slab.
[0050] FIG. 18 is a cross-sectional view of a wall segment arrangement of FIGS. 3A and 3B . FIG. 19 is a cross-sectional view of a wall segment arrangement of FIGS. 4A and 4B . FIG. 20 is a cross-sectional view of a wall segment arrangement of FIG. 5 . FIG. 21 is a cross-sectional view of another wall segment. This wall segment 180 has a thermal ply barrier 20 next to the framework 30 . Foam insulation 144 is next to the other side of the framework 30 and the last layer is a vapor barrier 190 . As disclosed herein with respect to the other wall segments, opening 104 for electrical connections and plumbing are also provided. FIG. 22 is a cross-sectional view of another wall segment arrangement. This wall segment 194 has a lightweight concrete coating 122 next to a foam insulation 144 . The next layer is a thermal ply 20 , followed by the framework 30 . A vapor barrier 190 is the final layer. FIG. 23 is a cross-sectional view of another wall segment arrangement. This wall segment 196 has a lightweight concrete coating 122 next to corrugated steel 191 . A thermal ply layer 20 is then provided. Foam insulation 144 is then provided, followed by the framework 30 . As illustrated two levels of foam insulation 144 are used. A vapor barrier 190 is the final layer. Also displayed in FIGS. 18 though 23 are rebar 201 , the concrete beam 166 , the steel upper track 157 , and a top plate 203 . In each configuration, the wall segment is fixed to the starter block 86 and to the foundation or floor 152 , including Z-flashing 206 between the foundation 152 and wall segment.
[0051] While the invention has been described with reference to various exemplary embodiments, it will be understood by those skilled in the art that various changes, omissions and/or additions may be made and equivalents may be substituted for elements thereof without departing from the spirit and scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Moreover, unless specifically stated any use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another. | A prefabricated wall system used in constructing a structure, the system including a wall segment configured to be lightweight and easily handled manually while constructing the structure, and a securing system configured to secure the wall segment in place on the structure. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention is applicable to the arithmetic-logic unit (ALU) or that functional part of a digital computer that carries out arithmetic and logic operations on operands. More particularly the invention is directed to a parsing technique for arranging the input information received by the ALU, which consists of operands, operation codes, and format codes.
2. Description of Prior Art
In the process of compilation into machine executable code of a program written in a high-level language, the procedure for examining arithmetic expressions and determining operator precedence, the order of execution of the operators, is often referred to as the arithmetic scan. Since syntactically correct arithmetic expressions are well formed in that they possess regular properties related to the operands and the operators, many specialized parsing or scanning techniques have been developed.
Although it is algebraically well defined, an arithmetic expression is not computationally well defined unless the precise order of arithmetic operations is specified. The specification of ordering can be exhibited by a computation tree, by a fully parenthesized statement or by a Polish form such as Polish prefix notation.
One possible, but impractical, technique is to require the programmer to write arithmetic expressions in fully parenthesized notation (i.e., parentheses must be placed around each pair of operands and its associated operator) to obviate the need for knowledge about the relationships between operators in determining the order in which the operations are to be performed.
Most commonly used are transformational systems, which convert the normal infix form (i.e., the form in which the operator is placed between its operands) to a Polish form, in which there exist no parentheses and the order of execution of the operators is specified by their positioning. Such a system is needed because of the difficulty of associating operands with operators in infix notation.
Polish notation was originally developed in the prefix form, in which the operators precede the operands.
The postfix or suffix form, also known as reverse Polish notation or RPN, which is logically equivalent to the prefix form, has been widely used in computing. Many compilers first transform an arithmetic expression from its ordinary or infix form into RPN, so that its evaluation can be done in a single left-to-right scan.
The usual approach for parsing arithmetic expressions is to make a one pass scan over the string of characters, operands and operations, to transform them into a Polish form by using single operand stack and operator stacks. An implicit assumption is made that these Polish strings are to be operated upon by a computing system that permits only one arithmetic operation to be performed at any given time. For example, the arithmetic expression
"Z=A+B+C+D"
would be transformed into the Polish prefix string
"Z←+++ABCD"
which defines the computation tree 10 shown in FIG. 1.
The operator precedence is not pre determined and no operational subgroupings or associations are pre defined. Hence, this parsed expression may only be operated upon sequentially, e.g., by a one processor.
SUMMARY
The present invention is directed to a method and an apparatus for an efficient one-pass parsing algorithm that exhibits in a compiler suitable Polish prefix form the maximal degree of computational parallelism within an arithmetic expression. Multiple processing units then may simultaneously operate upon the parsed expression, while one of the processing units parses the next arithmetic expression.
A general parsing algorithm of the present invention would relax the assumption that in a processor only one operation can be performed at any given time. By using one operator stack and two operand stacks the present invention produces a one-pass parsing algorithm for the generation of a Polish string that computationally defines the maximal possible parallel execution of a general class of arithmetic expressions.
For purposes of this disclosure, operands are taken left-to-right within an operand grouping and the associated operations are taken from right-to-left. The expression
Z=A+B+C+D
would then be transformed into
Z←++AB+CD
which defines the computation tree with maximal parallelism. Hence, expressions +AB and +CD can be evaluated simultaneously by independent processors.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a tree diagram of equation "Z=A+B+C+D";
FIG. 2 is a tree diagram of an alternative interpretation of equation "Z=A+B+C+D";
FIG. 3 shows a flowchart of the character scanning and processing phase of the present invention; and
FIG. 4 shows a flowchart of the stack processing phase of the present invention.
FIG. 5 shows changing contents of memory stacks, as equation "Z=A+B+C+D;" of Example 1 is parsed;
FIGS. 6a-6b show changing contents of memory stacks, as equation "Z=((A-B)*C-(D-E)*F/((G-H)-I-(j-K)-L);" of Example 2 is parsed;
DETAILED DESCRIPTION OF THE INVENTION
FIG. 2 shows the computation tree 10 defined by the expression
Z=A+B+C+D
which, for maximal parallelism, is transformed by the algorithm of the present invention into
Z←++AB+CD
The following criteria are followed by the algorithm of the present invention.
1. The arithmetic expression is well-formed, i.e., it is syntactically legal, and all operations are defined. In a well-formed arithmetic expression the commutative and non-commutative operations are recognizable and unary and binary symbols are distinguishable, e.g., unary minus is distinguishable from binary minus. An assumption is made that precedence is established for all the operations, e.g., multiplication has higher precedence than addition.
2. Three last in, first out (LIFO) stacks are available. These stacks are respectively, the low order operand stack (LOS), the high order operand stack (HOS) and the operator stack (RS).
3. The arithmetic expression consists of a string of characters classified into the following categories:
(a) variable or operand,
(b) operation,
(c) left parenthesis, "(",
(d) right parenthesis, ")",
(e) end-of-string delimiter, ";".
4. The two variables or operands, which produce a new variable through the action of an operation, are collectively termed a variable pair. Each variable is tagged with a unique precedence index, the low order variable in the variable pair is tagged with the lowest precedence index and the high order variable is tagged with the highest precedence index.
5. The characters in the string are sequentially scanned from left to right by a sequence counter (pointer) whose value or sequence number indexes the characters in the string.
The Parsing Algorithm
The algorithm of the present invention consists of three phases: the initialization phase, the character scanning and processing phase, and the stack processing phase. At the initialization phase, the pointer is set to point to the first character in the arithmetic expression string, i.e., it is set to one, and the variable precedence index is set to one and the stacks are emptied.
FIG. 3 shows the character scanning and processing phase 12 of the present invention. The character in the string position given by the pointer is scanned by the "scan a character" module 1 and processed according to its category by the "Character Processing" module 3. As defined above in the criteria (3), a character group consists of the variable or operand, the operation, the left parenthesis, the right parenthesis and the end-of-string delimiter.
If the character is a variable, the control is passed to the "Variable Processing" module 8. The "Variable Processing" module 8 tags the character with the current precedence index and places it into the low order operand stack. The precedence index is then incremented, the character pointer is advanced and the next character is scanned by the "Character Scanning" module 2.
If the character is an operation, the "Character Processing" module 3 calls the "Operation Processing" module 10. The character is tested to determine if it is unary. If this is the case, an appropriate indicator is set by module 11, the character pointer is advanced and the next character is scanned by the "Character Scanning" module 2.
If the character is not a unary operation, two tests 12, 13 are performed to determine whether the scanned operation has higher precedence than the top element in the operator stack, and whether the previous scanned character is not a right parenthesis. Failure of either test 12, 13 results in the operation character being placed into the operator stack by module 15, the character pointer is then advanced and the next character is scanned by the "Character Scanning" module 2.
Passage of either test 12, 13 results in testing of the top element in the operator stack, by module 14, to determine if it is a commutative or a non-commutative operation. If the operation is non-commutative, then the character pointer is advanced and the next character is scanned by the "Character Scanning" module 2.
If the operation is commutative, a determination is made, by module 17, whether there are two variables in the low order operand stack and whether the top two operations in the operator stack have the same precedence. Satisfaction of these conditions invokes the stack processing procedure shown in FIG. 4. Then, the character pointer is advanced and the next character is scanned by the "Character Scanning" module 2.
If the character is a left parenthesis, "(", then module 4 enters a special parenthesis character into both the high order operand stack and the low order operand stack, the character pointer is advanced and the next character is scanned by the "Character Scanning" module 2. If the character is a right parenthesis, ")", then module 5 repeatedly invokes the stack processing procedure to process the scanned equation within a set of parentheses. The special left parenthesis characters are then deleted from both the high order operand stack and the low order operand stack. Module 6 then determines whether the expression within the parenthesis is operated upon by a unary operation. That unary operation is then prefixed to the expression located on the stack. The character pointer is advanced and the next character is scanned by the "Character Scanning" module 2.
Finally, if the character is an end-of-string delimiter, ";", then module 9 invokes the stack processing procedure shown in FIG. 4. The stack processing continues until both the operator stack and the low order operand stack are empty. That void condition implies that the expression has been completely processed and the Polish string form exhibiting maximal parallelism is to be found in the high order operand stack.
Stack Processing
The function of the stack processing procedure phase is to adjoin the proper pair of variables with the appropriate operation, and to place the resulting variables in the high order operand stack with its correct precedence index. Shown in FIG. 4 is the flow diagram 14 of the stack processing procedure. Test 1 determines, if there is more then one element in each of the operand stacks. If there is more then one element, then test 2 is performed to determine if the top two elements in the operator stack are of equal precedence.
If there is more then one element in each of the operand stacks or if the top two elements in the operator stack are not of equal precedence, module 4 forms a new variable by joining the elements with the highest precedence tags from the high order operand stack and the low order operand stack and the element from the top of the operator stack.
If the top two elements in the operator stack are of equal precedence, then test 3 determines which operand stack has the element with the highest precedence tag. Module 5 then forms a new variable by joining together the top two elements from the operand stack with the highest precedence element and the element from the top of the operator stack.
In all cases, the operation is placed first, the low order variable is placed in the second position, and the high order variable is placed in the third position of any newly formed variable. Module 6 tags the new variable with the precedence index of the low order variable and places it into the high order operand stack. Test 7 determines what character triggered the stack processing. The possibilities are a semicolon, a right parenthesis and 2 consecutive operators of the same precedence as shown by module 17 (FIG. 3). The stack processing is then repeated or terminated based on the criteria of test 7.
To facilitate understanding, Example 1 shown in FIG. 5 illustrates the operation of the algorithm of the present invention in a step by step scanning and stack processing phases of equation
"Z=A+B+C+D;".
In the initialization phase the pointer is set to scan the first variable of the equation.
In step 1, the character "A" is scanned at the pointer. Variable module 8 (FIG. 3) gives it the precedence index 1 and places it in LOS 20. The precedence index is incremented and the pointer is set to scan the next variable.
In step 2, the character "+" is scanned at the pointer. Operation module 10 (FIG. 3) determines that it is not a unary operation. Test 12 (FIG. 3) determines that there are no other operators present on RS 30 hence, the present operator has higher precedence. Test 13 (FIG. 3) determines that the previous character is not ")". Module 15 (FIG. 3) places the character in RS 30 and the pointer is set to scan the next variable.
In step 3, the character "B" is scanned at the pointer. Variable module 8 (FIG. 3) gives it the precedence index 2 and places it in LOS 20. The precedence index is incremented and the pointer is set to scan the next variable.
In step 4, the character "+" is scanned at the pointer. Operation module 10 (FIG. 3) determines that it is not a unary operation. Test 12 (FIG. 3) determines that the present operator is of equal precedence with the operator present on RS 30. Test 13 (FIG. 3) determines that the previous character is not ")". Module 15 (FIG. 3) places the character in RS 30 and the pointer is set to scan the next variable.
In step 5, the "C" character is scanned at the pointer. Variable module 8 (FIG. 3) gives it the precedence index 3 and places it in LOS 20. The precedence index is incremented and the pointer is set to scan the next variable.
In step 6, the character "+" is scanned at the pointer. Operation module 10 (FIG. 3) determines that it is not a unary operation. Test 12 (FIG. 3) determines that the present operator has equal precedence to the other operators present on RS 30. Test 13 (FIG. 3) determines that the previous character is not ")". Module 15 (FIG. 3) places the character in RS 30 and the pointer is set to scan the next variable.
In step 7, the character "D" is scanned at the pointer. Variable module 8 (FIG. 3) gives it the precedence index 4 and places it in LOS 20. The precedence index is incremented and the pointer is set to scan the next variable.
In step 8, the character ";" is scanned at the pointer, the ";" module 9 (FIG. 3) invokes stack processing. Test 1 determines if there is more then one element in LOS 20, however HOS 10 is empty. Thus, module 4 joins the top two elements in LOS 20 to one another and to the top element of RS 30. Module 6 prefixes the result with the lower precedence number of the variable pair and places the result in HOS 10. Test 7 determines that the scanned character is ";" and that RS 30 is not empty, hence stack processing is repeated.
In step 9, Test 1 determines that LOS 20 and HOS 10 are not empty. Test 2 determines that the top two elements in RS 30 are of equal precedence. Test 3 selects LOS 20 because LOS 20 has entries with higher precedence than HOS 10. Thus module 5 joins the top two elements in LOS 20 to one another and to the top element of RS 30. Module 6 prefixes the result with the lower precedence number of the variable pair and places the result in HOS 10. Test 7 determines that the scanned character is ";" and that RS 30 is not empty, hence stack processing is repeated. In step 10, Test 1 determines that LOS 20 is empty however HOS 10 is not. Thus module 4 joins the top two elements in HOS 10 to one another and to the top element of RS 30. Module 6 prefixes the result with the lower precedence number of the variable pair and places the result in HOS 10. Test 7 determines that the scanned character is ";" and that RS 30 is empty, hence stack processing terminated.
Example 2 shown in FIGS. 6a, 6b illustrates the operation of the algorithm of the present invention in a step by step scanning and stack processing phases of equation
"Z=((A-B)*C-(D-E)*F)/((G-H)*I-(J-K)*L);".
Steps similar to the ones described above should be utilized to transform that equation into a Polish notation form designed for maximal parallelism.
While the invention has been particularly shown and described with respect to illustrative and preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and other changes in form and details may be made therein without departing from the spirit and scope of the invention that should be limited only by the scope of the appended claims. | The present invention describes a method for a one-pass parsing algorithm for generation of a Polish string that computationally defines the maximal possible parallel execution of a general class of arithmetic expressions using one operator stack and two operand stacks. This invention relaxes the assumption that in a processor, only one operation can be performed at any given time. | 6 |
FIELD OF THE INVENTION
The present invention relates to two piece fasteners and more particularly, to fasteners having a pin or bolt member and a collar or nut member.
DESCRIPTION OF THE PRIOR ART
Two piece fastening systems are quite numerous and include, for example, standard nut and bolt systems and pin and swaged collar systems. One such type of pin and swaged collar fastening system is disclosed in U.S. Pat. No. 4,472,096 to John Ruhl and Richard Dixon, issued Sep. 18, 1984, and assigned to the same assignee as the present invention and which is incorporated by reference herein. Ruhl discloses a headed pin member having a series of centrally located locking grooves on a shank of the pin and a series of pulling grooves on the shank at a free or tail end of the pin. The pin is adapted to pass through a bore in the pieces to be fastened together with the head on one side of the pieces and the locking grooves on the other side of the pieces. A tubular collar can then be positioned over the locking grooves and a swaging tool used to grip the pulling grooves to swage the collar over the locking grooves to fasten the assembly together. The pintail is then adapted to break off from the remainder of the fastened assembly for disposal or recycling.
Such fasteners are often used in applications where an individual cannot easily reach or effectively manipulate both sides of the pin at the same time to hold the pin in place while the collar and swaging tool are placed over the pin. Such an application would include the installation of a large surface skin to a supporting frame of a vehicle or airplane. In such applications, it is common for one individual to install a number of the pins through bores in the skin and framework and for another individual on the other side of the skin and framework to install the collars over the pins and swage the collars onto the pins. Alternatively, one individual may install the pins from one side and move to the other side to install the collars over the pins. Unfortunately, the vibration and pintail separation impact load from the installation tool and installation process will often cause other pins that have not had collars yet swaged on to back out of the bores and fall to the ground. This results in wasted time and effort in reinstalling the pins in the bores. Nor is it efficient to have one individual inserting a pin through the bore and holding it in place while another individual simultaneously installs the collar over the pin.
Kleinhenn, U.S. Pat. No. 3,638,980, issued Feb. 1, 1972, Sherman, U.S. Pat. No. 3,770,036, issued Nov. 6, 1973 and Wenger, U.S. Pat. No. 3,812,756, issued May 28, 1974, all disclose fastening systems utilizing a flexible, ring-like element installed over the shank of a fastening pin to retain the pin in a bore after installation of the pin in the bore. However, both Kleinhenn and Sherman position the rings behind the threaded portions of their respective pins so that debris in the bores (such as dirt, shavings, excess sealant, etc.) can foul the threads upon installation. They also both provide additional grooves in their respective pins for positioning and retaining the rings. These grooves require additional machining and can reduce the overall strength of the pin. Wenger discloses an embodiment in FIGS. 5-7 where the ring is a split ring positioned in a groove machined in the pin but forward of the threads. However, because of the split ring, the bore will not be cleared of all debris during installation of the pin and the ring is free to vibrate and move within the groove after installation. Further, additional length of the pin is needed to accommodate the groove, which can be expensive, especially when the pin is made of titanium or other relatively expensive material. In all three references, the ring is normally retained with the fastener after installation is completed. In certain applications, the ring will be exposed to fuels and solvents after installation and can degrade or dissolve if made of a flexible polymer, thereby contaminating the fuel or solvent and clogging fuel lines and filters.
Busch et al., U.S. Pat. No. 3,863,421, issued Feb. 4, 1975, discloses a fastener utilizing a split ring positioned in a groove in a pin for retaining the pin. Again, the groove requires additional machining and reduces the strength of the pin. Further, since the threads are internal, the pin does not prevent debris in the bore from getting to the threads. Wagner, U.S. Pat. No. 5,154,559, issued Oct. 13, 1992, and Ragaller, U.S. Pat. No. 5,064,324, issued Nov. 12, 1991, both disclose the use of protrusions on or behind the threads for retaining the threaded pins in the workpieces. Neither prevents debris in the bores from fouling the threads.
Smith, U.S. Pat. No. 4,813,834, issued Mar. 21, 1989, and assigned to the same assignee as the present invention, is incorporated by reference herein, and discloses the use of a tab on the locking collar for retaining the collar on the pin. Such types of self-retaining tabbed collars are in current use in industry. However, the tabs will occasionally fall off the collars, thereby eliminating the self-retaining feature, jamming or clogging the installation tool or becoming debris in the fastened structure. Nor do such tabbed collars provide any cleaning of debris from the pin bores.
SUMMARY OF THE INVENTION
The present invention provides a pin for a two piece swage-type fastener that includes a flexible member attached to a free end of the pin. The flexible member has a diameter slightly larger than a bore in the workpiece through which it is inserted so that the pin is retained in the bore after insertion. The flexible member also cleans debris from the bore as the pin is installed in the bore, thereby preventing the debris from fouling the locking or pulling grooves of the pin. The flexible member is either adhesively attached to the pin or adheres to the pin itself and does not require an additional groove in the pin for positioning. Further, as the flexible member is attached to the pintail, it is removed with the pintail upon completion of the swaging of the collar onto the pin and therefore, will not degrade or dissolve and contaminate the fuel or solvent with which it comes into contact. Since the flexible member is at the very end of the pin, it is not intended to be actually gripped by the gripping jaws of the installation tool but to pass beyond the gripping jaws when the installation tool is installed over the pin. Therefore, the flexible member will not clog or foul the gripping jaws of the installation tool.
It is an object of the present invention to provide a pin for use in a two piece fastener that positively retains a collar placed over the pin from falling off of the pin when exposed to gravitational forces, vibration, etc., prior to fastening of the collar to the pin, thereby allowing several collars to be placed over their respective pins prior to fastening the collars to the pins without fear of the collars falling off of the pins.
It is also an object of the present invention to provide a mechanism for positively retaining a pin in a bore, thereby preventing the pin from falling out of the bore when exposed to gravitational forces, vibration, etc., prior to fastening the pin in the bore.
It is also an object of the present invention to provide a self-retaining pin by adding a flexible member to the pin that does not require modification to the underlying pin, a collar to be used with the pin or a workpiece to be clamped.
It is also an object of the present invention to provide a self-retaining pin for use in a two piece swaged fastener that prevents debris in a bore into which the pin is installed or the self-retaining element itself from contaminating locking or pulling grooves in the pin or gripping jaws in an installation tool and resulting in improper fastening of a collar to the pin or slippage of the installation tool from the pin.
It is also an object of the present invention to provide a mechanism for retaining a pin in a bore and cleaning debris from the bore without reducing the strength of the pin and which mechanism is automatically removed from the pin upon completion of the fastening procedure.
The foregoing and other objects, features, characteristics and advantages of the present invention, as well as the methods of operation and functions of the related elements of structure, and the combination of parts and economies of manufacture, will be apparent from the following detailed description and the appended claims, taken in connection with the accompanying drawings, all of which form a part of the specification, wherein like reference numerals designate corresponding parts in the various figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a pin of a swage-type fastener of the present invention;
FIG. 2 is a side elevational view of an alternative swage-type fastener pin of the present invention;
FIG. 3 is a side elevational view of an alternative swage-type fastener pin of the present invention;
FIG. 4 is an end elevational view of an alternative embodiment of the disc of the present invention;
FIG. 5 is an end elevational view of an alternative embodiment of the disc of the present invention;
FIG. 6 is an end elevational view of an alternative embodiment of the disc of the present invention;
FIG. 7 is a side elevational view of an alternative swage-type fastener pin of the present invention; and
FIG. 8 is a side elevational view of an alternative swage-type fastener pin of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a swage-type fastener pin 10 of the present invention. The pin 10 includes a head 12 and an elongated shank 14. The shank 14 includes a plurality of locking grooves 16 over which a collar (not shown) can be swaged, as is conventionally known. The shank further includes a breakneck groove 18 and a tail portion or pintail 20. The pintail 20 includes a plurality of pulling grooves 22 adapted to be gripped by a swaging tool, as is conventionally known.
As disclosed in more detail in the Smith '834 patent discussed above, the installation tool includes a set of pulling jaws that are adapted to grip the pulling grooves 22 and a swaging anvil adapted to swage the collar onto the pin 10. In operation, the collar is inserted over the pin and the installation tool is then placed over the pin/collar assembly. Placing the installation tool over the pin causes the gripping/pulling jaws of the tool to engage the pulling grooves of the pin. Activation of the installation tool pushes the swaging anvil into contact with the collar by the pulling action of the pulling jaws, thereby pulling the pin through a bore in a workpiece until it is fully seated, seating the collar against the workpiece and then swaging the collar over the locking grooves 16 until sufficient pulling force is created against the pin 10 by the installation tool to break the pintail 20 away from the pin at the breakneck groove 18.
A retaining disc 24 is generally centered with respect to and attached to a free end 26 of the pintail 20. In the presently preferred embodiment, the disc 24 is round (see FIG. 4), made of a thin, flexible plastic such as polycarbonate or recycled LD polyethylene and is adhesively attached to a face 28 of the free end 26 of the pintail 20 with Loctite Black Max® 38050 adhesive. A depression 30 (shown in phantom in FIG. 1) can be provided in the face 28 for holding the adhesive. The outer diameter of the disc is sized to be slightly larger than an inner diameter of both a bore in the workpiece through which the pin 10 is inserted and an inner diameter of the collar to be swaged onto the pin. The flexibility of the disc 24 allows the disc to pass through both the bore and the collar even though the disc has a larger diameter than both. The disc can also be provided with a tab or nipple on one side (see FIG. 7) or both sides (see FIG. 8) to engage a retaining bore in the face 28. Additionally, adhesive can also be used with the configurations in FIGS. 7 and 8 to retain the disc on the pin.
The larger diameter disc 24 accomplishes three functions. First, it clears debris from the bore as it is pushed through the bore upon installation of the pin in the bore. This prevents the debris from fouling the locking grooves 16 and the pulling grooves 22, resulting in improper fastening of the collar to the pin or slippage of an installation tool from the pin. Second, once the disc 24 is passed through the bore, it will return to its normal diameter and prevent the pin from falling out of the bore. Finally, since the disc 24 is also larger than the inner diameter of the collar, it will retain the collar on the pin 10 once the collar has been inserted on the pin 10. The disc 24 is designed to have enough flexibility so as to be readily installable through the bore and collar without excess force, yet stiff enough to retain the pin in the bore and the collar on the pin under normal conditions. If necessary, the collar can be removed from the pin and the pin from the bore by the application of additional force. This type of retaining disc 24 can be utilized with a standard pin and does not require additional machining or modification of the pin, collar or clamped workpiece to function. By being placed at the very end of the pin, the disc does not interfere with the gripping of the swaging tool teeth onto the pulling grooves.
Alternatively, an o-ring of a flexible polymeric material can be attached to the free end 26 in place of the disc 24. The o-ring can be attached by adhesive alone, positioned in a locating groove provided in the outer surface of free end 26, or a combination of the two. Since the pin 10 is often made of titanium or other relatively expensive material, it is preferred to not have to lengthen the pin 10 to utilize a groove, if possible, so as to not incur additional material costs in manufacturing the pin 10. In yet another alternative embodiment, the disc 24 or o-ring 32 can be replaced by either 1) a "created" o-ring of a bead of flexible polymeric material deposited around the circumference of free end 26 and allowed to dry prior to installation of the pin in the bore, or 2) a cap of flexible material deposited on the face 28 and extending radially outward to the desired diameter and allowed to dry prior to installation.
The disc 24 can also be constructed from other types of materials, including other plastics, flexible polymers, metals and composites. The thickness and/or hardness of the disc 24 can also be varied, depending on the material used, to alter the flexibility of the disc and thus, the amount of force needed to install/remove the pin in/from the bore and the collar on/from the pin. The outer diameter of the disc 24 or ring 32 can also be altered with respect to the inner diameter of the bore or collar to adjust the amount of force needed for installation/removal. Additionally, the disc need not be round but could be annular, oval (see FIG. 5), have extended fingers (see FIG. 6) or be of another shape. In the configuration shown in FIG. 6, the root outer diameter 36 of the disc can be equal to or less than the inner diameter of the bore/collar while only the diameter 38 of the extended fingers exceeds the inner diameter of the bore/collar. In this way, only the extended fingers provide the retaining function while the root diameter can be sized to either provide a debris clearing function, or not. Alternatively, both diameters can be larger than the inner diameters of the bore and collar.
The disc also need not be flat but could be at least partially convex with the protrusion facing forward in the direction of the free end of the pin. See FIG. 3. This provides a "streamlined" cross-section in the direction of installation such that the force needed to install the pin/collar is less than the force needed to remove the pin/collar.
The present invention is also applicable to other types of swaged, threaded or alternative fasteners, whether two piece or not.
While this invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that it is capable of further modifications and is not to be limited to the disclosed embodiment, and this application is intended to cover any variations, uses, equivalent arrangements or adaptations of the invention following, in general, the principles of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains, and as may be applied to the essential features hereinbefore set forth and followed in the spirit and scope of the appended claims. | A pin for a two piece type fastener includes a flexible member attached to a free end of the pin. The flexible member has a diameter slightly larger than a bore in a workpiece through which it is inserted so that the pin is retained in the bore after insertion. The flexible member also cleans debris from the bore as the pin is installed in the bore, thereby reducing the possibility of the debris from fouling the grooves in the pin. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 12/323,723, filed Nov. 26, 2008, titled “Ridge Clip,” which issued as U.S. Pat. No. 7,963,490 on Jun. 21, 2011. The foregoing are incorporated herein by reference. U.S. Provisional Applications 61/004,213 filed Nov. 26, 2007, and U.S. Provisional Application 61/097,275 filed Sep. 16, 2008 are also incorporated herein by reference.
BACKGROUND
[0002] This specification relates to the field of home decorations, and more particularly to a ridge clip useful for mounting decorations on the ridge of a roof.
[0003] Many people enjoy stringing lights on their homes for Christmas and other holidays. One method of mounting lights to a roof is the use of a prior art shingle tab, which slides under the overhanging flap of a shingle. Shingle tabs are also sometimes used on the ridge of a roof by sliding it under ridge shingles, which run perpendicular to the regular shingles.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a top view of an embodiment of a ridge clip, shown as produced;
[0005] FIG. 1A is a perspective view of the ridge clip of FIG. 1 in modified for use;
[0006] FIG. 1B discloses a perspective view of a roof with a ridge on which ridge clips are displayed;
[0007] FIG. 2 is a perspective view of a prior art shingle tab;
[0008] FIG. 3 is a perspective view of an alternative embodiment of a ridge clip, including a light base clip oriented horizontally;
[0009] FIG. 3A is a perspective view of a ridge clip with a light base clip oriented vertically;
[0010] FIG. 4 is a perspective view of a ridge clip, including a tab holder configured to receive a shingle tab;
[0011] FIG. 5 is a perspective view of a ridge clip also configured to receive a shingle tab;
[0012] FIG. 6 is yet another perspective view of a ridge clip configured to receive a shingle tab;
[0013] FIG. 7 is a perspective view of a ridge clip including a tab rod, and adapted to receive a shafted tab.
SUMMARY OF THE INVENTION
[0014] In one aspect, a ridge clip is useful for attaching lights or other decorations to the ridge of a roof without compromising the seal on ridge shingles. The ridge clip includes a shingle hook that affixes to the overhanging portion of a shingle, and an extension arm that extends long enough to mount the decoration on the roof ridge. Ridge clips may be provided as an adapter for existing shingle tabs, or as stand-alone devices.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0015] A ridge clip provides an improved method of displaying lights and other decorative items along the ridge of a roof. Advantageously, the disclosed ridge clip permits a decorative item to be mounted along the ridge without compromising the seal of the ridge, because the ridge clip affixes to the overhanging part of a shingle beneath the ridge cap.
[0016] A ridge clip will now be described with more particular reference to the attached drawings. Hereafter, details are set forth by way of example to facilitate discussion of the disclosed subject matter. It should be apparent to a person of ordinary skill in the field, however, that the disclosed embodiments are exemplary and not exhaustive of all possible embodiments. Throughout this disclosure, a hyphenated form of a reference numeral refers to a specific instance or example of an element and the un-hyphenated form of the reference numeral refers to the element generically or collectively. Thus, for example, 102 - 1 may refer to a “pen,” which may be an instance or example of the class of “writing implements.” Writing implements may be referred to collectively as “writing implements 102 ” and any one may be referred to generically as a “writing implement 102 .”
[0017] FIG. 1 discloses a top view of a ridge clip 100 - 1 , as it may appear when newly purchased and before it is configured for final use. A ridge clip 100 includes an overhang engagement member 130 , which is adapted to engage the overhanging portion of a shingle 192 ( FIG. 1B ). In the embodiment shown in FIG. 1 , the overhang engagement member 130 is a shingle clip 130 - 1 , but in other embodiments, it may be any other kind of clip, adhesive, or other affixing means adapted to securely engage the overhanging portion of the shingle. A joint 112 joins shingle hook 130 - 1 to extension arm 110 . Extension arm 110 is designed with a length sufficient to extend up to the ridge cap. For example, in one embodiment, the extension arm extends approximately six inches, or between six and seven inches, and is two inches wide. Joint 112 is a flexible member and may be created with perforations or other hinge, thus allowing the shingle clip to hingedly flex underneath extension arm 110 . At a removed end, extension arm 110 is affixed to a mount 180 , which is adapted to receive a decorative item such as a light bulb in the disclosed embodiment, mount 180 includes two holes. The larger hole is adapted to receive a C7-size bulb, and the smaller hole is adapted to receive a C9-size bulb. In this embodiment, mount 180 includes two options for displaying the decorative item. A horizontal tab 150 is useful if the decorative item is to be oriented vertically with respect to the ridge cap. An upright tab 140 is useful if the decorative item is to be oriented horizontal with respect to the ridge cap. If upright tab 140 is to be used, it may be vertically supported by gusset 146 which joins lock hook 142 . Lock hook 142 may engage lock hole 144 for stability. Also disclosed are perforations 120 which extends upwards across gusset and horizontally across upright tab 140 . The perforations 120 may be provided to allow reconfiguration of the ridge clip 100 - 1 . For example, if the decorative item is to be oriented vertically, gusset 146 and upright tab 140 may be removed.
[0018] FIG. 1A discloses a perspective view of the ridge clip of FIG. 1 in an alternative configuration. In this configuration, it is seen that shingle hook 130 has been hinged under extension arm 110 at joint 112 . Thus configured, ridge clip 100 - 1 is ready to engage an overhanging shingle. Also seen in this view, an upright tab 140 has been raised along perforation 120 . As shown, gusset 146 has been disengaged from extension arm 110 and lock hook 142 has engaged lock hole 144 .
[0019] FIG. 1B discloses a perspective view of a roof 194 with a ridge 190 on which ridge clips 100 are displayed. Ridge clip 100 engage the overhanging portion of ridge shingles 192 , thus maintaining the integrity of the seal. For display purposes, ridge clips 100 are distributed along ridge 190 on alternating sides of ridge 190 .
[0020] FIG. 2 discloses a perspective view of a prior art shingle tab 210 . Prior art shingle tab 210 includes legs 220 adapted to engage the overhanging portion of a shingle. Also shown is mount 180 - 3 which is oriented vertically with respect to the legs 220 . The shingle tab 210 as disclosed is suitable primarily for insertion under the overhanging portion of a shingle but does not reach the ridge cap 190 . In some cases, it has also been used along the ridge of a roof. In this case it must be inserted into the ridge cap shingles 192 at the apex of the ridge cap 190 , rather than the overhanging portion, which in some cases may compromise the seal.
[0021] FIG. 3 discloses a perspective view of an alternative embodiment of a ridge clip 100 - 2 , including a light base clip oriented horizontally. In this case, extension arm 110 - 2 is a narrow rod. As with other embodiments, the extension arm 110 - 2 is approximately six inches, and generally between six and seven inches long. Shingle hook 130 - 2 is permanently molded in place. In this case there is no need for joint 112 or perforations 120 . In this embodiment of a ridge clip 100 - 2 , a light base clip 310 - 1 is provided. This is particularly suitable for use with a bulb 320 , which is a form of decorative item. Bulb 320 may include a light base 330 . Light base clip 310 - 1 is configured to snap snugly around light base 330 , thus holding bulb 320 in place. Light base clip 310 - 1 may be constructed of flexible plastic, or other flexible material, so that it may snap tightly around either a C9 size light, or may expand to snap around a C7 size light. In FIG. 3 it is shown that light base clip 310 - 1 is oriented so that bulb 320 would be aligned horizontally along the ridge 190 , or in other words bulb 320 will lie substantially along the top of the ridge.
[0022] FIG. 3A discloses a perspective view of a ridge clip with a light base clip oriented vertically. In this embodiment, ridge clip 100 - 3 is substantially similar to the ridge clip 100 - 2 of FIG. 3 . In this case, however, light base clip 310 - 2 is oriented so as to hold bulb 320 substantially in a vertical orientation. In this embodiment, bulb 320 will appear to be standing straight up from the apex of the roof ridge 190 .
[0023] FIG. 4 discloses a perspective view of a ridge clip, including a tab holder configured to receive a shingle tab. In this case, ridge clip 100 - 4 is an adaptor for receiving a prior art shingle tab. Ridge clip 100 - 4 includes a tab holder 410 which in this case is a tab frame. Tab frame 410 - 1 is adapted to receive and securely hold a shingle tab 210 .
[0024] FIG. 5 discloses a perspective view of a ridge clip also configured to receive a shingle tab. In this case, ridge clip 100 - 5 includes a different embodiment of a tab holder 410 , specifically a clasp 410 - 2 . Clasp 410 - 2 is adapted to receive one leg 220 of the shingle tab 210 by slidably engaging the leg to securely hold it.
[0025] FIG. 6 discloses another perspective view of a ridge clip configured to receive a shingle tab. This embodiment includes another embodiment of an adaptor for holding a shingle tab 210 . In this case, a tab plate 410 - 3 is adapted to receive shingle tab 210 . Tab plat 630 includes a protrusion 610 , preferably molded on to tab plate 410 , which is adapted to receive legs 220 of shingle tab 210 . Shingle tab 210 may thus mount securely to tab plate 410 - 3 . Although protrusion 610 is shown substantially circular, it may also be another shape adapted to engage legs 220 , such as an oval or rhombus.
[0026] FIG. 7 discloses a perspective view of a ridge clip including a tab rod 720 , and adapted to receive a shafted tab 730 . In this case, ridge clip 100 - 7 includes a tab holder plate 710 upon which is rigidly affixed a tab rod 720 . Tab rod 720 is configured to receive a shaft 732 . A shafted tab 730 is provided which includes shaft 732 adapted to slidably engage tab rod 720 . Thus shafted tab 730 may slide on its shaft 732 along tab rod 720 , and thus be secured to ridge clip 100 - 7 .
[0027] While the subject of this specification has been described in connection with one or more exemplary embodiments, it is not intended to limit the claims to the particular forms set forth. On the contrary, the appended claims are intended to cover such alternatives, modifications and equivalents as may be included within their spirit and scope. | A ridge clip is disclosed that is useful for attaching lights or other decorations to the ridge of a roof without compromising the seal on ridge shingles. The ridge clip includes a shingle hook that affixes to the overhanging portion of a shingle, and an extension arm that extends long enough to mount the decoration on the roof ridge. Ridge clips may be provided as an adapter for existing shingle tabs, or as stand-alone devices. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to an target irradiating device, and more particularly to target irradiating device adapted to be used for water treatment or medical treatment, for example. In case of the water treatment, a target irradiating energy generated from the target irradiating device is irradiated to a city water, for example, to improve it in taste and biological or physiological aspects. In case of the medical treatment, the target irradiating energy is irradiated to a living body such as a human body to cure or prevent some kind of affection.
In recent years, the existence of Chinese "Ki" to be exerted from the hands of a so-called "Kikoshi" has been noticed. The term of "Ki" is considered as an electromagnetic wave such as far infrared radiation to be radiated from a surface of a human body, especially, his hands. This electromagnetic wave has an intensity more than a certain level and has a specific wave form pattern. Thus, such an electromagnetic wave is radiated more or less, but it is positively radiated from the hands of a special person called "Kikoshi" who has an ability of generating the above specific electromagnetic wave in nature or by skill. In particular, "Ki" has been remarkably studied in China, and it is especially applied to a medical field where the specific electromagnetic wave generated from "Kikoski" is radiated against affection such as shoulder stiffness, lumbago or neuralgia to actually exhibit some effects for a remedy of such affection.
The target irradiating device of the present invention is designed to scientifically or technically generate target irradiating energy like the Chinese "Ki" to make same useful for water treatment and medical treatment, for example. Concretely, target irradiating energy to be provided by the present invention is a magnetic force and/or light with its intensity periodically changed.
In the case that the present invention is applied to water treatment, it is possible to obtain an irradiated water which has been unobtainable in the prior art.
As a conventional water treatment device, a water purifier for improving a quality of a city water has been recently developed for home use. It is known that such a water purifier utilizes a ceramic filter, hollow yarn film, or electrolysis, and that it is directly connected to a faucet. By using the water purifier, a bleaching powder smell in the city water can be reduced to provide a drinking water improved in quality.
Incidentally, water exists in the state that at least five molecules of water are gathered to form a so-called cluster rather than in the state of a single molecule. A, although the above-mentioned water purifier of the filter type or the electrolysis type has a function of reducing a bleaching powder smell in the city water or improving a taste of the city water, it cannot change a characteristic of the water in a biological or biochemical level. That is, it cannot create an activated water having a large biological or biochemical effect on animals (inclusive of a human body) and plants.
As to the medical treatment for a living body, some kind of affection such as stiffness of shoulders, lumbago, or neuralgia cannot be perfectly cured even by dozing a large quantity of medicine. However, it has been confirmed in the Oriental medicine that such affection can be remarkably cured by applying the aforementioned "Ki" to an effective spot on a living body.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide target irradiating device which can provide target irradiating energy like the Chinese "Ki" and can be applied to water treatment for providing an irradiated water effective in various aspects such as physiology, food processing, growth of plants and animals, suppression of putrefaction, or activation of cells.
It is another object of the present invention to provide a target irradiating device which can be applied to medical treatment effective for a remedy in a living body such as a human body.
According to a first aspect of the present invention, there is provided a target irradiating device comprising magnetic force generating means for electrically generating a magnetic force; power supplying means for supplying a driving power to said magnetic force generating means; control means for controlling said power supplying means so that a voltage signal for periodically changing an intensity of said magnetic force is supplied from said power supplying means, said voltage signal having a lowering pattern in one cycle such that a bottom point of voltage gradually lowers in terms of time with a top point of voltage maintained at a constant level and an irradiating member for irradiating said magnetic force generated by said magnetic force generating means to a desired target.
With this construction, the magnetic force generated by the magnetic force generating means with the intensity thereof periodically changed is irradiated from the irradiating member to the desired target such as water. In case of treating water according to the present invention, the cluster of the water can be enlarged by the irradiation of the magnetic force to the water. For example, the cluster as a group of about five molecules of water is changed into a large cluster as a group of tens of molecules of water. This phenomenon is contrary to the aforementioned phenomenon that the conventional water purifier functions to reduce the cluster of the water. The treated water having such a large cluster obtained by the target irradiating device can favorably affect as an activated water in biological or biochemical aspect.
According to a second aspect of the present invention, there is provided a target irradiating device comprising light generating means for electrically generating light; power supplying means for supplying a driving power to said light generating means; control means for controlling said power supplying means so that a voltage signal for periodically changing an intensity of said light is supplied from said power supplying means, said voltage signal having a rising pattern in one cycle such that a bottom point of voltage gradually rises in terms of time with a top point of voltage maintained at a constant level; and an irradiating member for irradiating said light generated by said light generating means to a desired target.
With this construction, substantially the same effect as that mentioned above can be obtained.
According to a third aspect of the present invention, there is provided a target irradiating device comprising magnetic force generating means for electrically generating a magnetic force; light generating means for electrically generating light; power supplying means for supplying a driving power to said magnetic force generating means and said light generating means; control means for controlling said power supplying means so that an intensity of said magnetic force to be generated by said magnetic force generating means and an intensity of said light to be generated by said light generating means are periodically changed; and an irradiating member for irradiating said magnetic force generated by said magnetic force generating means and said light generated by said light generating means to a desired target.
With these constructions, substantially the same effects as those mentioned above can be obtained.
Other objects and features of the invention will be more fully understood from the following detailed description and appended claims when taken with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a general perspective view of a water treatment device according to a first preferred embodiment of the present invention;
FIG. 2 is a perspective view of a body of the water treatment device shown in FIG. 1;
FIG. 3 is a circuit diagram of a control unit of the water treatment device shown in FIG. 1;
FIG. 4 is a circuit diagram of a modification of the control unit;
FIG. 5 is a block diagram of a further modification of the control unit;
FIGS. 6A to 6D are graphs illustrating various patterns of a driving voltage signal to be applied to a coil in the body of the water treatment device shown in FIG. 1;
FIG. 7 is a perspective view illustrating a manner of usage of the water treatment device shown in FIG. 1;
FIG. 8 is an elevational view of a part of FIG. 7;
FIGS. 9A to 9C are schematic elevations illustrating various manners of stirring of water to be treated by the water treatment device;
FIG. 10 is an enlarged elevational view of a diaphragm shown in FIG. 9C;
FIG. 11 is a schematic elevation of a seedling bed in a germination test of radish sprouts with use of a treated water obtained by the water treatment device;
FIG. 12 is a graph illustrating spectrums obtained by an NMR spectroscopy for a treated water by the water treatment device and an untreated water;
FIG. 13 is a circuit diagram of a control unit according to a second preferred embodiment of the present invention;
FIG. 14 is a circuit diagram of a control unit according to a third preferred embodiment of the present invention;
FIG. 15 is a schematic perspective view of a body in the third preferred embodiment shown in FIG. 14; and
FIG. 16 is a plan view of a modification of the body in the third preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, reference numeral 1 generally denotes a water treatment device functioning as the target irradiating device according to a first preferred embodiment of the present invention. The water treatment device 1 includes a body 3 which incorporates a coil 2, and an electronic control unit 6 (which will be hereinafter referred to as a control unit 6) connected through a cord 4 and a connector 5 to the body 3. The control unit 6 is provided with a cord 7 having a plug socket 8 at a free end thereof, which plug socket 8 is adapted to be connected to an AC power source.
Referring to FIG. 2, the body 3 is provided with a box-shaped case 9, in which the coil 2 is fixedly mounted. The coil 2 functions as the magnetic force generating means according to the present invention. The coil 2 is constructed by winding a conductive wire about an iron core 10 by 2000 turns to constitute an electromagnet. An upper end surface of the coil 2 is covered with a covering film 12 made of synthetic resin. Further, an upper opening of the case 9 is covered with a cover 13 having a magnetic permeability. The coil 2 is fixed in the case 9 so that when the case 9 is placed on a horizontal plane, the iron core 10 is directed in a substantially vertical direction, i.e., there is generated a line of magnetic force directed upwardly. The cover 13 provided on the upper surface of the case 9 forms a flat surface on which a water container or the like is to be placed, and the flat surface functions as a magnetic force irradiating member.
Referring next to FIG. 3 which shows a circuit construction of the control unit 6 for controlling a driving power (voltage) for the coil 2, the control unit 6 includes an oscillator circuit 6b consisting of digital integrated circuits IC1 and IC2, resistors R1 and R2, and capacitors C2 and C3. The oscillator circuit 6b generates pulses of a desired frequency.
The control unit 6 further includes an analog signal generator circuit 6c consisting of a counter integrated circuit IC3, an analog voltage generating integrated circuit IC4, and resistors R3 to R11. The analog signal generator circuit 6c generates a triangular wave voltage signal 6e.
The control unit 6 further includes a step form wave generator circuit 6d consisting of a counter integrated circuit IC5, amplifiers IC6 to IC9, and resistors R15 to R18. The step form wave generator circuit 6d generates a step form wave voltage signal 6f having a lowering pattern or a rising pattern.
The triangular wave voltage signal 6e and the step form wave voltage signal 6f are added together, and the sum of these voltages is in turn applied to a base of a transistor Tr1. Then, the transistor Tr1 changes an internal resistance in accordance with the voltage applied to the base thereof.
The transistor Tr1 is connected to a transistor Tr2. The transistor Tr2 is connected by Darlington connection to a transistor Tr3 to form an output transistor. The transistor Tr2 is driven by the transistor Tr1, and the transistor Tr3 is driven in accordance with a change in internal resistance of the transistor Tr2. The transistor Tr3 is connected in series with the coil 2. A current flowing in the coil 2 is adjusted by the transistor Tr3. Further, a diode D3 is provided to protect the transistor Tr3 from a reverse electromotive force of the coil 2. The control unit 6 further includes a power supply circuit 6a for converting a power of AC 100 V into a constant-voltage power.
In case of forming a step form wave of a rising pattern in the step form wave generator circuit 6d, the step form wave from the circuit 6d is synthesized with the continuous triangular wave from the circuit 6c to form a saw-toothed wave of a rising pattern as shown in FIG. 6A such that for example, a peak point is kept constant at 5 V and a bottom point is stepwise raised. Such a saw-toothed wave of a rising pattern is repeatedly generated at predetermined intervals. An output voltage wave pattern from the control unit 6 is not limited to that shown in FIG. 6A, but various patterns as shown in FIGS. 6B to 6D may be formed by suitably varying a circuit constant.
The circuit construction of the control unit 6 may be modified as shown in FIG. 4 in such a manner that a resistor R12 is grounded and the transistor Tr2 shown in FIG. 3 is eliminated with the diode D3 connected as shown.
Further, the circuit construction of the control unit 6 may be modified as shown in FIG. 5. Reference numeral 60 denotes a control unit including an oscillator (function generator) 64, a 10-16 digits counter 61, a D/A converter 62, and an amplifier 63. The oscillator 64 generates a triangular wave or a sine wave, and also generates a rectangular wave (10-16 waves). The rectangular wave is input into the counter 61 and then fed to the D/A converter 62, thereby obtaining a step form wave of a lowering pattern or a rising pattern. Then, the step form wave is synthesized with the triangular wave or the sine wave output from the oscillator 64, and is then amplified by the amplifier 63, thereby obtaining a voltage waveform as shown in FIG. 6A or 6B. The output voltage from the amplifier 63 is applied to the coil 2 to drive the same. A maximum current flowing in the coil 2 is set to about 0.1 A, for example.
The water treatment device 1 as constructed above is used as shown in FIGS. 7 and 8, for example. Referring to FIGS. 7 and 8, the body 3 of the water treatment device 1 is placed on a horizontal plane, and a water container 20 made of glass or synthetic resin is put on the upper surface of the body 3. In the case that an area of the bottom of the water container 20 is larger than that of the upper surface of the body 3, an assisting base 21 having a height slightly larger than that of the body 3 is placed on the horizontal plane so as to surround the body 3, and the water container 20 is placed on the assisting base 21. In this condition, an exciting voltage as shown in FIG. 6A, for example, is applied through the control unit 6 to the coil 2 in the body 3, so that a magnetic force of a pattern corresponding to the voltage waveform as shown in FIG. 6A is irradiated through the bottom of the water container 20 to the water contained therein.
The water treatment is carried out with the water in the water container 20 standing still as shown in FIG. 9A or with the water being stirred as shown in FIG. 9B or 9C.
As shown in FIG. 9A, the water in the water container 20 is treated under the condition of natural convection. In the case that the quantity of the water is about 1.5 liters, a time for the water treatment is set to about 2 hours.
As shown in FIG. 9B, a stirring screw 22 as the stirring means in the present invention is provided so as to be rotated in the water container 20 to forcibly stir the water. In this case, the time for the water treatment can be shortened as compared with the case shown in FIG. 9A.
As shown in FIG. 9C, a diaphragm 23 as the stirring means in the present invention is provided in the water container 20 to forcibly stir the water. A construction of the diaphragm 23 is shown in FIG. 10. As apparent from FIG. 10, the diaphragm 23 is constructed of a waterproof movable plate 23a made of a ferromagnetic material such as iron and an elastic skirt member 23b formed of an elastic material such as rubber. The skirt member 23b is formed with a plurality of through holes 23c for permitting pass of the water. The movable plate 23a is separatably mounted on the top of the skirt member 23b, so that when the coil 2 is driven, the movable plate 23a is vertically moved by a magnetic field generated by the coil 2 to stir the water. In this case, the time for the water treatment can be shortened to about 1/3 as compared with the case shown in FIG. 9A.
The treated water obtained by using the water treatment device 1 was tested by an NMR spectroscopy. A structure or state of water in its molecular level can be observed without breaking the molecule of water by the NMR spectroscopy. That is, since water is represented as H 2 O, the behavior of water in its molecular level can be grasped by observing a nuclear of hydrogen ( 1 H) or a nuclear of oxygen ( 17 O). As previously described, water exist in the state of a cluster as a group of at least five molecules rather than in the state of a single molecule. A life of the cluster (a change in magnitude thereof) is very short such as 10 -12 seconds (one picosecond). In the test, the 17 O-NMR spectroscopy for observing the nuclear of oxygen ( 17 O) was adopted to analyze and evaluate the treated water in comparison with an untreated water.
Water Analysis Test by NMR Spectrometry
(1) Measurement
(a) Water Used
A purified water of Japanese pharmacopoeia by Kyoei Yakuhin Kabushiki Kaisha was used.
(b) Samples Tested
The above purified water was used as the untreated water, while it was treated by the water treatment device 1 for 2 hours in the condition of natural convection to prepare a treated water.
(c) Elapsed Time from the Preparation of the Samples to the NMR Measurement
After 40 days from the preparation of the samples, the measurement was carried out.
(d) Measurement Conditions
Target Nuclear: 17 O
Measuring Frequency: 36.6 MHz
Measuring Method: SGNON (Normal measuring method)
Pulse Width: 21μ sec (90° pulse)
Repeating Time:
ACQTM=0.102 sec
PD=0.100 sec
Accumulation Times: 1000
Measuring Temperature: 20.0° C.
(2) Result
The result of the above NMR spectrometry is shown in FIG. 12. Referring to FIG. 12, a dashed line represents an NMR spectrum of the untreated water, and a solid line represents an NMR spectrum of the treated water. As apparent from FIG. 12, a line width of the spectrum of the treated water is larger than that of the untreated water. That is, a half width of the spectrum of the untreated water is 62.56 Hz, and a half width of the spectrum of the treated water is 70.81 Hz. These values are intrinsic line widths of the untreated water and the treated water. Each line width is inversely proportional to a relaxation time which is a time for discharging an energy absorbed by the nuclear ( 17 O) used in the NMR spectrometry. Therefore, when the cluster as a group of water molecules becomes large to cause slowing of a molecule motion, the relaxation time is shortened to cause an increase in line width of NMR spectrum. As a consequence, the increase in line width means that a proportion of enlarged clusters in the treated water is increased in average.
In general, it is known that when a very weak external energy such as ultrasonic wave, radio wave, or low-frequency vibration is applied to water, bonding of water molecules constituting a cluster is broken to reduce a size of the cluster, and that a life of such a small cluster is short to restore an original condition in a short period of time by rebonding of the molecules.
In contrast, the test result proves that the water cluster is increased in size by irradiation of a magnetic force with use of the water treatment device 1, and that the large cluster obtained remains still even at the time 40 days have elapsed after treating the water.
Germination Test for Radish Sprouts with use of a Treated Water
Using a treated water enlarged in its cluster in comparison with a normal city water as an untreated water, a germination test for radish sprouts was carried out as follows:
(1) Preparation
(a) Seed
60 seeds of radish sprouts made by Taiki Shubyo Kabushiki Kaisha were used.
(b) Water for Germination and Seedling
i) City Water (as an untreated water)
ii) Treated Water
A city water and 30 seeds were put into a heat-resistant cup, and a magnetic force was irradiated from a side surface of the cup for 30 minutes by using the water treatment device shown in FIG. 1 (Preparation of a treated water and treated seeds).
(c) Formation of Germination and Seedling Bed
i) City Water
As shown in FIG. 11, an absorbent cotton 52 in a cut condition was put into a plastic container 50, and the city water as the untreated water was put into the container 50 till a water level of 15 mm from the bottom of the container 50. Further, the 30 untreated seeds were regularly arranged on the absorbent cotton 52 submerged in the untreated water.
ii) Treated Water
Similarly to the case of the untreated water, the treated water was put into the container 50, and the 30 treated seeds were regularly arranged in the treated water.
(d) Place for Germination and Seedling
Near a south window in a room (at a height of man's waist)
(e) Sunlight Receiving Time
8:00 am-12:00 am
(f) Duration of the Test
14 days
(g) Temperature Change
12°-23° C.
(2) Progress
In the duration of 14 days from the start to the end of the test, the city water and the treated water were appropriately added into the container so that the seeds were submerged in the water. As compared with the untreated seeds in the city water, the treated seeds in the treated water absorbed the water more quickly, so that it was necessary to add the treated water in an amount about 2-3 times that of the city water.
In average, a seedling speed of the treated seeds in the treated water was higher than that of the untreated seeds in the city water.
(3) Results
After the 14-days test, lengths and weights of rhizomes of the radish sprouts were measured in the next day. The results of measurement are as follows:
Lengths
i) Average length of the 30 radish sprouts grown in the city water was about 5 cm.
ii) Average length of the 30 radish sprouts grown in the treated water was about 6.5 cm.
Weights
i) Total weight of the 30 radish sprouts grown in the city water was about 10 g.
ii) Total weight of the 30 radish sprouts grown in the treated water was about 15 g.
(4) Analysis
As apparent from the above results, the use of the treated water obtained by treating a city water contributes to quickness of growing by about 50% in terms of weight as compared with the use of the city water. This means a special effect of the water treatment device 1 according to the preferred embodiment.
Other Effects of the Water Treatment Device
It was observed that a treated water treated by the water treatment device has the following other effects.
(1) Taste Effects
In case of using the treated water as a drinking water, the taste of the drinking water became good. Further, in case of cooking with use of the treated water, the taste of the cooks became also good.
(2) Biological Effects
In case of ingesting the treated water as a drinking water or a content in cooks for a relatively long term (e.g., one month or more), the following biological effects were observed.
(a) Bleeding from a gum was suppressed.
(b) Falling of hair was reduced.
(c) A blood pressure became stable.
(d) Feces of human being and other animals became yellowish, and bad smell thereof almost disappeared. As to house pet dogs, an offensive odor (mainly ammonia odor) in a house remarkably decreased.
(3) The other effects
Rusting of iron was remarkably suppressed. A rusting test was carried out by immersing the same iron piece in the city water and the treated water and allowing it to stand for several days. In the fourth day after the start of the rusting test, the iron piece in the city water was completely rusted to such a degree that its color was generally changed into reddish brown. In contrast, the iron piece in the treated water was somewhat rusted in a proportion of about 1/4 of the whole.
FIG. 13 shows a circuit construction of a second preferred embodiment of the present invention. In the second preferred embodiment, an incandescent lamp 30 is substituted for the coil 2 shown in FIG. 3. A light strength of the incandescent lamp 30 is controlled by the control unit 6 to change with any pattern shown in FIGS. 6A to 6D. Infrared rays of light from the incandescent lamp 30 is irradiated to water to be treated. Although not shown, the coil 2 shown in FIGS. 4 and 5 may be, of course, replaced by the incandescent lamp 30. Also in the second preferred embodiment, substantially the same effect of the water treatment as that in the first preferred embodiment was obtained. That is, enlargement of a water cluster was effected, but the effect was quantitatively just smaller than that in the first preferred embodiment.
FIG. 14 shows a circuit construction of a third preferred embodiment of the present invention. In the third preferred embodiment, the incandescent lamp 30 is connected in series with the coil 2. FIG. 15 shows a concrete example of juxtaposed arrangement of the coil 2 and the incandescent lamp 30 corresponding to the third preferred embodiment. Alternatively, as shown in FIG. 16, a plurality of incandescent lamps 30 may be arranged around the coil 2. It is to be understood that these examples of arrangement are merely illustrative and various modifications may be made.
Further, while the target irradiating device of the present invention is preferably adapted to water treatment as hereinbefore described, it is also effective for a remedy to a living body such as a human body. For example, when a magnetic force of light having the waveform pattern shown in FIG. 6A or 6B was irradiated to the stiff shoulder of a patient repeatedly several times, the stiffness of the shoulder was almost cured. Further, such a medical treatment effect was also confirmed in lumbago, neuralgia, etc.
While the invention has been described with reference specific embodiments, the description is illustrative and is not to be construed as limiting the scope of the invention. Various modifications and changes may occur to those skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims. | A target irradiating device including a magnetic force generating member for electrically generating a magnetic force; a power supplying member for supplying a driving power to the magnetic force generating member; a control member for controlling the power supplying member so that a voltage signal for periodically changing an intensity of the magnetic force is supplied from the power supplying member, the voltage signal having a lowering pattern in one cycle such that a bottom point of voltage maintained at a constant level; and an irradiating member for irradiating the magnetic force generated by the magnetic force generating member to a desired target. The target irradiating device may be adapted to a water treatment device for treating water as the desired target to obtain an irradiated water. | 0 |
FIELD OF THE INVENTION
The present invention relates to methods and systems for altering the environment in closed chambers by the use of non-ionizing radiation that has been imprinted in water using a spectral region known as Terahertz Radiation. More particularly, there is provided a means for altering the environment so as to maintain the freshness of food products and retard the activity of bacteria associated with the food products.
BACKGROUND OF THE INVENTION
The use of magnets is known to create a magnetic field to energize water so as to permit the magnetized properties to dissipate to the surrounding areas.
U.S. Pat. No. 6,164,332 discloses an apparatus to deliver water energized by a vortex flow of water through a magnetic field.
U.S. Pat. No. 6,053,287 discloses a magnetic processing treatment facility for subjecting a fluid flow to magnetic energy that is integrated into an agricultural use to enhance activity in terms of crop growth and to increase the solubility of agricultural chemical agents to be used in a spray.
U.S. Pat. No. 6,602,411 discloses a magnetic treatment apparatus to “energize” water using at least two magnetic fields and an electrical current. The water is used to condition potable water, gardening water and recycled water.
U.S. Pat. No. 7,476,870 to Hopaluk et al, which is herein incorporated by reference, discloses a method of “energizing” water using reflected ultraviolet light.
There exists an AquaCharge® system for “energizing” water using paramagnetic material and Organite to clear harmful energy signatures from water. The system passes water through a concentrated paramagnetic system combined with quartz crystals in combination with orgone to provide the water with positive frequencies.
The article of Gerecht et al entitled “A Passive Heterodyne Hot Electron Bolometer Imager Operating at 850 GHz” in IEEE Transactions on Microwave Theory and Technoques , Vol 56, No. 5, May 2008, describes means for producing and detecting Tetrahertz radiation at a frequency of 720-930 GHz.
Light rays produced by the sun comprise electric and magnetic vibrations which are vibrating in more than one plane that is referred to as unpolarized light.
The spectrum of electromagnetic radiation striking the earth on a daily basis originates from the sun including for example commonly known spectra such as the visible and ultraviolet regions. The full spectrum is characterized by the term EOF representing the electro optical frequencies of solar radiation. The bands of these frequencies are characterized based upon wavelengths into nine general regions illustrated by the Solar Spectrum. These nine categories of increasing wavelength from 100 nm to 1 mm include Ultraviolet C, Ultraviolet B, Ultraviolet A, Visible light, Infrared A, Infrared B, Infrared C, FAR Infrared, and Extreme Far Infrared, the latter of which is part of the Terahertz spectrum.
This special region known as Terahertz spectrum radiation or the “Terahertz Gap” falls between electromagnetic frequencies (measured with antennas) and optical frequencies (measured with optical detectors). There are currently no known natural sources of Terahertz radiation in the Extreme Far Infrared region.
Terahertz radiation is a non-ionizing sub-millimeter radiation and shares with X-rays the capability to penetrate a wide variety of non conductive materials. Terahertz radiation can pass through clothing, paper, cardboard, wood, masonry and plastic. It can also penetrate fog and clouds, but cannot penetrate metal or water.
It is possible to transform unpolarized light into polarized light. Polarized light waves are light waves in which the vibrations occur in a single plane. The process of transforming unpolarized light into polarized light is known as polarization. There are a variety of methods of polarizing light. The most common method of polarization involves the use of a Polaroid filter. Polaroid filters are made of a special material which is capable of blocking one of the two planes of vibration of an electromagnetic wave. A Polaroid serves as a device which filters out one-half of the vibrations upon transmission of the light through the filter. When unpolarized light is transmitted through a Polaroid filter, it emerges with one-half the intensity and with vibrations in a single plane; it emerges as polarized light.
A Polaroid filter is able to polarize light because of the chemical composition of the filter material. The filter can be thought of as having long-chain molecules that are aligned within the filter in the same direction. During the fabrication of the filter, the long-chain molecules are stretched across the filter so that each molecule is aligned in the vertical direction. As unpolarized light strikes the filter, the portion of the waves vibrating in the vertical direction are absorbed by the filter. The general rule is that the electromagnetic vibrations which are in a direction parallel to the alignment of the molecules are absorbed.
The alignment of these molecules gives the filter a polarization axis. This polarization axis extends across the length of the filter and only allows vibrations of the electromagnetic wave that are parallel to the axis to pass through. Any vibrations which are perpendicular to the polarization axis are blocked by the filter. Thus, a Polaroid filter with its long-chain molecules aligned horizontally will have a polarization axis aligned vertically. Such a filter will block all horizontal vibrations and allow the vertical vibrations to be transmitted. On the other hand, a Polaroid filter with its long-c chain molecules aligned vertically will have a polarization axis aligned horizontally; this filter will block all vertical vibrations and allow the horizontal vibrations to be transmitted.
SUMMARY OF THE INVENTION
The present invention relates to a method and means for altering the environment in a closed system by non-ionizing Terahertz radiation emitted from water imprinted with wavelengths of 100 micrometers to 1 micrometers or frequencies from 300 GHz to 3 THz so as to reduce the activity of pathogens and maintain the freshness of food products. More particularly, there is provided water which has been imprinted with Terahertz non-ionizing in a geometrically suitable transparent container which emits radiation at least at a frequency of 720-930 GHz, preferably at 850 GHz into a closed environment containing food products.
Advantageously, the containers in which the food products are stored with the means for radiating the Terahertz non-ionizing radiation consists of refrigerators, coolers, food transports and the like.
The container storing the “energized” water is preferably egg shaped.
It is a general object of the invention to provide a means for generating non-ionizing radiation from a container to alter the environment in a storage container for foodstuff.
It is another object of the invention to reduce the pathogens associated with food by the use of Terahertz radiation and thereby extending the shelf life of the product.
It is yet another object of the invention to accelerate the conversion of glycogen in fruits and vegetables, such as apples and tomatoes, using Terahertz radiation.
It is a still further object of the invention to reduce oxidation and retain the moisture of food in the refrigerator or pantry without using chemicals.
It is a yet another object of the invention to provide a means for altering the environment in a closed chamber with Terahertz radiation so as to reduce pathogenic growth, mold and mildew.
These and other objects will become apparent from the reading of the description of preferred embodiments and the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a procedure for preparing a means for generating Terahertz radiation to imprint water.
FIG. 2 represents a geometric container for storing the energized water of the process and emitting radiation in a closed chamber.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to the present invention, there is provided a means for radiating in a closed chamber Terahertz radiation and imprinting water containing inorganic salts and/or minerals with wavelengths of about 100 micrometers to 1 micrometer or frequencies from 300 GHz to 3 THz, preferably radiation at a frequency of about 720 to 930 GHz, most preferably of about 850 GHz which is placed in a geometrically suitable transparent container to effect the environment in the chamber. Preferably, the chamber is environmentally controlled.
As seen in FIG. 1 of the drawing, a source ( 10 ) of Terahertz radiation which generates the desired Terahertz radiation, such as disclosed in aforementioned IEEE Transactions on Microwave Theory and Techniques or naturally from the sun, is beamed to a metal reflector ( 11 ). The electro-optical frequencies generated are reflected onto a polarization filter ( 12 ). The polarized rays are then directed into a tank containing ionized water ( 22 ) which contains inorganic salts and/or minerals to absorb the polarized Terahertz radiation and store imprinted information.
The tank of water contains a vortex generator ( 13 ) to create a spinning turbulent flow of water in the tank. The turbulence is produced for at least one hour in a tank containing about 125 liters of the polarized water. The irradiated polarized water is then rested for about one hour to allow imprinting of the Terahertz radiation. The vortex generated is preferably rotated in a counterclockwise direction.
The imprinted water can then be placed in a geometrically acceptable transparent container ( 14 ), for example, an egg shaped transparent container, which when placed into an environmentally controlled chamber ( 15 ) transmits the desired Terahertz radiation. The container can also be placed in a non controlled environment such as an insulated container.
When using sunlight as the source of Terahertz radiation, consideration is taken as to the amount of sunlight available. One of the properties of sunlight is its wave particle duality. The main property used in the process encompasses the particle aspect of the waves of sunlight. Using the high photonic energy of the unobstructed sunlight the polarized light has the ability to change the electromagnetic spin of the electrons in the water molecules containing the inorganic salts and/or minerals such as found in spring water. The process synchronizes the water molecules into certain formations allowing the water to absorb the Terahertz radiation, especially those in the Far Infrared end of the spectrum.
As seen in FIG. 2 , proper geometrically shaped containers ( 20 ), for example, egg shaped transparent containers ( 21 ) containing the energized water ( 22 ) are placed on a stand ( 23 ). Proper geometrically shaped containers are well known to transmit various energies whereby the wavelengths do not interfere with each other. Containers which are egg shaped have this capability. Pyramid configurations are considered to channel energies in the proper direction as well. Tubular containers also permit the energizing properties of the water to dissipate therefrom in proper order.
Use of the radiation emitting devices of the invention can reduce oxidation and retain moisture in food that are stored in chambers such as refrigerators, refrigeration vehicles, coolers, pantries and the like which causes odors and food spoilage.
Example 1
A comparison study was made wherein three controlled environment chambers were used. One chamber contained 25 fresh picked Gala apples. A second chamber contained 25 fresh picked Gala apples treated with gaseous 1-methylcyclopropene (1-MCP) which is commercially available under the trademark Smart Fresh®. A third chamber contained 25 fresh picked Gala apples and the egg shaped device with the Terahertz radiation treated water of the invention.
After 6 weeks the apples were tested to firmness, acid levels, color, taste and aroma.
Results
The non-treated apples had soft spots, brown spots when sliced, tasted as being stale and not fresh. The color was only slightly faded.
The apples treated with 1-MCP were crunchy, fresh tasting and similar to the fresh picked apples.
The apples from the third chamber had the same quality and characteristics as the apples from the second chamber.
The terms and expressions which have been used are not limitations and there is no intention in the use of these terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but recognize that various modifications are possible within the scope of the invention claimed. | The present invention provides a method for imprinting water so as to emit Terahertz radiation and a method for maintaining the freshness of foodstuff with an article containing the imprinted water. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to blotting test apparatus. More particularly this invention relates to a positive pressure blotting apparatus for biological molecules.
2. Description of the Prior Art
Blotting membrane based tests for biological samples have become common. The The tests are described in an article by Leary, Proc. Natl. Acd. Sci. USA, Vol 80, pp. 4045-4049, (1983). A standard apparatus for blotting or dot blotting onto membranes can be purchased can be purchased from many different suppliers. Each supplier appears to have a special design to accelerate filtration, avoid migration of test points, referred to as "cross-talk", and otherwise protect samples from contamination.
As the size of the biological molecule increases, greater difficulty is experienced in filtering the sample to bind the molecule to the filter material. In all of these devices, attempts are made to improve the filtration rate by applying negative pressure to the filter medium by creating a vacuum in the chamber under the filter medium.
Some in the prior art have suggested that applying positive or negative pressure are equivalent however, in all specific examples, negative pressure is used. Olsen, et al., in U.S. Pat. No. 4,853,335 describes using positive or negative filtration in a colloidal gold particle concentration immunoassay. Matkovich, et al., in U.S. Pat. No. 4,797,259, describes an improvement in "well-type" diagnostic plate devices in which the use of positive and negative pressure are considered to be equivalent. Matkovich suggests that in both cases it is necessary to wet the filter material. Normally hydrophobic membranes, such as polyvinylidene fluoride, must be made hydrophilic in order to operate in the Matkovich invention. Matkovich renders the polyvinylidene fluoride hydrophilic by washing with reagents such as methanol. Matkovich suggests that applying positive pressure up-stream of the membrane is equivalent to applying negative pressure down-stream of the membrane, but Matkovich illustrates only the use of negative pressure. Nothing in Matkovich provides evidence which supports the allegation of equivalence.
Methanol and other reagents used to render a membrane hydrophilic can denature or otherwise change the biological molecules which the blotting technique seeks to recover or analyses. It is preferred to have an apparatus and technique which avoids using damaging or denaturing reagents.
SUMMARY OF THE INVENTION
Accordingly, an object of this invention is an apparatus which uses a "dry" membrane.
Another object of this invention is an apparatus which will efficiently bind biological molecules to a membrane.
Yet another object of this invention is an apparatus which forms a closed system capable of continues operation.
These and additional objects of the invention are accomplished by a positive pressure blotting apparatus having a bottom section, at least one middle section and a top section. A first volume of space is encompassed between the top section and the middle section. A positive pressure is maintained in the first volume of the apparatus. A second volume of space is encompassed between the middle section and the bottom section to capture eluate. An alignment means is used to align the top section to the middle section. A means is provided to apply positive pressure in the first volume. A filter means for binding biological materials is positioned on or in the middle section, and a means is provided to secure the top, middle and bottom section together to form a pressure blotting apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention will be readily obtained by reference to the following Description of the Preferred Embodiments and the accompanying drawings in which like numerals in different figures represent the same structures or elements. The representations in each of the figures is diagrammatic and no attempt is made to indicate actual scales or precise ratios. Proportional relationships are shown as approximations.
FIG. 1 is a top view of the top section of an embodiment of the apparatus.
FIG. 2 is a side view of the top section of the apparatus illustrated in FIG. 1.
FIG. 3 is a top view of one embodiment of the middle section of the apparatus.
FIG. 4 is an exploded side view of an embodiment of the apparatus showing the relationship of the three major parts of this embodiment of the apparatus.
FIG. 5 is a top view of an embodiment of the bottom section of the apparatus.
FIG. 6 is a side view of the embodiment of the bottom section of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Blotting devices are used to bind the biological molecule to a membrane. The membrane can take many forms which are well known in the art of making blotting apparatus. In a blotting apparatus, the membrane is immobilized by being trapped or clamped between a middle section and a bottom section. In an alternative version, the middle section is formed from more than one piece and the membrane is wedged between the parts of the middle section. The middle section also forms the guides or wells for multiple blot tests.
The apparatus of this invention works equally well with any number of wells from one upward. Most preferred are between 96 and 135 wells. The wells can be arranged in any manner. 135 wells can be arranged is three rows of 3×15 to facilitate cutting the membrane into three strips each having three rows and a tab for use in "dip-stick" tests. Various means can be used to clamp or hold the membrane in place.
There are many membranes which are well known for use in immobilizing biological molecules in these blotting test apparatus. Representative materials are listed in Matkovich referred to above and in catalogs for blotting systems. These membrane materials include nitrocellulose, cellulose based filaments, nylon, and polyvinylidene fluoride (PVDF). Many of the most desirable membrane materials are hydrophobic. Filtration through these materials is slow. It is common to try and improve the filtration by applying negative pressure to the down stream side of the membrane material by the usual techniques of vacuum filtration. In all the vacuum techniques, the membranes are made wettable or hydrophilic to facilitate the binding process.
In this invention, it was discovered that pressing biological molecules through a membrane has unexpected advantages over vacuum filtration. The advantages are particularly marked when the membrane is non-wettable and has a high bubble pressure. These high bubble pressure materials include polyvinylidene difluoride which is sold as Immobilon-P®.
This invention imposes a positive pressure on the sample in the well pressing or forcing the sample through the filter material and membrane. In a vacuum filter apparatus vacuum pressure is dissipated over a portion of the membrane adjacent to the well. In a positive pressure apparatus, the well concentrates and directs the pressure to the top of the sample effectively pushing the sample through the membrane. Greater efficiency is achieved for the same power output to the pressure differential creating device such as a pressure pump or vacuum pump. Other pressure creating devices include syringes, motorized pumps, hand pumps, other piston powered pressure devices and compressed gas sources. Vacuum blotting through dry membranes or filters can not be achieved with a conventional vacuum technique.
The positive pressure causes another unexpected benefit. Positive pressure creates laminar flow through the membrane rather than the irregular or dispersed flow caused by a vacuum. The laminar flow reduces spread beyond the well boundaries on the down stream side of the membrane.
Having described the invention, the following is given to illustrate specific applications of the invention including the best mode now known to perform the invention. This illustration is not intended to limit the scope of the invention described in this application.
Referring to the drawings, FIG. 1 is a top view and FIG. 2 is a side view of the top section of the apparatus. In the embodiment illustrated, the top section 10 forms a hollow area or volume 12. Top section 10 serves as a manifold for pressurizing the apparatus. A conduit or tube 18 projects through the wall of the top section 10 through positive pressure can be applied to the hollow area 12. The top section 10 is mounted over a middle section 20 illustrated in FIG. 3 and 4. An alignment device 14a and b in the form of a triangular shaped post and socket assists in aligning all the well openings 27. An O-ring seal 16a is located about the periphery of the top section and in conjunction with the groove 16b forms a pressure seal. The seal should hold at least 20 psi gauge through much higher pressure is preferred. A device 11 secures the parts of the apparatus together and allows pressurization of the manifold top section 10.
Pressure is applied through conduit 18 through flexible tubing to a "Luer Lok" tip for a 50 ml or 100 ml syringe. The syringe will then be used to produce the desired pressure. This is a simple, low cost and preferred method. This syringe will produce between 30 and 60 psi at the membrane because of the low volume of the apparatus. In its preferred embodiment the apparatus is about the size of an ELISA plate. Of course, for larger apparatus alternate pressure sources can be compressed gas cylinders and pumps.
The middle section 20 can be of any design used for blotting tests. The section 20 contains wells 27 of approximately 0.2-0.3 mm in diameter and 1 cm in depth. This creates a well sufficient to hold approximately 250 μl of fluid in the well. Excess space or dead space in each well increases the pressure column above the fluid surface of the sample when pressure is applied to the manifold 10.
As shown in FIG. 4b, the well 27 extends through the middle section 20 and is preferably terminated in an O-ring 25a. The bottom section in the embodiment illustrated, contains a continuation of the well 27. An O-ring 25b is on the top surface of the bottom section 30. A membrane 22 is positioned between the sections 20 and 30. The O-rings 25a and b help to define the spot and keep the spot well defined. Alignment device 24a and b help to align section 20 and 30 so the wells 27 are aligned. In all cases, it is most preferred to have to membrane 22 sealed into position so that pressure or fluid does not dissipate around the membrane. The membrane can be sealed by clamping between two plates or between O-rings or gaskets or by any other means well known for these blotting devices.
A volume of space 33 in the section 30 is in communication with the down stream side of the wells 27 to collect the eluate. The space is in communication with conduit or tube 32 which is both an over flow to remove eluate and a means of applying negative pressure to the space 33.
Referring to FIG. 4, the sections 20 and 30 are assembled together fixing a membrane 22 between them. Alternately the section 20 and be made of more than one piece and the membrane 22 can be fixed within the section 20. In such an embodiment, the section 30 can be in the form of a simple basin. There is no need to continue the wells 27.
It is preferred that the sections 10, 20 and 30 are fastened together strongly enough to withstand the greater than 20 psi pressure applied to manifold 10. A latch device 11 secures the sections together. This latch device can secure all three sections at once or it can secure the sections separately. The latch securing sections 30 to 20 should be strong enough to prevent the membrane 22 from moving so there is no "cross talk" between wells.
In an alternate embodiment the apparatus can be adapted to a closed circuit, automated system. In this embodiment, the sample wells are loaded in the normal manner with a ligand to be bound to the membrane. The manifold is secured and the assay is performed in a "flow-through" mode with the reagents being flowed through the membrane in successive steps. The manifold is adapted to provide the feed tubes for each well.
In the closed circuit mode, fluid flow can be in any direction and can be reversed at any time. Reversal of flow allows for efficient washing and the removal of entrapped reagents. Flow of reagent even slightly into the membrane allows for ligand bound in the deeper recesses to have material to react with. Any type of chemical, biological or diagnostic assay can be automated, enhanced and controlled in this way.
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. | A positive pressure blotting apparatus having a bottom section, at least middle section and a top section. A first volume of space is encompassed between the top section and the middle section. A positive pressure is maintained in the first volume of the apparatus. A second volume of space is encompassed between the middle section and the bottom section to capture eluate. An alignment means is used to align the top section to the middle section. A means is provided to apply positive pressure in the first volume. A hydropholic filter means for binding biological materials is positioned on or in the middle section, and a means is provided to secure the top, middle and bottom section together to form a pressure blotting apparatus. | 6 |
BACKGROUND OF THE INVENTION
This invention relates generally to the propagation of bird eggs and, more specifically, to a device used for the incubation and/or hatching of emu, rhea and ostrich eggs. While the invention is discussed in particular detail with respect to such large bird eggs, those skilled in the art will recognize the wider applicability of the invention described hereinafter.
Within the last few years there has been a growing interest in the raising of emus, rheas, and particularly ostriches. The interest in ostriches is due to the fact that there is a growing market for ostrich products such as leather, feathers and the meat, which is low in cholesterol and has an appealing flavor. Ostrich hens generally lay eggs every other day between March and September. An adult hen of breeding age can sell for as much as $15,000.00. It is not unusual to see ostrich chicks sell for $1000.00 each. Accordingly, there is a significant incentive for maximizing the hatching of ostrich eggs.
The artificial incubation of eggs of various birds has been recognized as a means for producing larger numbers of birds that can be produced by natural incubation. It also has been recognized that the success rate for artificial incubation differs among the types of birds. The eggs of some birds are more sensitive to environmental conditions during incubation. Therefore, it is advantageous to incubate the bird eggs in uniform optimal environmental conditions including temperature, oxygen flow, and humidity.
Furthermore, it has been recognized that correct turning and positioning of the eggs improve the hatch. Turning is important to keep the yolk or the developing chick from sticking to shell membranes. If the eggs are not properly turned, the chicks can suffer late death in the shell or the surviving chicks can suffer weakness and retarded growth. Correct turning of the egg allows the placenta-like membrane surrounding the embryo to have equal exposure to gravity. I have found this can be accomplished effectively by placing the eggs on their side and rolling the egg 180° at least twice a day. There are a number of incubators available commercially. While these prior art devices work for their intended purpose, they do not exhibit the kinds of hatch rates available with the invention described hereinafter. In particular, I have found that hatch rates for large eggs increased substantially by maintaining the egg environment at a positive pressure. In my invention, this is accomplished by providing a substantially sealed unit and controlling air flow to the incubator in accordance with predetermined flow rates. By exhausting air at the bottom of the incubator, I am able to control humidity levels throughout the incubator precisely. In addition, I am able to roll the eggs with a relatively simple drive system. The incubator itself is controlled by a computer, giving the unit quick response to sensed conditions during the incubation period, including the ability to provide alarms should a catastrophic failure occur, in sufficient time to prevent loss of the entire hatch.
SUMMARY OF THE INVENTION
It is among the principal objects of the present invention to provide a novel device for the propagation of large bird eggs such as ostrich eggs.
It is another object of the invention to provide such a device that controls the environment in which the egg incubates to improve the hatching results of such eggs.
Another object of the invention is to provide such a device wherein the temperature, humidity and oxygen surrounding the eggs are controlled so as to create an optimal environment for the hatching of the eggs.
Yet another object of the invention is to provide such a device capable of rolling or turning the eggs to maximize successful hatching.
Still another object of the invention is to provide such a device that has a plurality of interchangeable devices for rolling or turning the eggs during incubation to enhance the hatching rate.
A still further object of the invention is to provide such a device that is well insulated and completely sealed when closed so as to protect the controlled internal environment.
Yet another object of the invention is to provide such a device that is economical to manufacture, easy to install and use, capable of expansion or stacking in multiple units, and well suited for its intended purpose.
In accordance with the invention, a device for the incubation and hatching of bird eggs is provided having an insulated cabinet for housing the eggs and a second smaller environmental control box mounted on the back of the cabinet. The cabinet has a sealed door and the cabinet is completely sealed when the door is closed to maintain the internal environment and a positive air pressure during use. The cabinet employs interchangeable egg rolling or rotating means. In one preferred embodiment, the cabinet contains an egg rolling device including a plurality of spaced apart rotatable rods, the spacing of which is such that the width of the eggs can be supported between adjacent pairs of rods so that the eggs are rolled when the rods are rotated. In another embodiment, the cabinet contains a rotary rack egg mining device. The rotary rack egg turner contains a plurality of egg holders formed from four horizontal rods. The eggs are held between the rods. The egg turner rotates thereby rotating the holders and eggs. The rotary rack egg turner can be round or rectangular in cross-section. In another embodiment, the egg rotator is a drawer having a plurality of rotatable egg holders in horizontal alignment within the drawer.
The environmental control box is in fluid communication with the cabinet. Outside air, moisture and heat are combined for flow into the cabinet. The temperature, humidity and oxygen flow in the cabinet are monitored and computer controlled. Air from the control box is forced into the top of the cabinet by one or more controlled fans to maintain the desired environment for the eggs. The cabinet is vented at the bottom to remove carbon dioxide and excess humidity. More air enters the cabinet than is exhausted thereby creating a positive pressure within the cabinet. The temperature, air flow, barometric pressure and humidity within the cabinet are substantially respectively uniform so that all of the eggs are exposed to the optimal environment. Preferably, the cabinet and control box are designed as an integral unit. The units can be stacked to form convenient multiple units.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front plan of a pair of the incubator devices of the present invention arranged in a stacked configuration;
FIG. 2 is a front plain of the incubator devices of FIG. 1 with the sealed doors open and the egg rotating elements removed;
FIG. 3 is a rear perspective view of the incubator devices of FIG. 1, the lower device having the environmental control box opened;
FIG. 4 is a rear elevational view of the incubator devices of FIG. 1, the top device having the environmental control box and motor cover removed;
FIG. 5 is a rear elevational view of another larger embodiment of the incubator device of the present invention, the environmental control box removed, showing the three fan configuration;
FIG. 6 is a rear perspective, partially schematic, illustrating the controlled air flow through an incubator device of the present invention;
FIG. 7 is a perspective view of one illustrative embodiment of an egg rolling device of the incubator device of the present invention;
FIG. 8 is a partial end, view from the bottom, of the egg rolling device of FIG.7;
FIG. 9 is a partial view of the motor coupling of the egg rolling device of FIG. 7;
FIG. 10 is a perspective view, partially cut away, of an alternative embodiment of an egg turning element of the incubator device of the present invention;
FIG. 11 is an enlarged end section of an egg holder of the egg turning element of FIG. 10;
FIG. 12 is a perspective view of another alternative embodiment of an egg turning element of the incubator device of the present invention;
FIG. 13 is a partial section of the drive track and egg holder assembly of the egg rotating element of FIG. 12;
FIG. 14 is a perspective view of another alternative embodiment of an egg rotating element of the incubator device of the present invention; and
FIG. 15 is an enlarged partial view of the egg holder drive from the egg rotating element of FIG. 14;
FIG. 16 is a schematic drawing of the incubator device of the present invention illustrating the test results from Test #1;
FIG. 17 is a schematic drawing of the incubator device of the present invention illustrating the test results from Test #2;
FIG. 18 is a schematic drawing of the incubator device of the present invention illustrating the test results from Test #3;
FIG. 19 is a schematic drawing of the incubator device of the present invention illustrating the test results from Test #4; and
FIG. 20 is a schematic drawing of the incubator device of the present invention illustrating the test results from Test #5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An egg incubating device of the present invention is indicated generally be reference numeral 1 in the drawings. FIGS. 1 and 2 illustrate a pair of devices 1 in a stacked arrangement. It will be appreciated that device 1 can be used alone or in the preferred stacked arrangement. As best seen in FIG. 2, each device 1 has a generally box-like cabinet 3. Cabinet 3 has a interior top wall 5, bottom wall 7, rear wall 8 and opposed side walls 9 and 10. The interior walls preferably are stainless steal and define an internal chamber 12. In the preferred embodiment, chamber 13 has a volume of approximately 16.5 cubic feet. There is a pair of conventional drawer rollers 14 and 15 mounted on interior side wall 9 and a complementary pair of drawer rollers 16 and 17 mounted on interior side wall 10. The drawer rollers are designed to accommodate a pull-out, shelf-type egg roller element to be described in detail below.
Cabinet 3 has outer side walls 18, top wall 19 (FIG. 6) and bottom outer walls (not shown) and an rear outer wall 19. Between the inner and outer side walls there is a suitable insulative layer 21. A two inch polymeric isocryanate injected insulation layer works well, for example. The lower cabinet 3 may be mounted on four casters 22.
Device 1 has a wide door 23. Each door 23 has a double pane window 24 with a gas between the panes and a sealed frame 26 around the panes. The door is connected to the cabinet by conventional hinges 27 and seals tightly with robber seals 29 and 31 which surround both the interior perimeter of the window and the door itself when closed.
As best seen in FIG. 2, interior rear wall 8 has a pair of upper louvered vents 33 and a substantially smaller lower louvered vent 35. The upper vents 33 functions to allow air to flow into the chamber from the environmental control box and lower vent 35 is a recirculating air vent. Vent 35 extends through both the interior and outer rear walls and can be seen externally in FIG. 4. An exhaust port 37 is located at the extreme lower corner of the back wall. The interactive functions of the respective vents and port will be described in greater detail below.
The environmental control box 40 and the components therein will now be described in detail. As best seen in FIGS. 3 and 4, control box 40 has a box-like shroud 42 which is attached to outer rear wall 20 with conventional hinges 43. Shroud 42 has an outer wall 44 and four side walls 45, 46, 47 and 48. Shroud 42 cooperates with outer rear wall 20 to form a closed box. Shroud 42 can be swung outward to provide access to the elements of the control box. A securing latch 49 holds the shroud tightly against the rear wall when closed. The embodiment illustrated has a dampered air inlet vent 51 approximately two-thirds of the way down the outer wall 44 and a humidifier inlet 53 near the top of side wall 46.
The components within control box 40 are best seen in FIGS. 3 and 4. Control box 40 functions as an air mixing chamber. There is a first or lower electric heating element 55 just above louvered vent 35 and a second or upper heating element 57 at an approximate midpoint of wall 20. A fan 59 is positioned above heating element 57 at the top of box 40. Fan 59 is positioned at louvered vent 33 (FIG. 2) so that air moved by the fan flows into chamber 12 through the vent.
FIG. 5 illustrates another embodiment of the incubator device of the present invention having a larger volume internal chamber. As will be appreciated, the device employs three fans, 59A, 59B and 59C in horizontal alignment across the back wall of the cabinet. The three fans are positioned to move air through the louvered vent 32 in the top of interior rear wall 8 and into the chamber 12. The three fan arrangement allows for an increased fresh air flow from the environmental control box into the chamber to maintain a positive pressure in a larger chamber 12.
There are a pair of electric motors 60 and 62 in vertical alignment on the back of the unit. Motor 60 is operatively connected to an upper egg rolling device and motor 62 is operatively connected to a lower egg rolling device, both located within the chamber. The motors are controlled by the electronic control system to drive the respective egg rolling devices, as will be explained in greater detail below. Both electric motors are protected by a removable shroud 63 (FIG. 4).
The various egg rolling or rotating devices of the present invention will now be described in detail. The preferred embodiment of an egg rolling device employed in the incubator of FIG. 1 is best illustrated and shown in greater detail in FIGS. 7 and 8. As there shown, the egg rolling device is indicated generally by the reference numeral 70. It should be noted that device 70 is shown upside down in FIG. 8 to better disclose the adjustability of the individual rollers.
As will be appreciated, device 70 is designed as a removable drawer. Device 70 has a generally rectangular frame 72 dimensioned to fit within chamber 12. Frame 72 has a pair of side members 73 and 75. Each side member has an elongated slot 77 centrally therein for the attachment of the roller bars, as will be described hereinafter. The frame also has a front wall 79 and a rear wall 80. Front wall 79 has a series of large openings 83 formed therein. Rear wall 80 also has a series of large openings 85 formed along its length. The openings 83 and 85 allow air to pass through the drawers and promote good air circulation. Furthermore, there is a series of grooves 86 formed on the top of rear wall 80 and a corresponding set of holes 87 formed in upper edge of front wall 79 to accommodate a 1/4 inch rod 88. One or more rods 88 are used to separate eggs or allow eggs to stand up, if desired. That is to say, the device 70 generally is used without the rods 88. However, some breeders prefer to stand the eggs upright and the construction described enables the drawer 70 to provide that function.
There is a conventional drawer roller 89 on a lower edge of side member 73 and a conventional drawer roller 90 on a lower edge of side member 75. Drawer rollers 89 and 90 are designed to engage the drawer rollers mounted on the interior chamber walls to allow device 70 to pull out and slide in like a conventional drawer for loading and unloading eggs.
There are a number of roller bars 92' extending between the side members. The roller bars preferably are covered with a cushioning material which fits securely around each rod to form padded rollers 92. The rollers 92 are spaced apart from each other such that eggs can be supported with their longitudinal axis parallel to the longitudinal axis of the roller. Each roller 92 is rotatably attached to the side members by end cap assembly 94, or other suitable means. Each cap assembly 94 is attached to the groove 77 with by nut and bolt assemblies 95. The end cap assembly has a fixed plate 96 with a bearing 97 that rotates within the fixed plates. The rod is connected to the bearing and the bearing is free to turn in the fixed plate. The fixed plate 96 is releasably secured to the side wall through the groove 77. This arrangement allows the nuts securing the end cap 94 to the side wall to be loosened and so that the end cap can be slid along the length of groove 77 so properly position each roller, relative to the adjacent rollers.
There is a drive roller 100 that extends transversely to the rollers 92. Each roller 92 is connected to the drive roller by a drive belt 101 so that rotation of the drive roller 100 turns each roller 92. The drive belt arrangement is extremely quiet during operation. Drive roller 100 is connected to front wall 79 with an end cap arrangement or other suitable means. A drive rod 102 extends from the drive roller and is adjustably connected to the rear wall 80 by an adjustable plastic bushing 103. Bushing 103 is a square plastic bushing having an upper slot 104 and a lower slot 105 formed therein. Bushing 103 is attached to rear wall 80 by screws 106. An end cap assembly 94 connected to the drive roller is attached to the bushing by screws 106. Slots 104 and 105 allow lateral adjustment of the drive roller so that the drive rod can properly engage the motor drive connector 110, shown in greater detail in FIG. 9.
As can be seen in FIG. 8, drive rod 102 protrudes through bushing 103. A small cross rod 112 extends through the tip of drive rod 102 to form a T. As shown in FIG. 9. a motor drive shaft 114 extends into the cabinet from one of the motors 60 or 62. A drive rod T plug 115 is attached to the drive shaft 114 by a pair of set screws 116 and 117 through threaded holes 119. The T plug has a generally cylindrical body 121 with a first end 123 and a second end 124. The first end has an opening 125 or other appropriate means formed therein to engage the motor drive shaft 114. There is a generally deep V-shaped groove 127 formed in the second end 124. The groove 127 has a pair of opposed ramps 129 and 131 which lead to a deep, substantially cylindrical horizontal groove tip 133. Groove tip 133 it dimensioned to seat cross rod 112. Rotation of the motor shaft 114 by the motor will cause the drive rod, and therefore the drive roller 100, to turn. The generally deep V shaped groove 127 provides easy introduction of the drive rod T into the T plug. It will be appreciated that the laterally adjustable arrangement of the drive rod through the bushing and the novel arrangement of the drive rod T and T plug allows the device 70 easily to be introduced into the drawer rollers and engage the motor drive protruding through the back wall of the cabinet.
FIGS. 10 and 11 illustrate an alternative embodiment of a device for turning or rotating eggs, indicated generally by reference numeral 130. Device 130 is a rotary rack egg turner having a generally drum-like configuration, or circular cross-section, and is dimension to fit with in the cabinet as shown in FIG. 10. Device 130 has a horizontal axle and a first circular end wall 132 and a second circular end wall 134. Gear or belt means (not shown) disposed to engage the motor drive are employed to rotate the device about its horizontal axle.
Device 130 has a number of egg holders 134. Each egg holder 134 is comprised of four horizontal rods 136. The rods are covered with a protective material such as foam rubber or the like. The rods 136 are arranged in a generally square pattern with one rod at each corner, and appropriately spaced apart so that an ostrich or emu egg E will be secured within the rods. The rods 136 are connected to a square end plate 138, as best seen in FIG. 11. The end plate 138 has an open corner slot 140. One of the rods 136 terminates in a first concentric rod section 142 and then a second concentric rod section 143, having a disc 144 on the end. The second concentric rod section 143 seats in slot 140 and the disc 144 engages the back side of the plate 138. A clip 148 slides over the first concentric rod section 142 to close slot 140 and secure the rod in place. This slot 140 and clip 148 arrangement allows the rod to be removed so that eggs can be placed in or removed from the holder 134. Other fastener arrangement are compatible with the broader aspects of my invention. It will be appreciated that as the device 130 rotates about its horizontal axis, the eggs in the respective holders 134 also with rotate about their horizontal axes. Since the device has a circular cross section, the associated eggs always are moved about their horizontal axes as the device rotates.
FIGS. 12 and 13 illustrate another alternative embodiment of a rotary rack egg turning device, indicated generally by reference numeral 150. The rotary egg turning device 150 has a generally rectangular cross-section which imparts a somewhat different rotational pattern than does the circular rotary device 130, just described.
Device 150 employs egg holders 134 constructed in accordance with the description above. However, the end plates 138 of the egg holders are attached to a pair of drive belts 151 and 153. Each belt engages at least four drive wheels 155. A four point positioning of the drive wheels 155 gives the device 150 its rectangular design. At least one of the drive wheels 155 is operably connected to the drive shaft of a motor 60 or 62. Rotation of the drive shaft turns the wheel 155 thereby moving the belts 151 and 153 and the associated egg holders 134. Since the device 150 is generally rectangular, the egg holders move about in a generally rectangular path. The eggs eventually are turned about their horizontal axis. However, in this embodiment the eggs remain positionally static for a longer period of time as the egg holder traverses each flat side of the rectangular travel path.
FIGS. 14 and 15 illustrate yet another embodiment of an egg turning device, indicated generally be reference numeral 160. Device 160 is designed like a drawer having a generally rectangular frame 161. Frame 161 has a front wall 163, a rear wall 165 and opposed side walls 167 and 169. There are a number of egg holders 134, constructed in accordance with the description above, in horizontal alignment within frame 161. However, each end plate 138 has a short drive rod 171 that extends through a bushing 172 in an opening in side wall 167. There is a gear 173 on the end of each drive rod. A continuous drive track 175 engages the teeth on the respective gears 173. The drive track 175 is driven by a drive wheel 178 which is operably connected to the drive shaft of a motor (not shown). It will be appreciated that as the drive track moves, the gears 173 are turned and the associated egg holders 134 are rotated about a horizontal axis, thereby rotating the eggs.
The device 1, as shown in FIGS. 1-4, has an electronic control system 180 housed on top of the unit. System 180 maintains separate and independent preset temperature and humidity in both the upper and lower units. It is believed that optimal temperature for propagation of ostrich eggs is in the range of about 97° to 97.5° F. and a humidity in the range of 20% to 55%. The control system, as best seen in FIGS. 1-4, has an electrical cord 183 for connecting the control system to a power source, not shown. The control system 180 has a plurality of digital set buttons and displays 185 that enable an operator to set and read the internal temperature and humidity for each unit. There are a series of button switches 187 for roll testing and resetting. There also are indicator lights 188 for indicating low water. There are fuse panels 189 on the back as well as ports 191 for connecting room air sensing devices to the control system.
The electronic control system 180 also controls the motors 60 and 62 to allow the associated egg rotating devices to rotate the eggs a complete 180° clockwise and then back 180°. The 180° rolling allows yolk sac nutrients to be supplied to the growing embryo. The system also has alarms for high/low temperature and high/low humidity. It is preferred that the eggs be rotated about 180° during each period of rotation and that the periods of rotation occur about every thirty minutes to about every four hours. Typically for ostrich eggs the egg is rotated about 180° in about one-half minute.
It will be appreciated that device has a computer operated monitoring system. The system monitors the temperature and humidity settings of the control module of each incubator and the room in which it sets and records the data on an hourly basis. The computer system tracks the weight loss of the eggs and calculates and displays projected weight loss. The computer system also keeps track of the eggs laid and the condition of the eggs when placed in the incubator and the outcome of incubated eggs, among other parameters. The computer system also can warn the operator if service goes out and can be linked to a remote site by telephone.
The unique environmental control box 40 functions to enhance the outcome of incubation by allowing fresh air, heat and humidity to be better controlled by premixing before introduction into chamber 12. As best seen in FIG. 6, fresh air enters air vent 51. The air is appropriately heated to a preset temperature under electronic control, by the heating elements 55 and 57. Moisture is added, as needed to reach a preset humidity, by a humidifier H connected to the humidifier vent 53. The controlled air enters the top of chamber 13 through the upper louvered vent drawn by fan 49. Preferably the fan can move 15 to 25 cubic feet of air per square foot of cabinet space. The air flows downward among the eggs and provides a uniform environment throughout the chamber. The various designs of the egg rotating devices described above enhance the air flow and promote uniformity of the internal environment. The air is drawn back into the control box 40 through the lower louvered vent 35. This circular flow pattern enhances the uniform dispersal of the air, heat and moisture. However, since the moisture and carbon dioxide are heavier that the air, those components of the recirculated air are vented off through the exhaust port 37 located near the bottom of the cabinet. The exhaust is vented at a rate of approximately 35 cubic feet of exhaust per minute or 2 cubic feet of exhaust per square foot of cabinet, less than the air flow into the cabinet, as stated above. The exhaust vent is the only exist from the device. Tests have shown that under normal operating conditions, the barometric reading outside the device was 958 millibars or 28.30 inches of Mercury while the reading inside was 961 millibars or 28.39 inches. Therefore, a positive pressure is maintained within the chamber.
Moreover, since the cabinet is so well insulated and sealed, the temperature inside is maintained within 0.35 degree. The device also controls the humidity to plus or minus 1% relative humidity. However, the electric control system can be monitored to make sure that the temperature and humidity are maintained at the desired settings.
The uniformity of the environment within the chamber 12 is demonstrated by a number of tests. The temperature was tested at discrete points in within the chamber. The points tested included the extreme corners of the cabinet as well as representative points therebetween. The tests indicated that beginning with a set-point temperature of 97° F., that there was an eveness of temperature throughout the chamber, varying between only by 0.7° between readings. Furthermore, the test indicated that the temperature within the cabinet was within ±0.35° over ten minutes starting at room temperature.
The above summarized tests are best illustrated by FIGS. 16-20 when viewed along with the following tables:
______________________________________TEST #1 (FIG. 16)OXYGEN AT EXHAUST: 21.1SET POINT AT 97.0° F.POSITION COLOR CODE TEMP.(degrees F)______________________________________START10 RED 94.28 BLUE 94.811 GREEN 93.59 YELLOW 92.71 MINUTE10 RED 96.38 BLUE 97.111 GREEN 96.29 YELLOW 95.02 MINUTES10 RED 97.08 BLUE 97.711 GREEN 97.19 YELLOW 95.73 MINUTES10 RED 97.28 BLUE 97.811 GREEN 97.49 YELLOW 96.24 MINUTES10 RED 96.98 BLUE 97.411 GREEN 97.29 YELLOW 96.15 MINUTES10 RED 96.48 BLUE 96.711 GREEN 96.69 YELLOW 95.86 MINUTES10 RED 96.28 BLUE 96.611 GREEN 96.59 YELLOW 95.77 MINUTES10 RED 96.38 BLUE 96.611 GREEN 96.59 YELLOW 95.88 MINUTES10 RED 96.38 BLUE 96.611 GREEN 96.59 YELLOW 95.89 MINUTES10 RED 96.38 BLUE 96.611 GREEN 96.59 YELLOW 95.9______________________________________
______________________________________TEST #2 (FIG. 17)OXYGEN AT EXHAUST: 21.1SET POINT AT 97.0° F.POSITION COLOR CODE TEMP.(degrees F)______________________________________START3 RED 94.21 BLUE 96.04 GREEN 96.32 YELLOW 95.31 MINUTE3 RED 98.21 BLUE 98.94 GREEN 98.92 YELLOW 98.12 MINUTES3 RED 98.01 BLUE 98.54 GREEN 98.52 YELLOW 98.03 MINUTES3 RED 97.31 BLUE 97.44 GREEN 97.32 YELLOW 97.24 MINUTES3 RED 96.71 BLUE 96.84 GREEN 97.02 YELLOW 96.75 MINUTES3 RED 96.51 BLUE 96.64 GREEN 96.82 YELLOW 96.66 MINUTES3 RED 96.51 BLUE 96.54 GREEN 96.72 YELLOW 95.68 MINUTES3 RED 96.31 BLUE 96.34 GREEN 96.52 YELLOW 96.4______________________________________
______________________________________TEST #3 (FIG. 18)CENTER DRAWERTEMPERATURE SET POINT AT 97.0° F.HUMIDITY SET POINT AT 30.0% → H = POSITION 10 → 32.6%POSITION COLOR CODE TEMP.(degrees F)______________________________________1 MINUTE5 RED 92.86 GREEN 94.47 BLUE 94.42 MINUTES5 RED 97.56 GREEN 97.67 BLUE 97.33 MINUTES5 RED 98.06 GREEN 98.07 BLUE 97.8S 96.8T 97.84 MINUTES5 RED 97.66 GREEN 97.57 BLUE 97.4S 97.0T 97.75 MINUTES5 RED 96.86 GREEN 96.87 BLUE 96.8S 97.0T 97.46 MINUTES5 RED 96.26 GREEN 96.27 BLUE 96.2S 96.9T 96.87 MINUTES5 RED 96.26 GREEN 96.17 BLUE 96.1S 96.9T 96.710 MINUTES5 RED 96.36 GREEN 96.37 BLUE 96.2S 97.0T 96.7______________________________________
______________________________________TEST #4 (FIG. 19)CENTER DRAWER BOTTOMHUMIDITY POSITION # 11 → 31.9%SET POINT AT 30.0%POSITION COLOR CODE TEMP.(degrees F)______________________________________1 MINUTE14 RED 89.313 GREEN 91.212 BLUE 92.3S 94.3T UNDER 94.0°2 MINUTES14 RED 97.213 GREEN 97.112 BLUE 97.3S 96.2T 96.83 MINUTES14 RED 98.413 GREEN 97.812 BLUE 97.7S 96.7T 97.54 MINUTES14 RED 98.313 GREEN 97.812 BLUE 97.7S 96.7T 97.55 MINUTES14 RED 98.313 GREEN 97.712 BLUE 97.4S 97.1T 97.76 MINUTES14 RED 97.513 GREEN 96.912 BLUE 96.7S 97.1T 97.37 MINUTES14 RED 96.813 GREEN 96.412 BLUE 96.3S 96.9T 96.68 MINUTES14 RED 96.513 GREEN 96.212 BLUE 96.1S 96.9T 96.611 MINUTES14 RED 96.713 GREEN 96.412 BLUE 96.3S 97.0T 96.713 MINUTES14 RED 96.613 GREEN 96.212 BLUE 96.1S 97.0T 96.6______________________________________
______________________________________TEST #5 (FIG. 20)HUMIDITYSET POINT AT 30.0%POSITION TEMP.(degrees F)______________________________________1 31.6%2 32.3%3 32.3%4 31.2%8 32.0%9 33.5%10 32.6%11 31.9%______________________________________
It will be appreciated that changes and modifications may be made in the incubator device of the present invention without departing from the scope of the appended claims. Therefore, the foregoing description and accompanying drawings are intended to be illustrative only and should not be viewed in a limiting sense. Merely by way of example, the design silhouette of the incubator may vary in other embodiments of the invention. Likewise, the overall size of the unit may be altered. Other materials maybe used in place of those described in connection with the preferred embodiments. These variations are merely illustrative. | A device for incubation and hatching of bird eggs having an insulated cabinet for housing the eggs and an associated environmental control box. The cabinet is completely sealed and has a sealed door to maintain internal air pressure. There is a controlled air inflow vent at the top of the cabinet and an exhaust vent at the bottom of the cabinet. There is an environmental control unit in fluid communication with the air inflow vent. The control box has an air inflow port, a heater and humidifier. The air flow, temperature and humidity are preset and electronically monitored and controlled. The device also contains computer means for monitoring the incubation of the eggs. One or more fans moves the air into the cabinet. The air flows from the top to the bottom of the cabinet to maintain a uniform desired environment for the eggs. The cabinet contains an interchangeable egg rotating device. In one preferred embodiment, the egg turning device includes a plurality of spaced apart rotatable rods to hold the eggs between the rods. The eggs rotate as the rods rotate. In another embodiment, the egg rotating device is a rotary rack having a plurality of egg holders. The rack can be round or rectangular in cross-section. In another embodiment, the egg rotating device is a drawer containing a plurality of horizontally aligned rotatable egg holders. | 0 |
FIELD OF THE INVENTION
This invention relates to a process for dispersing organic compounds using water as a dispersion medium, and more particularly to a process for producing heat-sensitive recording materials having excellent storage stability of the colored product and giving less fog at the background portion.
BACKGROUND OF THE INVENTION
It is very important to be able to uniformly disperse an organic compound in water since the dispersion can be industrially handled as an aqueous solution. Practically, there are dispersions of latex polymers, waxes, etc., and various kinds of emulsions. In particular, recently, in the field of manufacture of information recording papers such as heat-sensitive recording papers, etc., it has been required to disperse organic compounds having a low melting point in water uniformly and in a fine particulate state. More particularly, in the case of heat-sensitive recording papers, it is an important technical point to uniformly disperse fine particles of organic compounds since the particle size of the dispersion influences important properties such as the sensitivity, etc., of the recording material, as described in British Patent 2,085,178. Thus, various attempts such as the use of a media mill have been provided as described in JP-A-58-69089 (the term "JP-A" as used herein refers to a "published unexamined Japanese patent application"). However, in this case, there is a problem that when the temperature of the dispersion system necessary for obtaining a dispersion of desired fine particles is greatly increased, a stable dispersion is not obtained.
This tendency becomes more severe as the melting point of an organic compound being dispersed is lowered.
On the other hand, a recording material using an electron-donating dye precursor (hereinafter referred to as a color former) and an electron-accepting compound (hereinafter referred to as a color developer) is well known as pressure-sensitive recording papers, heat-sensitive recording papers, light- and pressure-sensitive recording papers, and electro-heat-sensitive recording papers. These recording papers are described in detail, for example, in British Patent 2,140,449, U.S. Pat. No(s). 4,480,052 and 4,436,920, JP-B-60-23922 (the term "JP-B" as used herein refers to an "examined Japanese patent publication"), JP-A-57-179836, JP-A-60-123556 and JP-A- 60-123557.
A recording material is required to perform so that (1) the color density and the coloring sensitivity are sufficient, (2) fog is not formed, and (3) the storage stability of the colored product after coloring is sufficiently high. However, recording materials completely satisfying the aforesaid requirements have not yet been obtained.
In particular, recently, the range of applications using heat-sensitive recording materials has increased and in various applications of the recording papers, the fastness required for the colored product has increased even more. In such recording materials, the storage stability of colored products under high temperature and high humidity conditions is important.
For improving the aforesaid storage stability, it has been proposed to use a mixture of two or more color formers, as disclosed in JP-B-59-53193. However, when two or more kinds of color formers are used as a mixture thereof, the formation of fog at white portions or background portions increases and the formation of the fog is particularly increased under high temperature and high humidity conditions.
Also, for obtaining a sufficient coloring sensitivity, an attempt has been made to reduce the particle sizes of the color former(s) and color developer, whereby their surface areas thereof are enlarged to increase the reactivities. However, such an attempt also increases the formation of fog in the heat-sensitive recording materials.
For preventing the formation of fog, various attempts have been proposed. For example, an attempt involving protecting at least one of the color former and the color developer with a protective colloid (water-soluble polymer) having a high adsorptive power to restrain the occurrence of reaction between the color former and color developer in the coating composition containing them is disclosed in JP-B-51-29945, JP-A-56-55288, JP-A-55-28805, and JP-A-55-159992, an attempt involving restraining the occurrence of reaction between the color former and color developer in the coating composition by keeping the pH of the coating composition at an alkaline state is disclosed in JP-B-51-28235 and JP-B-55-6077, an attempt involving using a neutral paper as the support for the heat-sensitive recording paper is disclosed in JP-A-55-14281, an attempt involving adding an antifoggant to the coating composition for the heat-sensitive layer is disclosed in JP-B-49-3943 and JP-A-48-101943, and also an attempt involving heat-treating the fine dispersion of the aforesaid two components is disclosed in JP-A-54-98253.
However, many of these attempts are accompanied by the disadvantages that the effects are insufficient, they raise the manufacturing cost, and/or the steps become complicated, and hence these attempts are not always satisfactory for practical purposes.
SUMMARY OF THE INVENTION
A first object of this invention is to provide a process of uniformly and finely dispersing an organic compound in an aqueous dispersion medium.
A second object of this invention is to provide a process of producing a heat-sensitive recording material having an excellent coloring property, giving a colored product having good storage stability, and giving less fog.
It has now been discovered that the aforesaid first object can be attained by the first embodiment of this invention as shown below.
That is, according to the first embodiment of this invention, there is provided a process for dispersing particles of an organic compound in water, which comprises dispersing the organic compound in water using (1) a water-soluble high molecular weight compound having a weight average molecular weight of at least 10,000, and (2) a copolymer formed from a monomer represented by formula (I) and a monomer represented by formula (II), said copolymer having a weight average molecular weight of not more than 10,000; ##STR2## wherein M 1 and M 2 each represents an alkali metal atom or an ammonium group; R 1 represents a hydrogen atom, a methyl group, or an ethyl group; and R 2 represents an alkyl group having from 2 to 18 carbon atoms.
It has also been discovered that the aforesaid second object can be attained by the second embodiment of this invention as shown below.
That is, according to the second embodiment for this invention, there is provided a process of producing a heat-sensitive recording material comprising a support having provided thereon a heat-sensitive color-forming layer containing finely dispersed particles of an electron-donating dye precursor (a color former) and finely dispersed particles of an electron-accepting compound (a color developer), which comprises the steps of: (a) dispersing at least one of the electron-donating dye precursor and the electron-accepting compound in water using a water-soluble high molecular weight compound having a weight average molecular weight of at least 10,000; (b) adding a copolymer formed from the monomer of formula (I) shown above and the monomer of formula (II) shown above to the dispersion, the copolymer having a weight average molecular weight of not more than 10,000; and then (c) heat-treating the dispersion at a temperature of from 30° C. to 90° C.
DETAILED DESCRIPTION OF THE INVENTION
Then, the first and second embodiments of this invention are explained in detail.
The water-soluble high molecular weight compound having a weight average molecular weight of at least 10,000 for use in this invention preferably has a water solubility of at least 5% by weight at 25° C. and practical examples thereof are polyvinyl alcohol, methyl cellulose, carboxymethyl cellulose, starches (including modified starch), gelatin, gum arabic, casein, a hydrolyzed product of a styrene-maleic anhydride copolymer, carboxy-modified polyvinyl alcohol, polyacrylamide, and a saponification product of a vinyl acetate-polyacrylic acid copolymer. The preferred molecular weight of the water-soluble high molecular weight compound is from 10,000 to 100,000.
Also, as the copolymer formed from the monomer of the above formula (I) and the monomer of the above formula (II), having a weight average molecular weight of not more than 10,000 for use in this invention, there are sodium salts, potassium salts, ammonium salts, etc., of a copolymer of maleic acid and 1-methyl-1-(2,2-dimethylpropyl)ethylene, a copolymer of maleic acid and 1-methyl-1-(3-methylbutyl)ethylene, a copolymer of maleic acid and 1-(2,2-dimethylpropyl)ethylene, a copolymer of maleic acid and 1-methyl-1-octylethylene, etc. The preferred molecular weight of the copolymer is from 2,000 to 10,000.
The addition amounts of these dispersing aids are as follows.
The addition amount of the water-soluble high molecular weight compound as the dispersing aid is preferably from 1% by weight to 25% by weight, and more preferably from 2% by weight to 15% by weight, based on the amount of organic compound(s) being dispersed. If the content of the dispersing aid is less than 1% by weight, the stability of the dispersion formed is inferior and if the content is higher than 25% by weight, the viscosity of the dispersion is increased to reduce the dispersion efficiency.
Also, the addition amount of the above-described copolymer as the dispersing aid is preferably from 0.1% by weight to 5% by weight, and more preferably from 0.2% by weight to 2% by weight, based on the amount of the organic compound(s). If the content is less than 0.1% by weight, the effect is low and even if the dispersing aid is added over 5% by weight, no further improvement of the effect is obtained.
The ratio of monomer of formula (I)/monomer of formula (II) is preferably from 1/1 to 3/7. More preferably the ratio is 1/1.
The effect of this invention is particularly remarkable when organic compound(s) having a melting point of 250° C. or lower, more particularly 200° C. or lower are dispersed in water using the above-described dispersing aids. Practical examples of such an organic compound are color formers, sensitizers, waxes, and other organic additives which are generally used for heat-sensitive recording materials. Specific examples of these organic compounds are described in JP-A-55-227253, JP-A-59-95190, JP-A-57-34995, JP-A-57-125092, and JP-A-59-190886.
In this invention, the dispersion may be performed using a high shearing type dispersing machine such as a homogenizer, a Kady mill, a dissolver, etc., or a media mill such as a ball mill, an attritor, a sand mill, etc., and the effect of this invention is more remarkable in the case of dispersing a dispersion having a high solid concentration of over 30% using a dispersing machine such as media mill.
That is, it is assumed that when a dispersion of high concentration as described above is finely dispersed using a media mill, the liquid temperature is greatly increased by the shearing of the media particles themselves and shearing between media and the dispersoid to locally melt the surfaces of the organic compound particles. Thus, in a case, a sufficient dispersing effect is not obtained by a conventional inorganic dispersing agent such as hexametaphosphate, sodium pyrophosphate, etc., or a conventional organic dispersing agent such as polyacrylic acid, etc. On the other hand, in this invention, the copolymer utilized as the dispersing aid shows a stable adsorptive faculty at high temperature and stabilizes organic compound(s) which are dispersed. Furthermore, water-soluble high molecular weight compound for use this invention as the other dispersing aid enhances effect as a protective colloid.
Then, the second embodiment of this invention is explained in detail.
According to the process of this invention, the formation of fog in the heat-sensitive recording material obtained can be greatly reduced without reducing the coloring property and the storage stability of the colored product. The process of this invention has the advantages that the improvement of the whiteness (reduction of the formation of fog) of the heat-sensitive recording material produced is remarkable as compared to a conventionally known process of simply heat-treating a dispersion of the components for a heat-sensitive layer as well as preventing occurrence of the troubles such as reaggregation of dispersed particles at the heat treatment, and further, gelation of the dispersion is remarkably reduced. The effects of this invention are more remarkable when the mean particle size of the dispersed color former and/or color developer is not larger than 2 μm. The effects of this invention are explained in detail by practically illustrating the production process.
In an embodiment of the production process of this invention, a color former and/or a color developer is finely dispersed in water and in this case, a water-soluble high molecular weight compound, a surface active agent, etc., are used as dispersing aids. In this case, the water-soluble high molecular weight compound having a molecular weight of at least 10,000 described above is used. Also, the copolymer formed from the monomer shown by formula (I) and the monomer shown by formula (II) may be used for dispersing the aforesaid components.
The dispersion can be performed by utilizing a dispersing means such as a ball mill, a pebble mill, a sand mill, an attritor, a three roller mill, etc. The mean particle size of the dispersed components is preferably as small as possible but is usually not larger than 5 μm, and preferably not larger than 2 μm as volume mean particle size in consideration of the dispersing time.
The concentration of solid components in the dispersion is generally from 10% to 50% (w/w).
The dispersion of the color former and/or the color developer is subjected to heat treatment in the presence of the copolymer of the monomer shown by formula (I) and the monomer shown by formula (II) in this invention for inhibiting the formation of fog. It is necessary that the copolymer for use in this invention is added to the dispersion before the application of heat treatment. If the dispersion does not contain the copolymer according to this invention, the dispersion is very liable to cause aggregation. The amount of the copolymer is preferably from 0.1% to 5% (w/w), and more preferably from 0.5% to 3% (w/w), based on the weight of the color former and/or the color developer. If the content thereof is less than 0.1%, the aforesaid effect is not obtained and if the content is more than 5%, further improvement of the effect is not obtained.
In a preferred embodiment of the copolymer compound for use in the second embodiment of this invention, M 1 and M 2 in formula (I) are sodium or potassium and in formula (II), R 1 is a methyl group and R 2 is a tert-pentyl group, a sec-pentyl group, a tert-butyl group, a sec-butyl group, or a propyl group.
The heat treatment can be performed by placing the dispersion in a tank equipped with a jacket followed by increasing the temperature with stirring, or increasing the temperature of the dispersion by heat change using a countercurrent heat exchange double pipe, or further increasing the temperature of the dispersion using a temperature-increasing means such as infrared rays, etc.
The heat treatment temperature is from 30° C. to 90° C., and preferably from 40° C. to 80° C. If the heat treatment temperature is lower than 30° C., the effect of inhibiting the formation of fog is insufficient and if the temperature is higher than 90° C., it becomes difficult to prevent the occurrence of troubles by the evaporation of water The preferred heat treatment time depends upon heat treatment temperature but may be from 15 seconds to 1 hour. An increase in the heat treatment temperature of 10° C. reduces the heat treatment time by almost 1/2.
The heat-treated dispersion is then cooled to a temperature below 30° C. and is mixed with other dispersions. When a color former and a color developer separately dispersed in water, each of the may be heat-treated as described above and after cooling, the dispersion may be mixed with each other. In this case, if necessary, a binder, an oil absorptive pigment, a wax dispersion, a lubricant, a water resistance increasing agent, etc., may be added.
Also, for improving the coloring sensitivity, sensitizer(s) can be used and in this case the sensitizer(s) may be dispersed separately in water and the dispersion may be mixed with the aforesaid dispersion color former and/or the color developer, or the sensitizer(s) may be simultaneously dispersed with a former and/or a color developer. In the latter case, the preferred amount of the copolymer for use in invention is based on the combined amount of the color former or the color developer and the sensitizer(s).
As the color former for use in this invention, there are triarylmethane series compounds, diphenylmethane series compounds, xanthene series compounds, thiazine series compounds, spiropyran series compounds, etc. Typical examples thereof are described, for example, in JP-A-55-227253. Specific examples thereof are triarylmethane series compounds such as 3,3-bis(p-dimethylaminophenyl)-6-dimethylaminophthalide, 3,3-bis(p-dimethylaminophenyl)phthalide, 3-(p-dimethylaminophenyl)- 3-(1,3-dimethylindol-3-yl)phthalide, 3-(p-dimethylamino-phenyl-3-(2-methylindol-3-yl)phthalide, etc.; diphenyl-methane series compounds such as 4,4'-bisdimethylaminobenzhydrin-benzyl ether, N-halophenylleucoauramine, N-2,4,5-trichlorophenylleucoauramine, etc.; xanthene series compounds such as rhodamine-B-anilinolactam, rhodamine(p-nitrilo)lactam, rhodamine(p-nitrilo)lactam, 2-(dibenzylaminofluoran, 2-anilino-3- methyl-6-diethylaminofluoran, 2-anilino-3-methyl-6dibutylaminofluoran, 2-anilino-3-methyl-6-N-ethyl-N-isoamylaminofluoran, 2-anilino-3-methyl-6-N-methyl-N-cyclohexylaminofluoran, 2-anilino-3-chloro-6-diethylaminofluoran, 2-anilino-3-methyl-6-N-ethyl-N-isobutylaminofluoran, 2-anilino-6-dibutylaminofluoran, 2-anilino-3-methyl-6-N-methyl-N-tetrahydrofluorofurylaminofluoran, 2-anilino-3-methyl-6-piperidinoaminofluoran, 2-(o-chloro-anilino)-6-diethylamnofluoran, 2-(3,4-dichloroanilino)-6-diethylaminofluoran, etc.; thiazine series compounds such as benzoylleucomethylene blue, p-nitrobenzylleucomethylene blue, etc.; and spiropyran series compounds such as 3-methyl-spiro-dinaphthopyran, 3-ethyl-spiro-dinaphthopyran, 3,3'-dichlorospiro-dinaphthopyran, 3-benzylspiro-dinaphthopyran, 3-methyl-naphtho-(3-methoxybenzo)-spiropyran, 3-propyl-spiro-dibenzopyran, etc.
As the color developer for use in this invention, phenolic compounds, salicylic acid derivatives nd the polyvalent metal salts thereof are preferably used. Specific examples thereof are phenolic compound such as 2,2'-bis(4-hydroxyphenyl)propane, 4-t-butylphenol, 4-phenylphenol, 4-hydroxydiphenoxide, 1,1'-bis(3-chloro-4hydroxyphenyl)cyclohexane, 1,1'-bis(4-hydroxyphenyl)cyclohexane, 1,1'-bis(3-chloro-4-hydroxyphenyl)-2-ethyl-butane, 4,4'-sec-isooctylidenediphenol, 4,4'-secbutylidenediphenol, 4-tert-octylphenol, 4-p-methylphenyl-phenol, 4,4'-methylcyclohexylidenephenol, 4,4'isopentylidenephenol, benzyl p-hydroxybenzoate, etc., salicylic acid derivatives such as 4-pentadecylsalicylic acid, 3,5-di(-methylbenzyl)salicylic acid, 3,5-di(tert-octyl)salicylic acid, 5-octadecylsalicylic acid, 5-α-methylbenzylphenyl)ethylsalicylic acid, 3-α-methyl- benzyl-5-tert-octylsalicylic acid, 5-tetradecylsalicylic acid, 4-hexyloxysalicylic acid, 4-cyclohexyloxysalicylic acid, 4-decyloxysalicylic acid, 4-dodecyloxysalicylic acid, 4-pentadecyloxysalicylic acid, 4-octadecyloxysalicylic acid, etc., and the zinc salts, aluminum salts, calcium salts, copper salts, and lead salts of these acids.
The color developer is used in an amount of preferably from 50 to 800% by weight, and more preferably from 100 to 500% by weight, of the amount of the aforesaid color former. If the content thereof is less than 50% by weight, the color formed is insufficient and even if the content is increased over 800% by weight, the further increase of the effect is not obtained and thus the use of such a large amount is undesirable.
The recording material of the present invention may contain various additives in the heat-sensitive color-forming layer for meeting various requirements. Specific examples of the various additives include a heat-fusible substance, a binder, a pigment, a lubricant, wax, a surface active agent, a color fading inhibitor, etc.
In this invention, a heat-fusible substance is preferably used for the heat-sensitive color-forming layer and examples thereof are benzyl p-benzyloxybenzoate, β-naphthylbenzyl ether, stearic acid amide, stearylurea, p-benzylbiphenyl, di(2-methy-phenoxy)ethane, di(2-methoxyphenoxy)ethane, β-naphthol(p-methylbenzyl)-ether, α-naphthylbenzyl ether, 1,4-butanediol-p-methylphenyl ether, 1,4-butanediol-p-isopropylphenyl ether, 1,4-butanediol-p-tert-octylphenyl ether, 1-phenoxy-2-(4-ethylphenoxy)ethane, 1-phenoxy-2-(4-chlorophenoxy)ethane, 1,4-butanediol phenyl ether, diethylene glycol-bis(4-methoxyphenyl) ether, etc.
The aforesaid heat-fusible substances may be used singly or as a mixture thereof. For obtaining a sufficient heat response, the heat-fusible substance is used in an amount of preferably from 10 to 200% by weight, and more preferably from 20 to 150% by weight, based on the amount of the color developer.
In this invention, the water-soluble high molecular weight compound which is used at dispersion can be used as it is as a binder for the heat-sensitive color-forming layer but a latex series binder of a synthetic polymer such as a styrene-butadiene copolymer, a vinyl acetate copolymer, an acrylonitrile-butadiene copolymer, a methyl acrylate-butadiene ccpolymer, polyvinylidene chloride, etc., can be further used as a binder.
As a pigment which can be used in this invention for the heat-sensitive color-forming layer, there are calcium carbonate, barium sulfate, lithopone, agalmatolite, caolin, silica, noncrystal silica, etc.
As a lubricant for use in this invention, metal salts of higher aliphatic acids may be used and specific examples thereof are zinc stearate, calcium stearate, aluminum stearate, etc.
Also, as wax for use in this invention, there are paraffin wax, microcrystalline wax, carnauba wax, methylolstearoamide, polyethylene wax, polystyrene wax, aliphatic amide series waxes, etc., they can be used singly or as a mixture thereof.
As the surface active agent for use in this invention, there are alkali metal salts of sulfosuccinic acid and fluorine-containing surface active agents.
Also, it is preferred to add a color fading inhibitor into the heat-sensitive color-forming layer for inhibiting fading of image printed portions and fastening the images formed. As the color fading inhibitors, there are phenol compounds, in particular, hindered phenol compounds. Specific examples thereof are 1,1,3-tris(2-methyl-4-hydroxy-tert-butylphenyl)butane, 1,1,3-tris(2-ethyl-4-hydroxy-5-tert-butylphenyl)butane, 1,1,3-tris-(3,5-di-tert-butyl-4-hydroxyhenyl)butane, 1,1,3-tris(2-methyl-4-hydroxy-5-tert-butylphenyl)propane, 2,2,'-methylenebis(6-tert-butyl-4-methylphenol), 2,2,'-methylenebis(6-tert-butyl-4-ethylphenol), 4,4'butylidenebis(6-tert-butyl-3-methylphenol) and 4,4'-thiobis(3-methyl-6-tert-butylphenol).
The addition amount of the phenolic compound is preferably from 1 to 200% by weight, and more preferably from 5 to 50% by weight, based on the amount of the color developer.
After mixing these components, the mixture is coated on a support. As the support, papers, synthetic papers, various film bases, etc., are used and in this case, a subbing layer can previously be formed on the support for obtaining high smoothness.
The heat-sensitive recording material thus formed is dried and subjected to calender treatment before use.
Then, the present invention is further explained practically by the following examples but the present invention is not limited to them.
EXAMPLES 1 TO 3
As organic compounds being dispersed, (A) β-naphthylbenzyl ether (m.p. 101° C., a sensitizer for heat-sensitive recording paper), (B) 2-anilino-3-methyl-6-isoamylethylaminofluoran (m.p. 164° C., a color former for heat-sensitive recording paper), and (C) bis(2-hydroxy-3-tert-butyl-5-methylphenyl)methane (m.p. 128° C., an additive for rubber) were selected and 50 g of each of the organic compounds (A) to (C) was added to an aqueous solution of 5% polyvinyl alcohol (weight average molecular weight 22,000, saponification degree 98%) for Examples 1, 2 and 3, respectively. Then, after further adding 0.5 g of the sodium salt of a maleic acid/1-methyl-1-(2,2dimethylpropyl)ethylene copolymer (weight average molecular weight 6,000) to each of the mixtures containing the aforesaid organic compounds, the mixtures were dispersed using a sand grinder, Dynomill KDL (trade name, manufactured by WAB Company in West Germany) until the mean particle size became 1 μm. The state and the viscosity of the dispersion are shown in Table 1 below. High viscosity causes the reduction of the dispersion efficiency and thus is undesirable.
COMPARATIVE EXAMPLES 1 TO 3
The same procedures as in the above examples were followed without using the copolymer employed in this invention.
COMPARATIVE EXAMPLES 4 AND 5
The same procedures as in Examples 1 and 3 were followed without using the polyvinyl alcohol of the water-soluble high molecular weight compound in this invention.
COMPARATIVE EXAMPLES 6 AND 7
The same procedure as in Example 2 was followed while using each of the dispersing aids shown in Table 2 below in place of the copolymer in this invention.
COMPARATIVE EXAMPLE 8
The same procedure as in Example 1 was followed using no dispersing aids.
The results of Comparative Examples 1 to 8 are shown in Table 2 below.
As is clear from the results of Tables 1 and 2, Examples 1 to 3 according to the present invention exhibit good dispersion state as compared to Comparative Examples. Further, Comparative Examples 2, 3, 6 and 8 cannot measure the viscosity of dispersion because of the occurrence of aggregation. Examples 1 to 3 provide the low viscosity as compared to Comparative Examples 1, 4, 5 and 7.
TABLE 1______________________________________Example Dis- DispersionNo. persoid Dispersing Aid State Viscosity*.sup.1______________________________________1 (A) Polyvinyl alcohol, Good 36 c.p. and sodium salt of maleic acid/ 1-methyl-1-(2,2- dimethylpropyl) ethylene copolymer2 (B) Polyvinyl alcohol, Good 42 c.p. and sodium salt of maleic acid/ 1-methyl-1-(2,2- dimethylpropyl) ethylene copolymer3 (C) Polyvinyl alcohol, Good 45 c.p. and sodium salt of maleic acid/ 1-methyl-1-(2,2- dimethylpropyl) ethylene copolymer______________________________________ *.sup.1 Viscosity of dispersion measured by Btype viscometer at 25.degree C.
TABLE 2______________________________________Com-parativeExample Dis- Dispersion Vis-No. persoid Dispersing Aid State cosity*.sup.1______________________________________1 (A) Polyvinyl alcohol Fairly 67 c.p. inferior2 (B) " Inferior*.sup.2 --3 (C) " Inferior*.sup.2 --4 (A) Sodium salt of Good 50 c.p. maleic acid/1- methyl-1-(2,2- dimethylpropyl)- ethylene copolymer5 (C) Sodium salt of Fairly 80 c.p. maleic acid/1- inferior methyl-1-(2,2- dimethylpropyl)- ethylene copolymer6 (B) Polyvinyl alcohol Inferior*.sup.2 -- and sodium hexametaphosphate7 (B) Polyvinyl alcohol Fairly 76 c.p. and sodium inferior polyacrylate (weight average molecular weight: 8,000)8 (A) None Inferior*.sup.2 --______________________________________ *.sup.2 "Inferior" means the occurrence of aggregation before the mean particle size reaches 1 μm.
EXAMPLE 4
To 20 parts by weight of an aqueous solution of 5% polyvinyl alcohol (Kuraray PVA-105, trade name, made by Kuraray Co., Ltd., weight average molecular weight: 22,000) was added 10 parts by weight of 2-anilino-3-methyl-6-diethylaminofluoran as a color former and the mixture was dispersed using a sand mill (Dynomill Type KDL-P, made by WAB Company in West Germany) at a medium packing amount of 80% and treatment amount of 0.5 liter/min. The dispersion step was carried out several times for finely dispersing.
Also, a color developer, 2,2-bis(4-hydroxyphenyl)propane was dispersed by the same manner as above.
After dispersion, a copolymer of sodium maleate and 1-tert-pentyl-1-methylethylene (average molecular weight 3,000) was added to each dispersion in an amount of 1% by solid component weight ratio of the color former or the color developer. Each dispersion was heated to 50° C. and after keeping the dispersion at the temperature for 30 minutes, the dispersion was cooled to 25° C.
After cooling, one part by weight of the dispersion of the color former was mixed with 2 parts by weight of the dispersion of the developer and further 2 parts by weight of a dispersion of 50% calcium carbonate, 0.5 part by weight of a dispersion of 30% zinc stearate, and 0.5 part by weight of a dispersion of 30% paraffin wax were added to the mixture to provide a coating composition for heat-sensitive color-forming (recording) layer.
The coating composition was coated on a wood free paper (basis weight of 50 g/m 2 ) at a solid component coverage of 6.0 g/m 2 dried at 50° C., and subjected to a supercalender treatment to provide a heat-sensitive recording paper.
The heat-sensitive recording paper thus obtained was printed on using a printing test machine made by Kyocera Corporation at 0.35 w/dot, a printing density of 8 dot×7.7 dot/mm 2 , a pulse width of 1 ms, and a pulse period of 10 ms and then the density was measured by a densitometer Type RD-918 (Wratten #106 filter) made by Macbeth Co. In this case, the density of the background portion of the heat-sensitive recording paper before printing was measured as "fog". The fog value of 0.20 or more may bring about a practical disadvantage.
Also, the particle sizes of the color former and the color developer thus dispersed were measured by Microtruck Type SPA, made by L & N Co., in U.S.A.
The results thus obtained are shown in Table 3 below.
EXAMPLES 5 TO 11
The same procedure as in Example 4 was followed except that each of the color formers shown in Table 3 below was used in place of the color former in Example 4.
The results obtained are shown in Table 3.
EXAMPLES 12 AND 13
The same procedure as in Example 4 was followed except that each of the color developers shown in Table 3 was used in place of the color developer in Example 4.
The results obtained are shown in Table 3.
EXAMPLES 14 TO 19
The same procedure as in Example 4 was followed except that the heat treatment time and temperature were changes as shown in Table 4.
The results obtained are shown in Table 4.
EXAMPLES 20 TO 23
The same procedure as in Example 4 was followed except that the copolymer in this invention was changed as shown in Table 5.
The results obtained are shown in Table 5.
COMPARATIVE EXAMPLE 9
The same procedure as in Example 4 was followed except that the copolymer in this invention was not used.
The results obtained are shown in Table 3.
COMPARATIVE EXAMPLES 10 TO 15
The same procedures as in Examples 14 to 19 were followed except that the copolymer in this invention were not used.
The results obtained are shown in Table 4.
COMPARATIVE EXAMPLE 16
The same procedure as in Example 4 was followed except that the heat treatment was not performed.
The results obtained are shown in Table 3.
TABLE 3__________________________________________________________________________Example No. Color Former Color Developer__________________________________________________________________________Example 4 2-Anilino-3-methyl-6-diethylaminofluoran 2,2-Bis(4-hydroxyphenyl)- propaneExample 5 2-Anilino-3-chloro-6-diethylaminofluoran 2,2-Bis(4-hydroxyphenyl)- propaneExample 6 2-Anilino-3-methyl-6-piperidinofluoran 2,2-Bis(4-hydroxyphenyl)- propaneExample 7 2-Anilino-3-methyl-6-N-isoamyl-N-ethyl- 2,2-Bis(4-hydroxyphenyl)- aminofluoran propaneExample 8 2-Anilino-3-methyl-6-N-isoamyl-N-ethyl- 2,2-Bis(4-hydroxyphenyl)- aminofluoran propaneExample 9 2-Anilino-3-methyl-6-dibutylaminofluoran 2,2-Bis(4-hydroxyphenyl)- propaneExample 10 Mixture (1:1) of 2-anilino-3-chloro-6- 2,2-Bis(4-hydroxyphenyl)- diethylaminofluoran and 2-anilino-3- propane methyl-6-piperidinofluoranExample 11 Mixture (1:1) of 2-anilino-3-chloro-6- 2,2-Bis(4-hydroxyphenyl)- diethylaminofluoran and 2-anilino-3- propane methyl-6-N-isoamyl-N-ethylaminofluoranExample 12 2-Anilino-3-methyl-6-diethylaminofluoran Benzyl 4-hydroxybenzoateExample 13 " 2,2'-Bis(4-hydroxyphenyl- thio)diethyl etherComparative " 2,2'-Bis(4-hydroxyphenyl)-Example 9 propaneComparative " 2,2'-Bis(4-hydroxyphenyl)-Example 10 propane__________________________________________________________________________ Heat Print Dispersed Particle SizeExample No. Copolymer Treatment Density Fog Color Former Color Developer__________________________________________________________________________Example 4 Applied Applied 0.75 0.06 0.92 1.68Example 5 " " 0.76 0.06 0.88 "Example 6 " " 0.74 0.07 0.86 "Example 7 " " 0.84 0.07 0.95 "Example 8 " " 0.68 0.05 2.2 "Example 9 " " 0.73 0.08 0.81 "Example 10 " " 0.80 0.07 0.91 "Example 11 " " 0.88 0.07 0.93 "Example 12 " " 1.31 0.07 0.92 1.32Example 13 " " 1.18 0.08 0.92 1.35Comparative None " Aggregated -- 0.92 1.68Example 9Comparative Applied None 0.77 0.29 0.92 1.68Example 10__________________________________________________________________________
TABLE 4______________________________________ Heat- Heat Treatment Treatment Temperature Time PrintExample No. (°C.) (min) Density Fog______________________________________Example 4 50 30 0.75 0.06Example 14 " 15 0.74 0.06Example 15 " 5 0.78 0.09Example 16 60 15 0.72 0.05Example 17 " 5 0.74 0.09Example 18 35 30 0.75 0.10Example 19 " 15 0.78 0.12Comparative 50 15 Aggregated --Example 10Comparative " 5 " --Example 11Comparative 60 15 " --Example 12Comparative " 5 " --Example 13Comparative 35 30 " --Example 14Comparative " 15 0.72 0.16Example 15Comparative -- 0 0.77 0.29Example 16______________________________________
TABLE 5______________________________________ High PrintExample No. Molecular Weight Compound Density Fog______________________________________Example 4 Sodium maleate/1-tert-pentyl-1- 0.75 0.06 methylethylene copolymer (Mw = 3,000)Example 20 Sodium maleate/1-tert-pentyl-1- 0.77 0.08 methylethylene copolymer (Mw = 1,200)Example 21 Sodium maleate/1-tert-pentyl-1- 0.73 0.05 methylethylene copolymer (Mw = 10,000)Example 22 Sodium maleate/1-propyl-1- 0.78 0.10 methylethane copolymer (Mw = 3,200)Example 23 Sodium maleate/1-hexyl-1- 0.72 0.09 methylethylene copolymer (Mw = 8,000)______________________________________
As is clear from the results of Tables 3 to 5, Examples according to the present invention show less fog values without the occurrence of aggregation, as compared to Comparative Examples.
While the invention has been described in detail and with reference to specific embodiments thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. | A process for dispersing particles of an organic commpound in water is disclosed, which comprises dispersing the organic compound in water using (1) a water-soluble high molecular weight compound having a molecular weight of at least 10,000 and (2) a copolymer formed from a monomer represented by the following formula (I) and a monomer represented by the following formula (II), said copolymer having a molecular weight of not more than 10,000: ##STR1## wherein M 1 and M 2 each represents an alkali metal atom or an ammonium group; R 1 represents a hydrogen atom, a methyl group, or an ethyl group; and R 2 represents an alkyl group having from 2 to 18 carbon atoms.
A process of producing a heat-sensitive recording material is also disclosed, which comprises the steps of:
(a) dispersing at least one of an electron-donating dye precursor and an electron-accepting compound in water using a water-soluble high molecular weight compound having a molecular weight of at least 1,000;
(b) adding a copolymer formed form a monomer represented by formula (II) shown above to the dispersion, said copolymer having a molecular weight of not more than 10,000; and then
(c) heat-treating the dispersion at a temperature of from 30° C. to 90° C. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority from provisional application No. 61/267,041 filed Dec. 5, 2009, the entire contents of which are herewith incorporated by reference.
BACKGROUND
Multiple approaches to booting from more than one storage device and for selecting one of a plurality of operating systems are known.
Systems often use boot.ini and the boot configuration data base. Microsoft has created a detailed document showing how the boot configuration data base is architected and edited as BCD objects.
The capability of computer systems to boot from more than one storage device or the ability to boot a selected operating system from a number of operating systems has been present for quite some time. Windows NT™ operating systems have been in the field since 1993 and have had multi-boot capability.
NT systems from NT 3.1 through NT 5.2 released in 2007 have typically used a boot preference file named boot.ini. This file if present is read by an early load portion of NT and processed. The file typically contains the ID and address of each partition and sub-folder in the partition that houses or contains an operating system, and the identity of a default operating system, and a timer value which states in seconds the amount of time the information will be displayed to a user before the default operating system will be booted.
Sophisticated users can edit the boot.ini file and change the default operating system to be booted and/or add or remove operating systems. See FIGS. 2A and 2B for examples of boot.ini files.
Starting with Windows™ NT 6 released in 2006, the boot.ini file was discarded and a new facility with increased capability called Boot Configuration Data base (BCD) was introduced to control the booting of a system.
The BCD provides a firmware-independent mechanism for manipulating boot environment data for typically for Windows VistaTMand later operating systems. Windows VistaTMand later versions of WindowsTMuse it to load the operating system or to run boot applications such as memory diagnostics. The BCD abstracts the underlying firmware. BCD currently supports both PC/AT BIOS and Extensible Firmware Interface (EFI) systems. BCD interfaces perform all necessary interaction with firmware.
The BCD allows developers to programmatically manipulate a BCD store or objects through the BCD WMI provider. The WMI provider supports a unified programming interface that can be used for both local and remote management of BCD stores. The interface is independent of the underlying firmware, so developers can write one application that works on any type of system.
The reference manual for the BCD facility is available at the microsoft dot com website and is incorporated by reference herein.
The manual describes the exact interface and how objects within the BCD are manipulated.
Additionally, if the operating system on the system drive becomes non-operational, and even if the user has a bootable backup storage device attached to the computer system, it can be a daunting task to use that backup as the primary bootable storage device. Until now, the user typically needed to change the BIOS settings to boot the backup storage device or remove the backup drive from its enclosure and install it into the computer system.
SUMMARY
Manually changing the boot order of the Boot Configuration Data is not a trivial task for an unsophisticated user. Performing an edit on the Boot Configuration Data can result in an unbootable condition.
Embodiments describe an improved programming interface to make changes in the boot order of a firmware-independent mechanism for manipulating boot environment data, e.g., the BCD in a PC.
Embodiments describe a new way to boot an attached storage device containing a bootable operating system without manually altering the system BIOS or physically moving the drive from the attached enclosure to the system.
An embodiment describes a new and unique system and method for booting an operating system from an attached storage device by a specified operation, e.g., pressing a single button on the attached storage device. This action and the underlying logic and apparatus causes the boot files to be automatically altered and a reboot to be forced, such that the reboot or restart uses the operating system contained on the attached storage device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a block diagram of a personal computer;
FIGS. 2A and 2B show different variations of a boot.ini file;
FIG. 3 shows a logic diagram for a pre-Vista operating system; and
FIG. 4 shows a logic diagram for a post-Vista operating system.
DETAILED DESCRIPTION
Referencing FIG. 1 which depicts a typical personal computer 10 which may be any of a plurality of personal computers such as laptops, desktops, servers, or handheld devices. In this depiction, personal computer 11 contains a system bus 15 which provides a common bus for microprocessor 12 , system memory 13 , system BIOS 14 , disk interface 16 , internal storage device 17 , external peripheral control 18 , external bus 19 , and attached storage 20 . For clarity, there are several sub-systems not shown in this depiction such as a graphical user interface monitor, graphics controller, keyboard, or mouse pointer. These items are not needed to describe embodiments of the invention, however, may be used with the invention.
31 in FIGS. 2A and 32 in FIG. 2B depict two variations of a boot.ini file that could be used for displaying a boot menu to the user prior to windows being completely loaded. Boot.ini files are used by pre-Windows Vista™ computers for controlling boot order. Boot.ini files can be used in two modes. The first mode allows the contents of the file to be displayed to the user at boot time if the timeout value 33 is some value other than zero. If the value of timeout value 33 is other than zero, the contents of the file identifying storage devices, partitions, and operating systems will be formatted and displayed as a menu allowing the user to select one of a number of operating systems to boot. If timeout value 33 is set to zero, the menu will not be displayed to the user and the operating system identified as default 34 or default 38 will be loaded.
Note that in the depictions of the boot.ini file shown in FIG. 2A , the default operating system to be booted in FIG. 2A is contained in disk 0, partition 1, subdirectory “\WINDOWS”. In FIG. 2B , the default operating system to be booted is contained in disk 1, partition 1, subdirectory “\ WINNT”. This demonstrates how different operating systems subdirectories can be used according to the values in the boot.ini file.
Element 40 in FIG. 3 is a logic diagram where the current operating system 44 is a pre-Windows VistaTMoperating system such as Windows XPTMor Windows 2000™. In FIG. 3 , the vertical members or objects represent functional portions of a personal computer or functional portions of software and the horizontal lines represent actions or processing steps. Logic diagram 40 begins at attached storage device 41 with processing step user presses button 47 . Push button 21 pressed by the user resides on the attached storage device 20 . Attached storage device 20 formats a data packet that is sent across external bus 19 through external peripheral controller 18 to system memory 13 where PC application 42 is executing. When PC Application 42 receives the data packet that indicates that push button 21 has been pressed, PC application 42 performs PC application processes Boot.ini 49 . PC application processes Boot.ini 49 by editing the Boot.ini file residing on internal storage device 17 such that the operating system resident on attached storage device 20 is set to be the default operating system. The Boot.ini file depicted in FIG. 2A as 31 is altered to that depicted in FIG. 2B and written back to internal storage device 17 . After PC application processes Boot.ini 49 processing is completed, PC application 42 will notify BIOS 43 to force a reboot by performing sent boot signal to BIOS 50 . BIOS 43 receives send boot signal to BIOS 50 and in turn notifies the current operating system 44 by performing send shut down to operating system 51 .
Current operating system 44 receives the shutdown notification from BIOS 43 and performs its orderly shut down processing by performing operating system shut down 52 . After current operating system 44 has finished shutting down, it will notify BIOS 43 by sending “shut down complete” 53 to BIOS 43 .
BIOS 43 receives a notification of shut down complete and performs the start boot loader for current OS 54 . This processing step reads the boot loader from the master boot record of internal storage device 17 into system memory 13 and starts executing the boot loader. The boot loader performs boot loader reads and processes current boot.ini file 55 . This processing step loads sufficient software from the internal storage device 17 that will allow it to allows the computing device to read the Boot.ini file from the internal storage device 17 .
Using the default entry for the operating system, here default operating system 38 in FIG. 2B , the software will perform BIOS reads using the boot loader from attached storage device 86 which reads the boot loader from attached storage device 20 into system memory 13 . After the boot loader from attached storage device 20 has been read into system memory 13 , BIOS 43 performs the start boot loader executing 57 . At this point, attached storage device boot loader 46 will perform load attached operating system 58 which reads those portions of the operating system residing on attached storage device 20 that are required to load the full operating system. Once the operating system has been loaded into system memory 13 , attached storage device boot loader 46 will send start attached operating system executing 59 to attached operating system 45 . This processing step starts attached operating system 45 executing which performs attached operating system starts 60 . At this point, the operating system that is resident on attached storage device 20 is booted up and running.
FIG. 4 shows the logic 40 for an operating system 44 which is a Windows Vista™ or newer operating system such as Windows 7™. In FIG. 4 , the vertical members or objects represent functional portions of a personal computer or functional portions of software and the horizontal lines represent actions or processing steps. Logic diagram 40 begins at attached storage device 41 with processing step user presses button 47 . Push button 21 pressed by the user resides on the attached storage device 20 . Attached storage device 20 formats a data packet that is sent across external bus 19 through external peripheral controller 18 to system memory 13 where PC application 42 is executing. When PC Application 42 receives the data packet notifying it of push button 21 being pressed, PC application 42 performs PC application processes Boot Configuration Data base 61 . PC application processes Boot Configuration Data 61 edits the Boot Configuration Data base (DCB) file residing on internal storage device 17 such that the operating system resident on attached storage device 20 is set to be the default operating system. This processing step sets the default operating system as the operating system resident on attached storage device 20 . After PC application processes Boot Configuration Data base 61 processing is completed, PC application 42 will notify BIOS 43 to force a reboot by performing sent boot signal to BIOS 50 . BIOS 43 will receive send boot signal to BIOS 50 and in turn will notify current operating system 44 by performing send shut down to operating system 51 .
The current operating system 44 receives the shut down notification from BIOS 43 and performs its orderly shut down processing by performing operating system shuts down 52 . After current operating system 44 has finished shutting down, it notifies BIOS 43 by sending shut down complete 53 to BIOS 43 . BIOS 43 will receive notification of shut down complete and perform start boot loader for current OS 54 . This processing step reads the boot loader from the master boot record of internal storage device 17 into system memory 13 and starts it to executing. The boot loader performs boot loader reads & processes current Boot Configuration Data base file 62 . This processing step loads sufficient software from the internal storage device 17 that will allow it to allow it to read the Boot Configuration Data base file from the internal storage device 17 .
Using the default entry for the operating system which is default operating system 38 in FIG. 2B , the software will perform BIOS reads boot loader from attached storage device 86 which reads the boot loader from attached storage device 20 into system memory 13 . After the boot loader from attached storage device 20 has been read into system memory 13 BIOS 43 will perform start boot loader executing 57 . At this point, attached storage device boot loader 46 will perform load attached operating system 58 which reads those portions of the operating system residing on attached storage device 20 that are required to load the full operating system. Once the operating system has been loaded into system memory 13 , attached storage device boot loader 46 will send start attached operating system executing 59 to attached operating system 45 . This processing step starts attached operating system 45 executing which performs attached operating system starts 60 . At this point the operating system that is resident on attached storage device 20 is booted up and running.
Although the invention has been described in language specific to structural features and/or methodological steps, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific features or steps described.
Rather, the specific features and steps are disclosed as preferred forms of implementing the claimed invention.
Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result.
Also, the inventors intend that only those claims which use the words “means for” are intended to be interpreted under 35 USC 112, sixth paragraph. Moreover, no limitations from the specification are intended to be read into any claims, unless those limitations are expressly included in the claims.
The various illustrative logical blocks, modules, and circuits described in connection with the embodiments disclosed herein, may be implemented or performed with a general purpose processor, a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), a Field Programmable Gate Array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, micro controller, or state machine. The processor can be part of a computer system that also has a user interface port that communicates with a user interface, and which receives commands entered by a user, has at least one memory (e.g., hard drive or other comparable storage, and random access memory) that stores electronic information including a program that operates under control of the processor and with communication via the user interface port, and a video output that produces its output via any kind of video output format, e.g., VGA, DVI, HDMI, display port, or any other form.
When operated on a computer, the computer may include a processor that operates to accept user commands, execute instructions and produce output based on those instructions. The processor is preferably connected to a communication bus. The communication bus may include a data channel for facilitating information transfer between storage and other peripheral components of the computer system. The communication bus further may provide a set of signals used for communication with the processor, including a data bus, address bus, and/or control bus.
The communication bus may comprise any standard or nonstandard bus architecture such as, for example, bus architectures compliant with industry standard architecture (“ISA”), extended industry standard architecture (“EISA”), Micro Channel Architecture (“MCA”), peripheral component interconnect (“PCI”) local bus, or any old or new standard promulgated by the Institute of Electrical and Electronics Engineers (“IEEE”) including IEEE 488 general-purpose interface bus (“GPIB”), and the like.
A computer system used according to the present application preferably includes a main memory and may also include a secondary memory. The main memory provides storage of instructions and data for programs executing on the processor. The main memory is typically semiconductor-based memory such as dynamic random access memory (“DRAM”) and/or static random access memory (“SRAM”). The secondary memory may optionally include a hard disk drive and/or a solid state memory and/or removable storage drive for example an external hard drive, thumb drive, a digital versatile disc (“DVD”) drive, etc.
At least one possible storage medium is preferably a computer readable medium having stored thereon computer executable code (i.e., software) and/or data thereon in a non-transitory form. The computer software or data stored on the removable storage medium is read into the computer system as electrical communication signals.
The computer system may also include a communication interface. The communication interface allows' software and data to be transferred between computer system and external devices (e.g. printers), networks, or information sources. For example, computer software or executable code may be transferred to the computer to allow the computer to carry out the functions and operations described herein. The computer system can be a network-connected server with a communication interface. The communication interface may be a wired network card, or a Wireless, e.g., Wifi network card.
Software and data transferred via the communication interface are generally in the form of electrical communication signals.
Computer executable code (i.e., computer programs or software) are stored in the memory and/or received via communication interface and executed as received. The code can be compiled code or interpreted code or website code, or any other kind of code.
A “computer readable medium” can be any media used to provide computer executable code (e.g., software and computer programs and website pages), e.g., hard drive, USB drive or other. The software, when executed by the processor, preferably causes the processor to perform the inventive features and functions previously described herein.
A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. These devices may also be used to select values for devices as described herein.
The steps of a method or algorithm described in connection with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module may reside in Random Access Memory (RAM), flash memory, Read Only Memory (ROM), Electrically Programmable ROM (EPROM), Electrically Erasable Programmable ROM (EEPROM), registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art. An exemplary storage medium is coupled to the processor such that the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an ASIC. The ASIC may reside in a user terminal. In the alternative, the processor and the storage medium may reside as discrete components in a user terminal.
In one or more exemplary embodiments, the functions described may be implemented in hardware, software, firmware, or any combination thereof. If implemented in software, the functions may be stored on or transmitted over as one or more instructions or code on a computer-readable medium. Computer-readable media includes both computer storage media and communication media including any medium that facilitates transfer of a computer program from one place to another. A storage media may be any available media that can be accessed by a computer. By way of example, and not limitation, such computer-readable media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to carry or store desired program code in the form of instructions or data structures and that can be accessed by a computer. The memory storage can also be rotating magnetic hard disk drives, optical disk drives, or flash memory based storage drives or other such solid state, magnetic, or optical storage devices. Also, any connection is properly termed a computer readable medium. For example, if the software is transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, then the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of medium. Disk and disc, as used herein, includes compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), floppy disk and blu-ray disc where disks usually reproduce data magnetically, while discs reproduce data optically with lasers. Combinations of the above should also be included within the scope of computer-readable media. The computer readable media can be an article comprising a machine-readable non-transitory tangible medium embodying information indicative of instructions that when performed by one or more machines result in computer implemented operations comprising the actions described throughout this specification.
Operations as described herein can be carried out on or over a website. The website can be operated on a server computer, or operated locally, e.g., by being downloaded to the client computer, or operated via a server farm. The website can be accessed over a mobile phone or a PDA, or on any other client. The website can use HTML code in any form, e.g., MHTML, or XML, and via any form such as cascading style sheets (“CSS”) or other.
Also, the inventors intend that only those claims which use the words “means for” are intended to be interpreted under 35 USC 112, sixth paragraph. Moreover, no limitations from the specification are intended to be read into any claims, unless those limitations are expressly included in the claims. The computers described herein may be any kind of computer, either general purpose, or some specific purpose computer such as a workstation. The programs may be written in C, or Java, Brew or any other programming language. The programs may be resident on a storage medium, e.g., magnetic or optical, e.g. the computer hard drive, a removable disk or media such as a memory stick or SD media, or other removable medium. The programs may also be run over a network, for example, with a server or other machine sending signals to the local machine, which allows the local machine to carry out the operations described herein.
Where a specific numerical value is mentioned herein, it should be considered that the value may be increased or decreased by 20%, while still staying within the teachings of the present application, unless some different range is specifically mentioned. Where a specified logical sense is used, the opposite logical sense is also intended to be encompassed.
The previous description of the disclosed exemplary embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these exemplary embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. | The present invention is an apparatus, system, and method for allowing a user to boot to an alternate operating system by pressing a single button on an externally attached storage device with a push button. The invention helps a user recover operational use of his computer system when the internal system drive suffers a software application or operating system failure. The invention consists of an attached storage device with a push button and supporting electronics capable of formatting and transmitting a recognizable data packet to the host computer and an application program in the host computer that can receive the data packet, process boot files, and force a reboot of the operating system with the attached storage device as the boot device. | 6 |
FIELD OF THE INVENTION
[0001] The present subject matter relates to color sensing in appliances. More particularly, the present subject matter relates to color sensing of previously used or “grey water” in appliances.
BACKGROUND OF THE INVENTION
[0002] In a typical laundry cycle the user will fill the tub with a laundry load and the machine will wash and rinse the load several times. A typical cycle may have 1 or more separate rinses and spinouts in which you would expect the wastewater to get progressively cleaner with each rinse.
[0003] In water reuse the concept is to save the water from any portion of the wash cycle, including but not limited to the last rinse, as this water would be the cleanest of any of the otherwise waste water, and then use it as either wash or rinse water in the next clothing load.
[0004] It is therefore very important to detect multiple characteristics of this grey water such as microbial content, color and turbidity, bleach content, etc.
[0005] In view of these known concerns it would be advantageous to provide a apparatus and methodology to accurately determine the color and turbidity of the grey water to prevent damaging clothing unintentionally should the wastewater be reused.
BRIEF DESCRIPTION OF THE INVENTION
[0006] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
[0007] The present subject matter relates to methodologies provided for selecting usage options for a liquid in a washing appliance. The method provides a plurality of different light sources and directs light from the light sources through a liquid to be tested. The light intensity received from each of the sources is measured after passing through the liquid. The turbidity within the liquid is also measured and the values of the measure light intensities are adjusted based on the measured turbidity. A selection from a plurality of water usage options is made based on the adjusted values.
[0008] In certain embodiments red, green, and blue light sources are provided and measurements are made by a light sensor paired with each of the light sources. In other embodiments a single light sensor is used and in particular embodiments an adjustment is made to the measured light values based on the angle of incidence of the light from the plurality of sensors onto the single sensor.
[0009] In other embodiments, the method provides for measuring turbidity using infrared light by directing light from the infrared light sources through a liquid to be tested and measuring the infrared light intensity received after passing through the liquid. Selected embodiments provided for establishing a reference value for light levels based on the measuring light intensity received after passing through a clear liquid. In certain embodiments, the method determines whether to dump the liquid or to keep and possibly treat it for later use.
[0010] In particular embodiments, the method establishes a plurality of light quantization levels so that measuring the light intensity received from each of the sources after passing through the liquid corresponds to assigning a measurement value corresponding one of the quantization levels. In particular such embodiments, the method established five quantization levels.
[0011] The present subject matter also relates to apparatus for selecting usage options for a liquid in a washing appliance. The apparatus includes a chamber for holding a liquid to be tested. There are also provided a plurality of different light sources configured to shine light through the liquid toward at least one light sensor. A turbidity sensor is provided to measure turbidity within the liquid and a controller is provided to receive signals from the at least one light sensor and the turbidity sensor and to adjust the values of the signals from the light sensor based on the measured turbidity. The controller will then activate a usage option based on the adjusted values.
[0012] In particular embodiments, the apparatus includes a source of clear liquid and a grey water storage tank. In such embodiments, the controller is further configured to establish color reference levels based on measured light levels through the clear liquid and to measure light levels after passing through grey water from said grey water storage tank. The controller then selectively operates either a valve or a pump to selectively dump, treat, or keep the grey water for later use.
[0013] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
[0015] FIG. 1 is a cubical representation of a Red-Green-Blue (RGB) color space;
[0016] FIG. 2 is a Cartesian coordinate representation of the RGB color space of FIG. 1 ;
[0017] FIG. 3 is a schematic diagram of a first embodiment of an RGB detector circuit in accordance with present technology;
[0018] FIG. 4 is a schematic diagram of a second embodiment of an RGB detector circuit in accordance with present technology;
[0019] FIG. 5 is a schematic diagram of a turbidity detector;
[0020] FIG. 6 is a graphical representation of the output voltage of a turbidity sensor vs. Nephelometric Turbidity Unit (NTU) for ten representative turbidity sensors;
[0021] FIG. 7 is a graphical representation of percent differences vs. turbidity measurements for the sensors of FIG. 6 ;
[0022] FIG. 8 is a schematic representation of a water color detection circuit in accordance with present technology;
[0023] FIG. 9 is a color cube representation of an RGB color approximation space in accordance with present technology;
[0024] FIG. 10 is a color matrix lookup table of representative RGB percentiles for each of the colors represented in FIG. 9 ;
[0025] FIG. 11 is a flow chart of a method in accordance with present technology; and
[0026] FIG. 12 is a representation of a washing appliance in which the present subject matter may be employed.
[0027] Repeat use of reference characters throughout the present specification and appended drawings is intended to represent same or analogous features or elements of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0028] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
[0029] As noted in the Summary section, the present subject matter is directed toward color sensing of previously used or “grey water” in appliances such as the washing appliance illustrated in FIG. 12 .
[0030] Referring now to FIGS. 1 and 2 , the visible spectrum is the portion of the electromagnetic spectrum that is visible to the human eye. Electromagnetic radiation in this range of wavelengths is called visible light or simply light. A typical human eye will respond to wavelengths from about 390 to 750 nm. Typically the eye is most sensitive to light at about 555 nm, generally corresponding to the green region of the optical spectrum. The spectrum does not, however, contain all the colors that the human eyes and brain can distinguish. Unsaturated colors such as pink, or purple variations such as magenta, are absent, for example, because they can only be made by a mix of multiple wavelengths.
[0031] The RGB color space is the best-known and most widely used color model. In RGB each color is represented by three values red (R), green (G) and blue (B), positioned along the axes of the Cartesian coordinate system as illustrated in FIG. 2 . The values of RGB are assumed to be in the range of [0,1] or in some cases in the range of [0-255]. In this way black may be represented as (0, 0, 0), and white as (1, 1, 1) or, in alternate scales, as ( 255 , 255 , 255 ). These black and the white colors are represented in FIG. 1 by two of the opposite corner 102 , 104 of cube 100 that can be defined by the R, G, B axes of the Cartesian coordinate systems illustrated in FIG. 2 . Other corners of cube 100 represent the red ( 106 ), green ( 108 ), blue ( 110 ), cyan ( 112 ), magenta ( 114 ) and yellow ( 116 ) colors. Grayscale colors may be represented with identical R, G, B components.
[0032] With reference to FIG. 3 , there is illustrated a schematic diagram of a first embodiment of an RGB detector circuit 300 in accordance with present technology. The hardware used to detect color in accordance with present technology consist of an array of photo-emitters 302 , 304 , 306 on one side of a chamber 310 and an array of photo-detectors 312 , 314 , 316 on the opposite side. In one embodiment, RED, GREEN, and BLUE Light Emitting Diodes (LEDs) may be used as the photo-emitters 302 , 304 , 306 and photo-diodes as the photo-detectors 312 , 314 , 316 . The selection of these colors is made as the present technology uses calculations based on the RGB Color Space.
[0033] LEDs 302 , 304 , 306 are controlled by a controller that can alter their brightness, duty cycle, and timing. The photo-diode signal is boosted through an op-amp network 324 , 322 , 326 and the resulting signals are fed into controller 330 for processing.
[0034] The medium, whether it be “clear reference fluid” or “filter medium” will act as a lens, allowing certain light frequencies to pass while blocking others. Theoretically the “clear” condition will allow all frequencies to pass unimpeded. In practice there will typically be some impedance, which will be accounted and corrected for in software for any condition.
[0035] In the instance of a clear condition when one of the colored LEDs 302 , 304 , 306 is turned on at a certain intensity, the output on the detector side will be at 100% for that color. When in a filter condition the output will be reduced based on the type, that is, color of the medium. In a further alternative configuration, it is possible to use actual colored LEDs as the detector and not emitter because they will work similarly and are more sensitive at the color they would normally emit.
[0036] An example of this is when in CLEAR condition, when LEDs 302 , 304 , 306 are turned on individually the OUTPUT=100% for each color. In an exemplary circuit, the 100% output level may correspond to about 4 Volts DC. When a colored lens such as a dyed water enters the chamber 310 the medium characteristics change. In an instance where the medium is slightly red colored it would be expected that the RED output should remain around 100% while the BLUE and GREEN outputs will drop to, for example, around 80%. The values of each color intensity/output drop permits approximation of the true color of the liquid.
[0037] There are several ways of implementing this principle concept including using only one photo-detector and compensating for the angle of each LED in relation to the photo-detector. FIG. 4 illustrates such an alternate embodiment of an RGB detector circuit 400 in accordance with present technology. As may easily be seen from a comparison of FIGS. 3 and 4 , the embodiment illustrated in FIG. 4 is identical to that of FIG. 3 except that the FIG. 4 embodiment uses only a single photo-detector 414 to measure the outputs of the photo-emitters 402 , 404 , 406 . In this instance, controller 430 may be configured to operate LEDs 402 , 404 , 406 sequentially and to compensate for the angles of incidence of light represented by arrows 432 , 434 , 436 onto the single photo-detector 414 . Single op-amp circuit 424 then amplifies the received light signal from photo-detector 414 and passes the amplified signal on to controller 430 .
[0038] Within the context of the embodiments of both FIGS. 3 and 4 , those of ordinary skill in the art should appreciate that the transmitters can be any combination of colored LEDs and the receivers can be multiple different components such as photo-diodes, photo-transistors, IC detectors, LEDs in reverse, etc.
[0039] With reference now to FIGS. 5 , 6 , and 7 , aspects of the present subject matter relating to turbidity detection will now be described. FIG. 5 illustrates a schematic diagram of hardware corresponding to a turbidity detector 500 in accordance with present technology. The turbidity hardware 500 used is similar to turbidity sensors used in dishwasher and laundry systems currently and in principle is the same as described above but it utilizes infrared light from, for example, an infrared producing LED 502 so it is unaffected by the visible color spectrum. It is also put in line with the chamber 510 and its measurements not only give a reading of turbidity but also provides a measurement that is utilized in the to compensate the color calculations which will be discussed further below.
[0040] Turbidity within the context of laundry water reuse systems is most likely caused by, but not limited to, lint and fabric fibers in the water. The output of the turbidity sensor 504 will be a DC voltage and, in an exemplary configuration may range from 0 V to about 4 VDC. In this exemplary configuration, 4VDC output from sensor 504 would correspond to a clear condition while 0VDC would correspond to a maximum turbid condition. In certain embodiments of the present subject matter, a temperature sensor 506 may be provided as a part of turbidity sensor 500 to provide temperature feedback that can be used to calibrate the system under different temperature conditions.
[0041] Referring now to FIGS. 6 and 7 , charts 600 and 700 illustrate the relationships between turbidity and sensor output. FIG. 6 graphically illustrates a chart 600 of representative output voltages for an exemplary group of ten turbidity sensors. Graph 600 is presented in terms of turbidity sensor output voltage vs. Nephelometric Turbidity Units (NTU). FIG. 7 illustrates a chart 700 of representative percent differences vs. turbidity measurements given in Nephelometric Turbidity Units (NTU) for the sensors represented in FIG. 6 .
[0042] Referring now to FIG. 8 , there is illustrated a schematic representation of a water color detection circuit 800 in accordance with present technology. The hardware of the system may be completely integrated and includes a controller system 810 , a sample chamber 820 , light emitters 832 , 834 , 836 , one or more light detectors 842 , 844 , 846 , a turbidity sensor 850 , a tap water source 862 , a grey water storage tank 864 and associated plumbing, valves, and pumps (not separately numbered). Controller system 810 may include a storage device corresponding to a memory 812 . Memory 812 may also be provided as a separate entity within the overall system.
[0043] Those of ordinary skill in the art will appreciated that while the system may be configured as a completely integrated package, other options are possible. Such options may include, for example without limitation, the use of a personal type computer or other software and/or hardware driven computational device operating as controller system 810 . The controller system 810 may also be constructed using application specific integrated circuit (ASIC) device.
[0044] In whatever manner the hardware portion of the system is implemented, the overall system, never-the-less, relies on a controller system in order to drive components, receive and analyze feedback, and then take actions based on the feedback analyzed. Implementation of such systems given the present level of disclosure herein is deemed to be well within the capabilities of those of ordinary skill in the art and thus will not be further described.
[0045] Referring now to FIGS. 9 and 10 , there is illustrated in FIG. 9 a color cube representation 900 of an RGB color approximation space in accordance with present technology and in FIG. 10 a chart 1000 of representative RGB percentiles for each of the colors represented in FIG. 9 . In general the control associated with color sensing takes a light intensity measurement of a known medium, for example, clear tap water, and compares it to the light intensity of a filter medium, for example, discolored water, for Red, Green, and Blue light. The filter mediums output may be less for at least some of the colors than the clear tap water. By comparing these two results a percentage may be calculated which indicates the amount of light intensity of each color being filtered by the filter medium. Using these percentages and applying to the RGB color scheme an approximation of the filter color can be achieved.
[0046] In accordance with present disclosure, a few assumptions may be made. The first is that RGB [0,0,0] equates to completely BLACK while RGB[1,1,1] is CLEAR, that is, not white. Secondly, all points where R=G=B, such as RGB[0.5,0.5,0.5] are considered to be grayscale shades which grow darker as you approach RGB[1,1,1].
[0047] As previously noted, in some color scales, the scale for colors ranges form 0-255. Because the present technology is configured for local, as opposed to online, calculations, a lookup table may be created in software and stored in a memory which contains “all colors.” In reality, not all colors are seen continuously but rather are seen in discrete levels. For example, if colors are quantize in levels from 0 to 255 there would be produced a color cube of length, width, and height 255 which would consist of 255 3 =16581375 individual cubes of discrete color. This number is quite large so that in practice to conserve memory space and complexity while still meeting system performance requirements the quantization level can be brought down to below 255 or higher if precise resolution is required at the cost of memory.
[0048] Referring to FIG. 9 , there is illustrated a cube 900 with quantization levels 0-4. These five levels may be considered to be equivalent to 0%, 25%, 50%, 75%, and 100% color intensity output such that there are 5 3 =125 discrete colors that can be referenced. Cube 900 and associated color matrix lookup table 1000 may be implemented in software as appropriate for a particular implementation of the present technology. It should be appreciated that while this particular embodiment provides for a reduced quantization level of 125 discrete colors for the color cube, other scales and quantization levels can be provided to meet resolution demand of any particular system. The more levels provided, the more colors that can be approximated. With reference to FIG. 10 , it will be appreciated that color matrix lookup table 1000 , in order to avoid unnecessary clutter, does not list all 125 different combinations of colors, but the percentage of RGB colors for all 125 should, never-the-less, be quite evident to those of ordinary skill in the art based on the illustrated progression.
[0049] This reduced quantization level scheme will work for all transparent liquids with some level of coloring. However, laundry system, as described herein, will often encounter turbid conditions which can result in unreliable color approximations. In accordance with present technology, in order to compensate for such turbid conditions a turbidity measurement may be taken and then mathematically apply the results to accurately sense the true color and turbidity.
[0050] Referring to FIG. 11 there is illustrated a flow chart 100 of a method in accordance with present technology. In accordance with present technology, it has been appreciated that turbidity in the system will cause inaccurate color approximations. While the system will accurately detect the color of a liquid that is not turbid using color sensing methodologies alone, turbidity compensation is needed for most cases where the liquid will be at least somewhat turbid.
[0051] Turbidity is the measure of how cloudy, or how much material, is in a liquid. So in the instance of a laundry environment, lint, soils, detergents, etc could all add to system turbidity. Because the present technology uses photo-optics to emit and receive light to provide intensity measurements, system turbidity could introduce errors in intensity measurements and hence calculations and color approximations, since the turbid material may block some elements of the light.
[0052] The color sensing methodology of the present technology relies on the color of the medium alone to block elements and frequencies of light between the photo-emitters and photo-detectors. Given that a turbid condition would also block these frequencies, regardless of color, the system should be configured to compensate for the turbid condition. In accordance with present technology, this may be accomplished through the use of a turbidly sensor 500 as previously discussed with reference to FIG. 5 . In a manner and similar to the way color intensity is measured in the visible spectrum turbidity content may be measured by examining the infrared spectrum intensity that can pass through a medium. The infrared light will be impeded only by turbidity and not the color of the liquid.
[0053] In this manner the system is made aware of how turbid the liquid is and can calculate a percentage decrease in the output due to the turbidity. Because the turbidity will effect all visible colors equally, the amount of intensity that is lost due to turbidity needs to be added back to the color-detectors. In accordance with present technology, a percentage of output lost due to turbidity to all color intensity measurements will be restored to obtain a true and accurate approximation of color. This turbidity correction may be made using the equation:
[0000] COLOR(adjusted)=%COLOR/%TURBIDITY
[0054] For example if %TURBIDITY=80% and %RED=50% the adjusted color approximation for RED due to error caused by turbidity would be:
[0000] Red(adjusted)=%RED/%TURBIDITY
[0000] Red(adjusted)=50/80=62.5%
[0055] This difference of 12.5% between the observed RED intensity and the adjusted RED intensity is caused by the amount of turbidity in the water and if not corrected would cause a great deal of error in the color approximation.
[0056] Consider another example where the measured color percent output intensities are RGB [0.329, 0.706, 0.176] or in the rounded 255 scale, RGB [84, 180, 45]. Without turbidity compensation, the color sensing methodology would approximate the color incorrectly. In accordance with present technology, however, when examining the contribution of turbidity it may be found that the percent turbidity is measured at 75%. This means that there is a 25% decline in the entire scale of light intensity output for all colors of 25%. Compensation for this decline should be made as follows:
%TURBIDITY=75% %RED=32.9% %GREEN=70.6% %BLUE=17.6% Red(adjusted)=%RED/%TURBIDITY Red(adjusted)=32.9/75=43.4% GREEN(adjusted)=%GREEN/%TURBIDITY GREEN(adjusted)=70.6/75=94.1% BLUE(adjusted)=%BLUE/%TURBIDITY BLUE(adjusted)=17.6/75=23.5%
[0067] With turbidity compensation in accordance with present technology, the color sensing parameters become RGB [0.434, 0.941, 0.235] or in the rounded 255 scale RGB [112, 240, 60]. Through the implementation of the present technology, an accurate means of measuring color and turbidity is obtained such that the washer control system can take proper actions with respect to decisions including such as whether to save and/or treat the rinse water for further use or to dump the water.
[0068] An embodiment of the present invention can also be embodied in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. When implemented on a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic circuits. The technical effect of the executable code is to facilitate prediction and optimization of modeled devices and systems.
[0069] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention 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 if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. | Apparatus and methodologies are provided to selectively activate a liquid usage option in a washing apparatus based on the color of the liquid. Light from different light sources is passed through a liquid to be tested and the intensity of the light passing through the liquid is measured. The measurement is adjust based on a measurement of the turbidity of the liquid and the measurement compared to a reference value derived from measurements of a clear liquid. A decision is made based on the adjust measured color of the liquid regarding retention of the liquid for further use in the washing apparatus. The liquid tested may correspond to grey water from a previous wash cycle. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to conversion devices for use in enabling chain stitches to be sewn on a lock stitch sewing machine.
2. Description of the Prior Art
Various conversion devices with which a lock stitch sewing machine is enabled to sew chain stitches can be found in the prior art. Such conversion devices commonly include a thread retaining post on which a loop cast off by a looptaker may be retained until the sewing needle has been stepped therethrough, mechanism for stripping the retained loop from the post, and a bobbin case insert for guiding the thread cast off the looptaker onto the post. A lock stitch conversion device as described may be found for example, in U.S. Pat. No. 4,278,037 for "Chain Stitch Conversion for Lock Stitch Sewing Machine" of Gerald J. Creed et al., issued July 14, 1981.
When chain stitches were to be formed on a lock stitch sewing machine fitted with a conversion device, it was necessary to thread the machine differently than for lock stitching. For chain stitching, the thread was passed through a special chain stitch eyelet or guide, effective to limit the quantity of thread supplied to the looptaker by a descending takeup, and so enable the loop-taker to pull loops stripped from the post of the conversion mechanism up to a piece of material being sewn for the setting of chain stitches by the takeup. However, it was easy for an operator to mistakenly thread the machine for lock stitching when it should have been threaded for chain stitching, and when switching from a chain stitching mode to a lock stitching mode to leave the machine threaded for chain stitching. In either event, faulty stitches were produced.
It is a prime object of the present invention to render a lock stitch sewing machine convertible for chain stitch sewing without the need for a special chain stitch guide or eyelet.
It is another object of the invention to provide a bobbin case insert which is effective on a lock stitch sewing machine to consume thread as required for the machine to form chain stitches.
Other objects and advantages of the invention will become apparent during a reading of the specification taken in connection with the accompanying drawings.
SUMMARY OF THE INVENTION
A thread consuming bobbin case insert is provided for use in a lock stitch sewing machine. The insert along with other devices, including a thread retaining post on which a loop cast off a looptaker can be retained until the sewing needle is stepped therethrough, and including mechanism for stripping the retained loop from the post, serves to render the machine capable of sewing chain stitches. The insert includes a ledge which captures the upper limb of a loop of thread while being moved about the bobbin case by the looptaker. Such ledge delays the movement of thread across the top of the bobbin case and so consumes thread enabling the looptaker to pull a loop stripped from the loop retaining post up to a piece of material being sewed for the setting of a chain stitch thereat by the takeup of the machine. The need for a special chain stitch guide or eyelet on the machine is therefor eliminated.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a head end elevational view of a lock stitch sewing machine including chain stitch converting mechanism according to the invention, and with the bed partially broken away to expose parts therein;
FIG. 1A is an enlarged fragmentary, vertical, sectional view showing a portion of the mechanism depicted in FIG. 1;
FIG. 2 is a front elevational view of the throat plate illustrated in FIG. 1;
FIG. 3 is a bottom view of the throat plate of FIG. 2;
FIG. 4 is a perspective view showing a bobbin case insert according to the invention;
FIG. 5 is a perspective view of portions of the machine of FIG. 1 showing stitch forming instrumentalities, chain stitch conversion mechanism, and thread loops as the sewing needle of the machine penetrates a work piece;
FIGS. 6, 7, 8 and 9 are perspective views showing the stitch forming instrumentalities, chain stitch conversion mechanism, and thread loops in different positions of the sewing needle.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, reference character 10 designates a conventional lock stitch sewing machine, including a work supporting bed 12 and sewing head 14. A needle bar 16 is carried in the sewing head for endwise reciprocation. A sewing needle 18 is affixed in the lower end of the needle bar and cooperates with a rotary looptaker 20 journalled in the bed and driven in timed relationship to the needle bar and takeup of the machine in a manner well understood in the art. A presser foot 22 affixed to a presser bar 24 is utilized to urge fabric 26 and 28 into contact with a feed dog 30 by means of which work is advanced under the needle 18. The feed dog is moved in timed relationship to the needle, looptaker and takeup by conventional work feeding mechanism which may be of the type shown and described, for example, in U.S. Pat. No. 3,527,183 for "Work Feeding Mechanism for Sewing Machines" of The Singer Company, issued Sept. 8, 1972.
Lock stitch machine 10 is rendered capable of sewing chain stitches with conversion mechanism including a loop retaining post 32 and wire loop stripper 34 which depend from the underside of a chain stitch throat plate 36 of the kind shown and described in the aforementioned U.S. Pat. No. 4,278,037. The conversion mechanism also includes a thread controlling insert 38 which is received in the well 40 of a bobbin case 42 that is restrained from rotating in the base 12 of the machine as with a bracket 44.
Depending post 32 serves to temporarily retain successive loops of thread moved about the bobbin case of looptaker 20. Each loop is retained on the post against the action of the takeup 46 of the machine until the sewing needle has passed through the loop, after which the loop is removed from the post with loop stripper 34, and a new loop is formed for subsequent retention. Post 32 is fashioned with an inclined groove 47 to receive one end of the loop stripper 34.
Throat plate 36 is provided with slots 48 to accommodate the feed dog 30, and with an aperture 50 between the feed dog slots to permit the needle 18 to pass through the plate. Adjacent the feed dog slots 48, a trench 52 is cut in the throat plate 36 to accommodate a block 54 which is attached to the throat plate at 56. By reference to FIG. 3, it may be seen that the underside of the block 54 is formed with a groove 57 which extends diagonally from the top of the block to adjacent the bottom edge where the groove turns abruptly and extends out the side of the block. The groove is a guide for loop stripper 34 having one end 60 slidable in the groove 47 on post 32, and having the opposite end 62 extending to lie beneath the adjacent feed dog slot 48. A wire spring 64 having one end 65 located in an aperture 66 in block 54 constantly urges end 62 of loop stripper 34 upwardly towards the throat plate. When the throat plate 36 is installed on the sewing machine, a leg 67 of the feed dog 30 closely adjacent the block 54 extends above end 62 of the wire loop stripper 34 (FIG. 1A), and downward motion of the feed dog during needle penetration causes end 60 of the wire to strip a retained loop from the depending post 32, whereas motion of the feed dog upwardly is followed by end 62 of the wire due to the urgings of the spring 64.
Referring now to FIG. 5, there may be seen fragments of the stitch forming instrumentalities of the sewing machine along with depending post 32 and the block 54. The throat plate 36 to which post 32 and block 54 are attached has not been shown so that the function of these elements may be more readily apparent. Sewing needle 18 with thread extending thereto from a thread tensioning device 69 and over takeup 46 is shown extending through fabric 26 and 28, and through a loop retained on depending post 32, the depending post being of sufficient width to insure that the sewing needle 18 steps through retained loops without fraying or piercing the thread thereof. End 60 of the wire loop stripper 34 extends into the groove 47 of the depending post 32 above the loop retained thereon. End 62 of the wire stripper 34 extending beneath one leg of feed dog 30 has been moved an insufficient distance by the feed dog to cause the end 60 of the wire to strip the loop from the depending post 32. The loop taker 20 carries therein the bobbin case 42, and set within the bobbin case is the insert 38.
Insert 38 takes the place of the bobbin normally present in the bobbin case 42 during lock stitch sewing, and provides a relief 68 into which the depending post 32 attached to the throat plate 36 may extend. The insert 38 directs the loop shed by the loop taker 20 to the depending post 32, and eliminates the possibility of skipped stitches due to the shed loop avoiding the post.
The looptaker 20, post 32, loop stripper 34, and insert 38 cooperate to provide for the formation of chain stitches in machine 10 in much the same way as described in the aforementioned U.S. Pat. No. 4,278,037, which is incorporated herein by reference. It is therefor unnecessary to describe the operation of the converting mechanism in detail herein, except, however, for insert 38 which is specially formed according to the invention to perform an additional function to that described in the patent. Successive loops of thread presented for pick-up to the hook 71 of the looptaker by the needle 18 are moved about the bobbin case by the looptaker during the rotation thereof. Each loop after being cast off the looptaker is retained on depending post 32 until the needle 18 steps through the retained loop after which the retained loop is stripped from the post by wire stripper 34, and a succeeding loop is moved about the bobbin case, all as described in the said patent.
As stated, insert 38 is specially formed according to the invention. The insert is formed with a ledge 70 to rise above and overlap the top surface 72 of the bobbin case 42. Ledge 70 is located on one side of the insert between recess 68 and a key 76 which is received in a cut-out 78 in the bobbin case. The insert also includes a ramp 80 extending to an elevated surface 81. Insert 38 is preferably a one-piece molded plastic piece.
Insert 38 controls the movement of a loop 82 of thread about the bobbin case 42 in a manner made apparent in FIGS. 6, 7, 8 and 9. During the initial portion of the movement of loop 82 about the bobbin case, upper limb 84 of the loop moves across the top surface 72 of bobbin case 42 approaching insert 38 (FIG. 6). Needle 18 is then moving upwardly out of the work 26 and 28, the takeup 46 is moving downwardly, and a previous loop 86 has been stripped from post 32 by wire stripper 34. As loop 82 is moved further about the bobbin case to the position shown in FIG. 7 by hook 71, limb 84 is caused to move under ledge 70, and is captured thereby against depending flange 88 on the insert. At the same time, needle 18 continues to move upwardly and the takeup downwardly. While limb 84 is captured under ledge 70, loop 82 is prevented from moving across the insert. Thread is therefor consumed by rotation of the looptaker and prior loop 86, which has been removed from post 32, is drawn upwardly toward the work. Continued rotation of the looptaker causes limb 84 to ride up ramp 80 onto elevated surface 81 and the thread is thereby caused to gradually move out from under, over and about ledge 70 (FIG. 8). In the FIG. 8 position of the looptaker, the needle has moved to the elevated position indicated and the takeup has moved upwardly. As the looptaker continues to rotate, limb 84 is caused to ride up ramp 90 onto an elevated surface 92 on the insert (FIG. 9) and while thereon is cast off hook 71. As the looptaker rotates further, the feed dog 30 moves upwardly and is followed by end 62 of loop stripper 34, due to the upward bias of spring 64 thereon. The loop stripper pivots in groove 57 causing end 60 to move upwardly in groove 47, and the takeup 46 with continued upward movement pulls loop 82 under loop stripper 34 onto post 32 and sets a chain stitch in the work with loop 86.
Although the invention has been described with a certain degree of particularity, it is to be understood that the present disclosure of the preferred form has been by way of example and that numerous changes in the details of construction, and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention. | A chain stitch insert receivable in the bobbin case of a sewing machine is formed with a topside ledge which captures and consumes thread as a hook point carries a loop of thread around the bobbin case. The ledge enables the formation of chain stitches without the need for a special eyelet on the machine. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority to U.S. Provisional Application Nos. 60/411,006, 60/434,526 and 60/458,800, filed on Sep. 16, 2002, Dec. 19, 2002 and Mar. 28, 2003, respectively, the contents of each are hereby incorporated by reference herein in the entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
REFERENCES TO SEQUENCE LISTING, TABLES OR COMPUTER PROGRAM LISTING APPENDIX ON COMPACT DISK
Not applicable.
FIELD OF THE INVENTION
The present invention relates to electrostatically charged filter media and more particularly to an electrostatically charged media with an active agent incorporated thereon, and a method of making the same.
BACKGROUND OF THE INVENTION
Prior art filter methods include, for example, mechanical filtration—a physical retention of particles larger than the pores of the filter media; electrostatic filtration—adhering particles to fibers in the filter without killing/deactivating the particles; and filtration as taught and claimed in U.S. Pat. No. 5,980,827 which issued to the inventor hereof on Nov. 9, 1999 and is entitled “Disinfection Of Air Using An Iodine/Resin Disinfectant.” It has been determined that improved iodinated resin filtration occurs in a thin media when the product is incorporated to a media with a convoluted pathway. By forcing the microorganism/toxin to pass through a circuitous route, the microorganism/toxin is eventually killed/deactivated. One method for providing a circuitous route is to employ a nonwoven media.
In published U.S. patent application number 20010045398 entitled “Process For The Immobilisation Of Particles In A Three Dimensional Matrix Structure” the non-woven material is first produced and then an iodinated resin, such as the one disclosed in U.S. Pat. No. 5,639,452 (the '452 patent) is added using alcohol or a partial solvent with a high pulsation vacuum pump that opens the filter pores so that the active agent will go through it (the “Triosyn” resin). The contents of the '452 patent is incorporated by reference in its entirety herein.
U.S. Pat. No. 6,346,125 teaches incorporating an aqueous antimicrobial agent into a non-electrostatically charged non-woven material. Specifically, the '125 patent describes a particular process for incorporating an aqueous antimicrobial agent into a non-electrostatically charged non-woven. However, without the electrostatic properties, the non-woven must be of greater thickness so that the microorganism has sufficient contact time with the antimicrobial agent for decontamination.
U.S. Pat. No. 5,952,092 teaches a non-woven fabric with chemically active particles. However, this patent does not teach using an electrostatic substrate as in the present innovation.
Nonwoven electrets and methods of manufacturing the same are known in the art. For example, U.S. Pat. No. 5,409,766 describes a nonwoven fabric in an electret state composed of monofilaments formed of a polymer composition capable of dust collection over a prolonged time and in a hot and humid condition. Also disclosed are processes for producing this nonwoven fabric, as well as a filtering air masking material composed of that nonwoven fabric. However, this prior art system does not provide antimicrobial/antitoxin properties. Thus, the microorganism/toxin, while suspended within the nonwoven fabric, is not sterilized or deactivated. Once the electrostatic properties of the nonwoven are depleted or the material is saturated, the microorganism/toxin may be released back into the atmosphere.
Electrostatically charged filters are known to be used in facemasks, for example. With respect to both, one of the problems of face seal is well known and represents a limitation that the industry has been trying to address. The problem resides in the fact that from one morphological physical structure of a human being or structure to the next the differences generate such a wide spectrum of geometrical deviations that it has been difficult to create a 100% airtight seal. For a facemask the difficulty in creating a seal occurs between the skin and the mask for a range of face sizes and shapes. Various different technological means have been tried, for example using, adhesive seals, flat and wide seals and resilient material seals. The industry has oriented its work on creating an airtight seal, however, the pressure differential generated actually forces air in the gaps between seal and skin thus bypassing the air filter material. The electrostatic filter of the present invention may be made of a spongy or other breathable nonwoven material so as to minimize the pressure differential, thus preventing air from being forced through the gaps. Further, it effectively makes the gasket used to create a closure between the user and the facemask out of a thin filter having a low-pressure drop like the electrostatic filter and having the added benefit of the active agent incorporated thereon.
Other known prior art that teach the use of high pressure drop media includes the mechanical filtration of the HEPA filter. However, the pressure drop of the present invention is approximately 50% to 90% lower than that of the HEPA filter alone. The filter further includes a material that kills on passage vegetative bacteria, spores, and viruses. They are filtered out of the airstream and are killed. In addition, the present invention is self-sterilizing, meaning that not only does it filter air passed there through, it kills the bacteria trapped on the filter. Therefore, the media protects both the user and the outside air.
Given the shortcomings of the prior art, it is advantageous to have an electret, which has improved characteristics over known solutions. The present innovation comprises a substrate that supports an active agent and is a dielectric.
SUMMARY OF THE INVENTION
The present invention overcomes the aforementioned problems of the prior art. Specifically and in accordance with one aspect of the present invention, there is provided herein an electrostatically charged non-woven media that has active agents incorporated therein. This innovative media is capable of eradicating microorganisms and/or toxins more efficiently than prior art solutions and can also self-sterilize.
The present invention additionally provides for methods of making the electrostatically charged filter media having an active agent incorporated therein. The substrate may be manufactured according to various methods; the active agent may be incorporated according to various methods; and the electrostatic charge may be provided according to various methods, all of which are described herein or are known in the art.
Because substantially less active agent is used for each filter costs are reduced while maintaining effectiveness. Additionally, the enhanced electrostatic filter of the present invention provides added performance of the active agent and electrostatic properties.
In addition to the above aspects of the present invention, additional aspects, features and advantages will become better understood with regard to the following description in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts aspects of an exemplary embodiment of the present invention in accordance with the teachings presented herein.
FIGS. 2 and 3 depict exemplary embodiments of electrostatically charged substrates.
FIG. 4 depicts an exemplary embodiment for providing a nonwoven media with an active agent incorporated thereon.
DETAILED DESCRIPTION OF THE INVENTION
The following sections describe exemplary embodiments of the present invention. It should be apparent to those skilled in the art that the described embodiments of the present invention provided herein are illustrative only and not limiting, having been presented by way of example only. All features disclosed in this description may be replaced by alternative features serving the same or similar purpose, unless expressly stated otherwise. Therefore, numerous other embodiments of the modifications thereof are contemplated as falling within the scope of the present invention as defined herein and equivalents thereto.
The present invention provides an electrostatically charged filter media comprising a substrate with an active agent incorporated therein.
Filter Media
The filter media of the present invention includes (1) a substrate, (2) an active agent incorporated therein and (3) an electrostatic charge.
Substrate
The substrate comprises any material having dielectric properties or capable of being enhanced to have dielectric properties and which is capable of having an active agent incorporated therein.
In a particular embodiment, the substrate may be a fiber based material having a fibrous matrix structure; it may be a sponge like material have an open cell matrix structure; it may be flexible or inflexible; etc.
As stated above, in one embodiment, the substrate is a nonwoven fabric. Nonwoven is a type of fabric that is bonded together rather than being spun and woven into a cloth. It may be a manufactured sheet, mat, web or batt of directionally or randomly oriented fibers bonded by friction or adhesion; it may take the form of a type of fabric. FIG. 1 is provided as an exemplary embodiment of a nonwoven fabric.
In another embodiment, the substrate may be a nonwoven textile of varying fluffiness, comprising polymer fiber. The polymer may be for example, nylon, polyethylene, polypropylene, polyester, etc. or any other polymer suitable for a filter substrate. Additionally, the substrate can be made of materials other than polymer fiber.
The nonwoven material may be of a type suitable for a high efficiency particulate air filter (i.e. a HEPA filter). A suitable nonwoven material may be obtained from Technol Aix en Provence Cedex 03 France (see Canadian patent no. 1,243,801); another suitable material may also be obtained from Minnesota Mining & Manufacturing Co. (3M). The nonwoven material has a three dimensional structure which should be configured in such a fashion as to provide a matrix capable to entrap (i.e. physically) the desired active agent. For example if the nonwoven material is based on fibers, the structural fibers of the nonwoven material may be present and distributed in such a fashion as to provide a fibrous matrix structure able to entrap the desired active agent. The nonwoven material may have a microstructure. In a particular embodiment, the active agent has a size appropriate to be entrapped by the three dimensional (e.g. web) matrix structure of the desired nonwoven material.
Alternative substrates may further include glass fibers and fibers, such as cellulose, that are ultimately formed into a paper-based filter media. Any substrate capable of acting as carrier for the active agent and having dielectric properties or capable of having dielectric properties imparted to it, would be a suitable substrate for the present invention. When substrates that do not have strong dielectric properties are used, such as glass fibers, additives may be provided to improve the dielectric properties of the substrate. The present invention is not limited to a nonwoven material. Other suitable substrates may include spongy materials or foam.
Active Agent
The active agent of the present invention may be, for example, an antimicrobial, an antitoxin, or the like. The antimicrobial may be biostatic and/or biocidal. Biostatic is a material that inhibits the growth of all or some of bacteria spores, viruses, fungi, etc. (having bioactive particles), and a biocidal is a material that kills all or some of bacteria spores, viruses, fungi, etc. Preferably, the biocidal comprises the iodinated resin particles, such as those described above in the '452 patent, as described above. Other suitable active agents include silver, copper, zeolyte with an antimicrobial attached thereto, halogenated resins, and agents capable of devitalizing/deactivating microorganisms/toxins that are known in the art, including for example activated carbon, other metals and other chemical compounds. For example, a non-exhaustive list of suitable metals and/or chemical compounds is as follows:
Exemplary Metals
Aluminum
Barium
Boron
Calcium
Chromium
Copper
Iron
Magnesium
Manganese
Molybdenum
Nickel
Lead
Potassium
Silicon
Sodium
Strontium
Zinc
Exemplary Chemical Compounds
N-methyl piperazine
Potassium Hydroxide
Zinc Chloride
Calcium chloride
Mixture of Sodium carbonate and sodium bicarbonate
Reference in the specification to antimicrobial is used for ease of reading and is not meant to be limiting.
Electrostatic Charge
The filter media with an active agent incorporated thereon is also electrostatically charged. Accordingly, there is a potential across the surface(s) of the media creating a field wherein the field can attract and/or repel charged particles introduced to the media so that in some instances it alters the path of travel of the charged particles.
FIGS. 2-3 provide exemplary representations of electrostatically charged media. Electrostatically charged filter media of the present invention may, for example, be single or multi-layered. Each layer may be individually charged. A single layered media can have a positive charge on one side and a negative charge on the other. An example of a multi-layered media is a double-layered media. Preferably, a double layered media is used wherein the double-layered media comprises two layers, each being positively charged on one side and negatively charge on the other side, wherein the two layers are separated by an airspace and the two layers are oriented so that the negative side of one of the two layers is closest to the positive side of the other layer. In this two-layer embodiment, the air space increases the net dielectric constant of the electrostatically charged filter media.
Preferably, a high dielectric constant is provided to maintain the charge for an extended period of time. For example, air provides a good dielectric constant, as can be employed in an airspace as described above. Thus, the present invention may be effective even when wet or in a humid environment.
The resulting media is an insulating carrier with an active agent adhered thereto or impregnated therein and having an electrostatic charge. The media according to the present invention can be produced of different thickness, density and pressure drop. The media described herein can be used in, for example: clothing, wound dressings, air filters, shelters, liners and generally, any filter material.
Method of Manufacturing
The present invention additionally provides for a method of manufacturing the electrostatically charged filter media having an active agent incorporated thereon. The substrate itself may be manufactured according to various known methods, such as melt blown, spun blown, air laid, carted, etc.
Method of Incorporating the Active Agent
Prior art incorporation methods using polypropylene require the use of polyethylene to maintain a tackiness to the fibers to hold the solid particulate for a longer amount of time to prevent the particulate from falling off the fibers. In the present invention, the active agent, such as the iodinated resin disclosed in the '452 patent, may be physically entrapped in the fibers. Thus, the active agent does not have to adhere to the fibers to be incorporated into the media.
In the present invention, the active agent may be incorporated to the substrate according to various methods. For example, liquid emulsification of the active agent in the melt at increased temperature and increased pressure for mix and melt processes, or incorporation by spraying the active agent after extrusion of non-woven fibers during processing.
In a preferred embodiment, as shown in FIG. 4 , polymer granules, such as polypropylene granules, are extruded through an extruder; the extruded fibers being of varying thickness and length. As the fibers are extruded they fall toward a collecting web. A desired active agent is provided in a cloud at a location closest to the extrusion point of the resulting fibers. The cloud envelops the cooling fibers while the fibers are still in a quasi-liquid quasi-solid state. In one embodiment, the active agent particulate may range from 0.2 microns to 0.5 millimeters. However, one of ordinary skill in the art can apply active agents with smaller and bigger particulates size. The active agent particulate settles and collects so that it is intermeshed or entrapped with the fibers on the collecting web. After the fibers with the active agent incorporated thereon falls to the collecting web, the resulting media is formed into a mesh by known methods. Additionally, the cloud may be in various physical states including a vapor, fine dry dust, or atomized or aerosolized particulate. Advantageously, cloud incorporation may occur at room temperature with particulate also at room temperature. Further, the thickness, length and pressure define the mechanical properties of the resulting media.
A suitable melt blown system for the above embodiment is the Accuweb provided by Accurate Products Co. of Hillside, N.J.
Various other methods of incorporating an active agent to a filter media are suitable for the present invention. First, for example, using the method disclosed in published U.S patent application number 20010045398 A1. Second, soaking a bail of hair-like extruded fibers in an active agent (and using alcohol to achieve the soak) and then creating the felt using pressure and temperature. Third, taking solid polymer granules manufactured with an active agent mixed in an extruder hopper to create a mixture that is then extruded into fine hair-like bails. Felt is then formed through a temperature and pressure process. Fourth, extruding a substrate, such as a polymer in to a hair-like substance on to which an active agent is sprayed in solid after the extrusion. The active agent may be vaporized like an aerosol. Fifth, the active agent can be injected or sprayed into non-woven fabric as the fabric is being pressurized. Sixth, carting bails of filament and mixing the resulting media with the active agent to generate a sheet having the active agent incorporated therein. Seventh, depositing the active agent on a non-woven media and thereafter needle-punching the media to impregnate the active agent through and through the media. Other methods may be used.
In another embodiment of the present invention, polymer granules are placed in a hopper of an extruder with active agent in dust form prior to extrusion. Thus, the active agent is mixed in the hopper prior to the melt. The two components are mixed, heated and then extruded to form a thin “hair” fiber used to make a felt. The resulting hair in the above embodiments having the active agent incorporated thereto is a bail-like wool. The substrate could be transparent depending on the polymer used. Additionally, a resulting polymer fiber having the active agent incorporated thereto can be treated with water, pressurized and then heated to form a felt. In other embodiments, the resulting polymer fiber having the active agent incorporated thereto can an be air laid, vacuum laid, water laid, etc.
Although not specifically described herein, other conventional or known methods that achieve incorporation of an active agent to a substrate are suitable for the present invention. Thus, at this point the substrate has an active agent incorporated therein.
Method of Electrostatically Charging
The substrate having an active agent incorporated therein is provided with an electrostatic charge. The charge may be induced by using a corona, needle punching, chemical enhancement, any other known charge inducing system or method, or a combination of any of the foregoing. Needle punching creates high-level friction thus adding a charge.
In a particular embodiment, to make the electrostatically charged non-woven fabric the formed media, such as felt, is placed into a corona system of about 25 Kv, slow pass, until fully charged. The resulting material holds its charge for between about 6 months to 2 years.
Operation of an Electrostatic Filter Media
In operation, a contaminated air or fluid stream is introduced to a filter employing the electrostatically charged filter media of the present invention. The air/fluid stream may be forced or drawn through the filter media by means of a pressure gradient. The stream may contain contaminant particles of various sizes to be removed or treated by the filter element. As the stream approaches the filter media, it is directed through the filter media such that the contaminate particles are brought into contact with the filter media and removed from the stream or treated by the active agent as describe elsewhere in this application. This is achieved through the properties of the filter, which causes the particles to follow a convoluted pathway through the filter element, thus increasing the time that the contaminant is in contact with the active agent. This increased contact time increases the effectiveness of the active agent in treating the particles in the stream.
The convoluted path that the particles follow is the result of the added electrostatic properties and the nonwoven properties of the substrate of the filter element. With respect to the electrostatic properties of the filter element, the convoluted pathway of the contaminant particles may be attributed to the particles polar nature. Polar molecules are neutrally charged and are also large in size. Because of the large size, the contaminants have a magnetic moment, which when subjected to an electric field causes the contaminant particle to be diverted from its pathway.
Additionally, the convoluted path of the contaminant particles is attributable to the nonwoven properties of the filter substrate. This is achieved because the nonwoven substrate had no direct and continuous pathway for the stream to pass through. Instead, due to the nonwoven properties, the substrate is made up of a porous material wherein no single pores of the material forms a continuous pathway through the substrate. Therefore, the stream and the particles carried by the stream are continuously diverted through the substrate. Accordingly, the travel time through the filter is lengthened and the exposure to the active agent is increased.
Additional Uses
The present invention can also be used in a manner consistent with existing nonwoven fabrics. Uses in various goods include both durable and disposable goods. For example, nonwovens can be used products such as diapers, feminine hygiene, adult incontinence, wipes, bed linings, automotive products, face masks, air filtration, water filtration, biological fluids filtration, home furnishings and geotextiles. The media described herein can also be used in, for example: clothing, wound dressing, air filter, shelters, and liners. Additional uses include those known in the art for electrostatic filters and antimicrobial or antitoxin filters.
In a particular embodiment, the filter media according to the present invention with or without the active agent can be used as a closure or to make a filter closure for air filters for products such as facemasks and HVAC. According to the present invention there is provided a closure material made of substrate having electrostatic properties and an electrostatic material with an active agent incorporated therein, where the material is a high loft (in one embodiment, approximately, 1″ thick) breathable material of a tri-dimensional structure and is placed around the mask or air filter in order to not create a so-called airtight junction but instead creates a breathable closure that actually covers all the contours of the different geometrical surface to provided a permeable closure, having filtering properties. This approach makes the closure into a filter whereby air that bypasses the mask through gaps caused by a non-perfect fit, still passes through the closure and is filtered. In addition, contrary to a “resilient” closure the pressure differential that is detrimental in an airtight approach is reversed in our approach since the air following the path of least resistance will pass through the filter material of the mask instead. This method of closing a facemask or other filter type could also be achieved with a substitution of the non-woven filter element with a breathable foam having the same properties. Thus, while prior art facemask attempt to block air flow at the closure, the facemasks of the present invention acts as a gasket that allows air there through and kills the spores, virus, bacteria, fungi, etc. traveling through the airstream with an effective active agent, such as the iodinated resin disclosed in the '452 patent, described above. Additionally, the use of straps to hold the mask in place compresses the gasket of the present invention to fit essentially all faces.
Experimental Data
Experimental tests were performed comparing a particular embodiment of the filter media of the present invention to an existing electrostatic filter. Each test was run in the same environment to treat air with a different contaminant. The experimental data provided was collected during these tests. In each of the tests a contaminant was introduced into a chamber in a controlled amount and fed into four lines. Two of the lines included a filter according to the present invention comprising an electrostatically charged filter with an iodinated resin according the the '452 patent incorporated thereto. The third line included an electrostatically charged filter, known as Transweb. This filter does not have antimicrobial properties or any other type of active agent incorporated thereto. And a fourth line was provided as a control, having no filter and was used to confirm that the amount of contaminant entering the control chamber was equivalent to the amount of contaminant exiting the control chamber.
Exhibit A sets forth experimental data illustrating certain features of exemplary embodiments of the present invention. Experiment No. AF276, describes the performance of different filtration membranes against BG spores for 30, 60, 120, 180, 240, 300, and 360 minutes of filtration. BG spores must be present in amounts of about 8,000 to 30,000 spores to cause illness in the average human. As can be seen in Exhibit A, for each of the 30, 60, 120, 180, 240, 300 and 360-minute tests, the filter of the present invention achieved a 100% reduction of BG spores from the airstream.
As can be seen in Exhibit A, the electrostatic filter of the present invention achieves the essentially the same or similar net effect as the Transweb in these tests. However, an important advantage provided is that the present invention sterilizes the spores rather than just holding the spores to the filter. Thus, unlike the present invention, if the Transweb is handled by a user or is contacted by the skin, contamination will occur. The present invention maintains the hygiene of the filter.
Turning now to Exhibit B, the results of Experiment AF270 there is shown test results for the performance of different filtration membranes against MS2 viruses for 30, 60, 120, 180, 240 300, and 360 minutes of filtration. Virus amounts ranging from 1 to 1000 viruses will cause illness in the average human. Thus, the presence of even one virus can cause illness in a human. As can be seen in Exhibit B, for each of the 30, 60, 120, 180, 240, 300 and 360-minute tests, the filter of the present invention achieved a 100% reduction of MS2 viruses from the airstream. However, the Transweb does not achieve a 100% reduction in MS2 viruses and allows between 1000 to 10000 viral units to be found in the effluent air stream. Use of Transweb to air contaminated with MS2 viruses would not achieve desired results. Thus, as can be seen in Exhibit B, in addition to the benefits of sterilization properties described above with respect to Exhibit A, the present invention protects more effectively over viruses such as MS2 over time. Because only a small amount of viruses contaminate a human (1 to 1000 viruses), unlike the present invention, Transweb does not effectively protect a user from these viruses.
CONCLUSION
Having now described one or more exemplary embodiments of the invention, it should be apparent to those skilled in the art that the foregoing is illustrative only and not limiting, having been presented by way of example only. All the features disclosed in this specification (including any accompanying claims, abstract, and drawings) may be replaced by alternative features serving the same purpose, and equivalents or similar purpose, unless expressly stated otherwise. Therefore, numerous other embodiments of the additions and modifications thereof are contemplated as falling within the scope of the present invention as defined by the appended claims and equivalents thereto. | There is provided a protective media and a method of manufacturing the same. In one aspect, the protective media includes a porous dielectric carrier, an active agent incorporated in the porous dielectric carrier, and an electrostatic charge across at least a portion of the porous dielectric carrier. This innovative media is capable of eradicating microorganisms and/or toxins more efficiently than prior art solutions and can also self sterilize. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional Application No. 61/433,896 filed 18 Jan. 2011; and 61/486,720 filed 16 May 2011, both of which are incorporated herein by reference.
BACKGROUND
[0002] 1. Technical Field
[0003] Inflatable medical devices and methods for making and using the same are disclosed. More narrowly, medical invasive balloons, such as those used for trans-cutaneous heart valve implantation are disclosed. For example, those balloons used for trans-catheter aortic-valve implantation.
[0004] Inflatable structures are widely used in medical procedures. A structure is inserted, typically on the end of a catheter, until the structure reaches the area of interest. Adding pressure to the structure causes the structure to inflate. In one variation of use, the structure creates a space inside the body when the structure inflates.
[0005] Inflatable structures may be used in the heart valves, including during Balloon Aortic Valvuloplasty (BAV) and Transcatheter Aortic Valve Implantation (TAVI). The structures can be used to open a stenosed aortic valve. A stenosed valve may have hard calcific lesions which may tend to tear or puncture a structure. Additionally, a precise inflated structure diameter may be desired for increased safety and control.
[0006] Inflatable structures may be used to move plaque or a constriction away from the center of a vascular or other lumen toward the lumen walls, such as during an angioplasty or a peripheral vasculature or an airway procedure. During this procedure, an inflatable structure on the distal end of the catheter is placed in an obstruction. As the structure is inflated, the constriction is dilated, resulting in improved flow of the liquid (such as blood) or gas (such as air).
[0007] Current or typical inflatable structures can be balloons. When a typical balloon inflates, it may block a body lumen. For instance, a typical balloon may block the flow of blood in the vasculature or air in the airway. Blocking this vital supply of liquid or gas may cause short or long term health problems for the patient. This blockage may minimize the time that the physician can keep a balloon inflated during medical procedure.
[0008] Typical balloons, when used to perform a BAV and/or TAVI procedure will block the entire output of the heart at the aortic valve. This causes the pressure in the heart to increase to uncomfortable levels. It may also generate enough force to eject the balloon from the aortic valve. Finally, typical balloons provide poor dimensional (particularly diametric) control and do not resist tear and puncture (from, for instance, aortic calcifications) well.
[0009] Alternately, a physician may use rapid pacing of the heart (artificially accelerating the natural heart beat pace) during BAV and/or TAVI to minimize pressure buildup and the forces on the balloon. However, rapid pacing carries risk for the patient as well. Even with rapid pacing, typical balloons may only be inflated for a few seconds before being withdrawn and still suffer from poor dimensional control and toughness.
[0010] A balloon or inflatable structure is desired that can maintain flow of liquid or gas while providing precise shape control and being highly resistant to tear and puncture.
SUMMARY OF THE INVENTION
[0011] An inflatable medical device such as inflatable structure apparatus is disclosed. The apparatus can have a shell having a shell longitudinal axis, a central section and a first neck section. The first neck section can have a first neck first end and a first neck second end. The first neck first end can have a first neck first end diameter. The first neck second end can have a first neck second end diameter. The first neck first end diameter can be larger than the first neck second neck diameter. The first neck first end can be adjacent to the central section.
[0012] The apparatus can have a balloon at least partially inside of the shell. The balloon can be fixed in the shell.
[0013] The shell can have a shell longitudinal axis and a central fluid passage. The central fluid passage can be radially inside of the balloon with respect to the shell longitudinal axis. The first aperture can be in fluid communication with the central fluid passage. The balloon can have a first cell and second cell in a single cross-section of the inflatable structure. The balloon can have a balloon surface area in the single cross section. At least 5% of the balloon surface area can be concentric (i.e., have the same center of radius of curvature) with the shell.
[0014] A wall of the first cell adjacent to the second cell can be greater than about 5% in contact with the second cell. The apparatus can have a first flute in the shell. The first flute can have a first flute first inner pleat, a first flute second inner pleat, and a first flute outer pleat between the first flute first inner pleat and the first flute second inner pleat. The apparatus can have a first aperture. The first aperture can be at least partially on the first flute. The first aperture can be arranged as to not cross the first flute outer pleat.
[0015] The first neck section can have a first neck section stiffness. The central section can have a central section stiffness. The first neck section stiffness can be greater than the central section stiffness.
[0016] The apparatus can have a tube extending along the shell longitudinal axis. The central fluid passage can be between the tube and the inside radius of the balloon with respect to the shell longitudinal axis. The tube can have a lumen extending therethrough.
[0017] The first neck section can have a first neck section average wall thickness. The central section can have a central section average wall thickness. The first neck section average wall thickness can be greater than the central section average wall thickness. The first flute can be in the first neck section.
[0018] At least 30% of the perimeter of the shell can be concentric with the balloon surface area. The balloon can have a first cell and second cell in a single cross-section of the inflatable structure. At least 30% of the perimeter of the shell can be in contact with the cells.
[0019] The balloon can have a first cell and second cell in a single cross-section of the inflatable structure. At least 5% of the balloon surface area can be in contact with the shell.
[0020] The apparatus can have a second flute. The first aperture can be covered by the second flute when the inflatable structure is in a deflated configuration. The second flute can have a second flute first inner pleat, a second flute second inner pleat, and a second flute outer pleat between the second flute first inner pleat and the second flute second inner pleat. The apparatus can have a second aperture. The second aperture can be at least partially on the second flute. The second aperture can be arranged to not cross the second flute outer pleat.
[0021] The shell can have a second neck section. The second neck section can have a second neck first end and a second neck second end. The second neck first end can have a second neck first end diameter. The second neck second end can have a second neck second end diameter. The second neck first end diameter can be greater than the second neck second end diameter. The second neck first end can be adjacent to the central section.
[0022] The apparatus can have a second aperture on the second neck section. The first aperture and the second aperture can be in fluid communication with the central fluid passage.
[0023] The central section can have a central section diameter. The central section diameter can be constant along the length of the central section. The balloon can be at least partially in the central section of the shell.
[0024] The shell can have a shell wall having a fiber. The shell can be non-compliant. The shell can have a fiber.
[0025] A method for using an inflatable structure in a biological body is disclosed. The method can include positioning the inflatable structure at an aortic valve in the body. The inflatable structure can have a balloon that can have first and second flexed flexion sections. The method can include inflating the balloon. The method can include perfusing the aortic valve. Perfusing can include perfusing through the inflatable structure. Perfusing can occur while the balloon is inflated.
[0026] The aperture can be in fluid communication with the central fluid passage.
[0027] The method can also include expanding the expandable implant. The expanding of the expandable implant can include inflating the inflatable structure. At least some of the flow routes through the aperture and central fluid passage. The method can include separating the expandable implant from the inflatable structure.
[0028] A method for using an inflatable structure in a biological body is disclosed. The method can include positioning the inflatable structure at an aortic valve in the body. The inflatable structure can have a shell. The balloon can be at least partially inside the shell. The shell can have a shell longitudinal axis and a central fluid passage radially inside of the balloon with respect to the shell longitudinal axis. The shell can have a flute and an aperture on the flute. The aperture can be in fluid communication with the central fluid passage. The method can include inflating the balloon. The method can include perfusing the aortic valve. Perfusing can include perfusing through the inflatable structure.
[0029] A method of manufacturing the inflatable structure is disclosed. The method can include making a shell. The shell can have a central section, a first neck section, and a second neck section. The first neck section can be distal to the central section and the second neck section can be proximal to the central section. The method can include cutting apertures in the first neck section. The method can include loading the balloon into the shell. The method can include pressing the balloon again the shell. The method can include fixing that balloon to the inside of the shell.
[0030] Making the shell can include applying a first film on the first neck section, and applying a second film to the first neck section. Making the shell can include adding a first layer and a second layer to the shell. The first layer can have a first fiber. The second layer can have a second fiber. The method can include compressing the balloon in the shell. Compressing can include forming the balloon such that at least 5% of balloon circumference can contact the shell in the central section of the shell. Loading can include inserting the balloon through the aperture.
[0031] Another method of manufacturing the inflatable structure is disclosed. The method can include forming a balloon along a longitudinal axis of the balloon. Forming can include bending the balloon at a flexion section of the balloon. The method can also include joining the balloon in a compression fixture. The compression fixture can have the same inner diameter as the shell.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1A illustrates a variation of the device.
[0033] FIG. 1B illustrates a variation of cross section A-A of FIG. 1 .
[0034] FIG. 2A illustrates a variation of the device.
[0035] FIG. 2B illustrates a variation of the device.
[0036] FIG. 2C illustrates a variation of the device.
[0037] FIGS. 3A through 3D illustrate variations of the device.
[0038] FIGS. 4 through 6 illustrate variations of the device.
[0039] FIG. 7A illustrates a variation of the device in a partially deflated condition.
[0040] FIG. 7B illustrates a variation of cross-section D-D of FIG. 7A .
[0041] FIG. 7C illustrates a variation of cross-section E-E of FIG. 7A .
[0042] FIG. 7D illustrates a variation of the device in a deflated condition.
[0043] FIG. 8 illustrates a variation of the device.
[0044] FIGS. 9A through 9D illustrate variations of the device.
[0045] FIGS. 10A through 10B illustrate variations of cross-section B-B of FIG. 1A .
[0046] FIGS. 11A through 11B illustrate variations of cross-section C-C of FIG. 3C .
[0047] FIGS. 12 through 14B illustrate variations of the device.
[0048] FIGS. 15 through 18 illustrate variations of the device.
[0049] FIG. 19 illustrates a method of manufacturing a variation of the inflatable device.
[0050] FIG. 20A illustrates a variation of the device.
[0051] FIG. 20B illustrates a variation of a tool for manufacturing a variation of the inflatable device.
[0052] FIG. 20C illustrates a method of manufacturing a variation of the inflatable device.
[0053] FIGS. 21 through 22B illustrate variations of the device.
[0054] FIG. 23A illustrates a variation of the device.
[0055] FIG. 23B illustrates a variation of cross-section F-F of FIG. 23A .
[0056] FIG. 24A illustrates a variation of the device.
[0057] FIG. 24B illustrates a variation of cross-section G-G of FIG. 24A .
[0058] FIG. 25A illustrates a variation of the device.
[0059] FIG. 25B illustrates a variation of cross-section H-H of FIG. 25A .
[0060] FIG. 26A illustrates a variation of the device.
[0061] FIG. 26B illustrates a variation of cross-section J-J of FIG. 26A .
[0062] FIG. 27A illustrates a variation of the device.
[0063] FIG. 27B illustrates a variation of cross-section K-K of FIG. 27A .
[0064] FIG. 27C illustrates a variation of FIG. 27B in a deflated state.
[0065] FIG. 27D illustrates a variation of a close-up cross sectional view of FIG. 27B .
[0066] FIG. 27E illustrates a variation of a close-up cross sectional view of FIG. 27C .
[0067] FIG. 28A illustrates a variation of cross-section K-K of FIG. 27A
[0068] FIG. 28B illustrates a variation of FIG. 28A in a deflated state.
[0069] FIG. 28C illustrates a variation of a close-up cross sectional view of FIG. 28A .
[0070] FIG. 28D illustrates a variation of a close-up cross sectional view of FIG. 28B .
[0071] FIGS. 29 through 31A illustrate variations of the device.
[0072] FIGS. 31B through 31C illustrate details of an element shown in FIG. 31A .
[0073] FIG. 32A illustrates a variation of the device.
[0074] FIG. 32B illustrates a variation of a cross section of the device shown in FIG. 32A .
[0075] FIG. 32C illustrates a variation of the device.
[0076] FIG. 32D illustrates a variation of a cross section of the device shown in FIG. 32C .
[0077] FIGS. 33A through 33B illustrate variations of the device.
[0078] FIG. 34 illustrates a variation of the device in a deflated state.
[0079] FIGS. 35A through 35D illustrate variations of a fiber matrix.
[0080] FIG. 36 illustrates a variation of a tool for manufacturing a variation of the inflatable device.
[0081] FIGS. 37A through 37C illustrate a variation of a method for manufacturing the device.
[0082] FIG. 37D illustrates a variation of cross-section L-L of FIG. 37C .
[0083] FIGS. 38A through 38B illustrate a method for manufacturing the device.
[0084] FIGS. 39A through 39C are transverse cross-sections of variations of fiber tows in various configurations during a method of manufacturing.
[0085] FIGS. 40A through 40H illustrate a method of making a panel.
[0086] FIGS. 41A through 42C illustrate variations of a panel.
[0087] FIGS. 43A through 43B illustrate a method for manufacturing the device
[0088] FIG. 44 illustrates a method for manufacturing the device.
[0089] FIGS. 45A and 45B illustrate a method for manufacturing the device
[0090] FIGS. 46A through 46B illustrate variations of a panel.
[0091] FIG. 47 illustrates a variation of a method for removing the mandrel.
[0092] FIGS. 48A through 48C illustrate a method for manufacturing the device
[0093] FIGS. 49A through 49F illustrate a method for manufacturing the device
[0094] FIG. 50 illustrates a variation of a deployment tool for the device.
[0095] FIG. 51 illustrates a cross-section of a variation of the device contracted inside of a tube.
[0096] FIG. 52 illustrates a cross section of a human heart.
[0097] FIG. 53 is a graph showing the flow rate on the y-axis for a vascular lumen during stress and at rest corresponding with the percent stenosis of the lumen.
[0098] FIGS. 54A through 54E illustrate a variation of a method for using the device.
[0099] FIGS. 55A through 55F illustrate a variation of a method for using the device.
[0100] FIGS. 56A through 56C illustrate a variation of a method for using the device.
DETAILED DESCRIPTION
[0101] FIGS. 1A and 1B illustrate a shell 678 . The shell 678 can have a shell longitudinal axis 26 . The shell 678 can have a shell wall 684 with an average shell thickness 686 .
[0102] The shell 678 can be a tube or a sheath or combinations thereof.
[0103] FIG. 1B illustrates a cross section A-A of shell 678 . The shell can have a shell proximal stem 30 and/or a shell proximal taper 34 and/or a central section 38 and/or a shell distal taper 42 and/or a shell distal stem.
[0104] The shell 678 can have shell length 28 . Shell length 28 may be the sum of lengths 32 , 36 , 40 , 44 and 45 . The shell 678 can have a shell proximal stem 30 having a shell proximal stem length 32 . The proximal stem length 32 can be from about 3 mm to about 15 mm, more narrowly about 10 mm. The shell 678 can have a shell proximal taper 34 having a shell proximal taper length 36 . The shell proximal taper length 36 can be from about 0 mm to about 25 mm, more narrowly from about 10 mm to about 22 mm, yet more narrowly from about 16 mm to about 20 mm. The shell 678 can have a central section 38 having a central section length 40 . The central section length 40 can be from about 0 mm to about 55 mm, more narrowly from about 30 mm to about 50 mm. The shell 678 can have a shell proximal taper 42 having a shell proximal taper length 44 . The shell proximal taper length 44 can be from about 0 mm to about 25 mm, more narrowly from about 10 mm to about 22 mm, yet more narrowly from about 16 mm to about 20 mm. The shell 678 can have a shell distal stem 43 having a shell proximal stem length 45 . The proximal stem length 45 can be from about 3 mm to about 15 mm, more narrowly about 10 mm. The shell length 28 can be from about 10 mm to about 250 mm, more narrowly from about 50 mm to about 150 mm, still more narrowly about 75 mm to about 125 mm.
[0105] The shell 678 can have a shell central section outer diameter 50 . The central section 38 may have a shell inside radius 706 and a shell outside radius 708 . Diameter 50 may be twice shell outside radius 708 . The central section 38 may be cylindrically shaped, as shown. The shell central section outer diameter 50 can be from about 2 mm mm to about 40 mm, more narrowly about 8 mm to about 30 mm, still more narrowly from about 16 mm to about 28 mm, for example 26, 24, 22 or 20 mm.
[0106] The central section 38 may have a shell outside radius 708 . The shell outside radius 708 can have a maximum dimension at the longitudinal location where the central section 38 meets the tapers 34 or 42 . The shell outside radius 708 can have a minimum dimension in the longitudinal center of the central section 38 .
[0107] The shell 678 can have a shell proximal stem diameter 31 . The shell proximal stem diameter 31 can be from about 0.5 mm to about 8 mm, more narrowly about 1 mm to about 5 mm, for example about 3 mm. The shell 678 can have a shell distal stem diameter 41 . The shell distal stem diameter 41 can be from about 0.5 mm to about 8 mm, more narrowly about 1 mm to about 5 mm, for example about 3 mm.
[0108] The shell 678 can have one or more neck sections adjacent to and extending from the central section 38 . For example, a proximal neck section can be a shell proximal taper 34 extending proximally from the central section 38 . A distal neck section can be a shell distal taper 42 extending distally from the central section 38 . Each of the neck sections can have a neck first end 60 and a neck second end 62 . The neck first end 60 can have identical or different dimensions that the neck second end 62 . The neck first end 60 may be adjacent to the central section 38 . The neck first end 60 can have a neck first end diameter 61 . The neck second end 62 can have a neck second end diameter 63 . The neck first end diameter 61 can be larger than the neck second end diameter 63 . The neck sections can be tapered, conical, multi-splined (e.g., having a plurality of concave and a plurality of convex portions on each neck section), or combinations thereof.
[0109] The shell 678 can have an inner lumen 154 A and an outer lumen 154 B. Inner lumen 154 A may be formed by second hollow shaft 2000 B. Inner lumen 154 A may provide a lumen thru the entire shell. Inner lumen 154 A may allow a guidewire to pass thru the interior of the shell. Outer lumen 154 B may connect to balloon inflation/deflation ports 654 . Outer lumen 154 B may be formed between the inner wall of first hollow shaft 2000 A and the outer wall of second hollow shaft 2000 B.
[0110] The distal taper angle 90 A can be from about 0 to about 90°, more narrowly about 50° to about 20°, yet more narrowly about 45° to about 30°, for example about 35°. The proximal taper angle 90 b can be from about 0 to about 90°, more narrowly about 50° to about 20°, yet more narrowly about 45° to about 30°, for example about 35°.
[0111] The first hollow shaft 2000 a can have a hollow shaft distal port 54 . One of the balloon inflation/deflation ports 654 can attach to the hollow shaft distal port 54 .
[0112] The shell 678 can be resilient (i.e., elastic) or non-compliant (i.e., inelastic).
[0113] If shell 678 is configured to be patent and used as a balloon, the shell 678 may have a burst pressure of greater than 3 atm, more narrowly, greater than 10 atm, still more narrowly greater than 15 atm. If shell 678 is configured to be patent and used as a balloon, the shell 678 may have a diametric elasticity of less than 0.35 mm/atm, more narrowly less than 0.2 mm/atm, still more narrowly less than 0.03 mm/atm, still more narrowly less than 0.02 mm/atm.
[0114] The shell wall 684 can have high puncture strength. For example, when a shell 678 is pressurized to about 4 atm and a 1 mm gauge pin is driven into the balloon at about 1 mm/sec, the pin may need to exert more than 13 newtons of force to puncture the balloon wall, more narrowly more than 18 newtons. The shell wall 684 can be non-compliant. The shell wall 684 can have a polymer. The shell wall 684 can be fluid-tight (e.g., non-porous enough to prevent water, and/or saline solution, and/or air transfer or osmosis through the shell wall 684 ). The shell wall 684 can have a wall thickness of about 0.04 mm to about 0.8 mm.
[0115] FIG. 2A shows a shell 678 with first, second and third shell taper reinforcements 862 a , 862 b and 862 c respectively in the proximal taper 34 and fourth, fifth and sixth shell taper reinforcements 862 d , 862 e and 862 f respectively in the distal taper. Each of the shell taper reinforcements 862 may have different sizes, for instance different lengths. In FIG. 2A , shell taper reinforcements 862 can be arranged such that a portion of each reinforcement 862 is visible. Shell taper reinforcements 862 may cover part or all of the shell tapers 34 and 42 , stems 30 and 43 and central section 38 . Shell taper reinforcements 862 may have shell taper reinforcement lobes 866 . Shell taper reinforcement lobes 866 may have a semi-circular shape and extend in the shell longitudinal direction, as shown in FIG. 2A . Shell taper reinforcements 862 may increase the stiffness of the shell wall 684 in areas covered by shell taper reinforcements 862 . For example, either or both the neck sections 34 and/or 42 can have a greater stiffness than the central section 38 . Shell taper reinforcements 862 may be panels 196 . Shell wall 684 may comprise a polymer such as PET, Mylar, Nylon, Pebax, polyurethane or combinations thereof.
[0116] FIG. 2B shows a shell 678 with shell apertures 714 . Shell apertures 714 may penetrate the entire wall of the shell 678 . Shell apertures 714 may release internal pressure from the shell 678 and may allow materials such as blood or air to cross the plane of the shell wall 684 . The shell apertures 714 can be in fluid communication with the inside and outside of the shell 678 . Shell apertures 714 may be circular, elliptical, rectangular, teardrop shaped, hexagonal or other shapes or combinations thereof. Shell apertures 714 may be located in the shell proximal stem 30 , the proximal taper 34 , the central section 38 , the distal taper 42 or the shell distal stem 43 or combinations thereof. There may be less than 500 apertures 714 in shell 678 , more narrowly less than 100, still more narrowly less than 25. For instance, there may be 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23 or 24 apertures 714 in shell 678 .
[0117] FIG. 2C illustrates that shell 678 may have teardrop shaped shell apertures 714 . Shell apertures 714 may be cut through shell taper reinforcements 862 . The portion of the edge of the shell aperture 714 that extends furthest towards the longitudinal center of the shell 678 may align with the part of the shell taper reinforcement lobe 866 that extends furthest towards the longitudinal center of shell 678 as shown in FIG. 2C . Thus the aperture 714 can be angularly aligned with lobe 866 .
[0118] FIGS. 3A , 3 B, 3 C and 3 D illustrate that the shell 678 can have reinforcement fibers 86 . Second or latitudinal reinforcement fibers 86 a can be perpendicular to the shell longitudinal axis 26 . Fibers 86 a may be one continuous fiber wound around the part (a “hoop wind”). Fibers may be applied with a certain density. For example, fibers may be applied at 100 winds per 1 inch (25.4 mm). The number of winds per inch is often referred to as the “pitch” of the wind. The pitch can vary across the length of the shell. Fibers 86 a may be omitted entirely from portions of the shell 678 .
[0119] First or longitudinal reinforcement fibers 86 b can be parallel with the shell longitudinal axis 26 . Fibers can be applied with a certain density. For instance, there may be 50 fibers 86 b per 1 inch (25.4 mm) around the circumference of the shell 678 . Fiber 86 b density can vary around the circumference of the shell. Fibers 86 b may be omitted entirely from portions of the shell 678 .
[0120] The angle between fibers 86 a and 86 b may be approximately perpendicular and may not change between inflation and deflation.
[0121] FIGS. 3A , 3 B, 3 C and 3 D show that the shell can have a longitudinal proximal zone 618 a , a longitudinal central zone 618 b and a longitudinal distal zone 618 c . Proximal zone 618 a may cover the proximal taper 34 and proximal stem 30 . Distal zone 618 c may cover the distal taper 42 and distal stem 43 . Central zone 618 b may cover the central section 38 . Fibers 86 a and/or 86 b may be present or absent in zones 618 a and/or 618 b and/or 618 c . The fiber 86 a pitch may be different in each of zones 618 a , 618 b and 618 c . The fiber 86 a pitch may vary within each of zones 618 a , 618 b and 618 c . The fiber 86 b density may be different in each of zones 618 a , 618 b and 618 c . The fiber 86 b density may vary within each of zones 618 a , 618 b and 618 c.
[0122] FIG. 3A shows that fibers 86 a and 86 b can be present in zone 618 b . Fibers 86 a and 86 b may not present in zones 618 a and 618 c . FIG. 3B shows that fibers 86 b can be present in zones 618 a , 618 b and 618 c . Fibers 86 a may be present only in zone 618 b . FIG. 3C shows that fibers 86 b and 86 a can present in zones 618 a , 618 b and 618 c . FIG. 3D shows that the pitch of fibers 86 a in zone 618 b may be less than the pitches in zones 618 a and 618 c . The pitches in zones 618 a and 618 c may be substantially equivalent. For example, the pitch in zones 618 a and 618 c may be 128 winds per inch, while the pitch in zone 618 b may be 100 winds per inch. Lower pitch fibers 86 in one zone 618 may cause the shell wall to structurally fail in the lower pitch zone 86 before the pitch zones 86 with a higher fiber pitch. In the example above, zone 618 b can burst before zones 618 a and 618 c when the shell wall 684 experiences structural failure. Zones 618 with lower pitch may be more compliant and foldable than zones 618 with higher pitch. A zone 618 may have a 10% lower pitch than the remainder of the part, more narrowly a 20% lower pitch than the remainder of the shell wall 684 .
[0123] The boundaries between zones 618 a and 618 b and between 618 b and 618 c may move. For instance, the boundaries may be located in the shell tapers 34 or 42 or the central section 38 . Second or latitudinal reinforcement fibers 86 a may or may not be a continuously wound single fiber.
[0124] FIG. 4 illustrates that first reinforcement fiber 85 a can be at a first reinforcement fiber angle with respect to the shell longitudinal axis 26 . For instance, the first reinforcement fiber angle can be 10, 15, 20, 25, 50, 55 or 60 degrees to the shell longitudinal axis. Second reinforcement fiber 85 b can be at a second reinforcement fiber angle with respect to the shell longitudinal axis 26 . For instance, the second reinforcement fiber angle can be 10, 15, 20, 25, 50, 55 or 60 degrees to the shell longitudinal axis. Second reinforcement fiber 85 b can have an equal but opposite angle to first reinforcement fiber 85 a . For example, first reinforcement fiber 85 a can be at +20 degrees and second reinforcement fiber 85 b can be at −20 degrees to the shell longitudinal axis. Third reinforcement fiber 85 c can be substantially perpendicular to the shell longitudinal axis. Third reinforcement fiber 85 c may be omitted from the shell wall 684 .
[0125] FIG. 5 illustrates longitudinal reinforcement fiber 86 b can be parallel with the shell longitudinal axis 26 . Second longitudinal reinforcement fiber 87 b can be parallel with the shell longitudinal axis 26 . Fibers 86 b and 87 b can be separated by areas of missing longitudinal fiber 614 . Areas 614 may separate fibers 86 b and 87 b by 2 mm, more narrowly less than 1 mm, still more narrowly less than 0.25 mm. Areas 614 may be distributed on the shell surface such that no area longitudinally substantially overlaps any other area on the shell. Areas 614 may be distributed such that latitudinally adjacent areas do not have any longitudinal overlap. Areas 614 may be distributed in a regular, repeating pattern around the diameter of the shell sufficient to prevent any fiber from reaching from one end of the shell to the other while still maximizing the longitudinal strength of the shell. Fibers 86 B and 87 B may be less than 80% as long as the shell, more narrowly less than 75%, still more narrowly less than 70%, still more narrowly less than 65%, still more narrowly less than 60%. Second or latitudinal reinforcement fibers 86 a can be substantially perpendicular to the shell longitudinal axis 26 .
[0126] FIG. 6 illustrates that the longitudinal reinforcement fiber 86 b can be parallel with the shell longitudinal axis 26 . Second longitudinal reinforcement fiber 87 b can be parallel with the shell longitudinal axis 26 . Fibers 86 b and 87 b can overlap in reinforcement fiber overlap area 612 . Reinforcement fiber overlap area 612 may form a hoop shaped area that can completely encircle the central section 38 .
[0127] FIG. 7A illustrates that a shell 678 can be pleated to form flutes 84 , for example four, five, six, seven or eight flutes 84 , such as first flute 84 a , second flute 84 b . The flutes 84 can be made from accordion pleats, box pleats, cartridge pleats, fluted pleats, honeycomb pleats, knife pleats, rolled pleats, or combinations thereof. The pleating can be heat and/or pressure formed and/or the reinforcement fibers and/or panels can be oriented to form the flutes 84 . Pleating the shell 678 may create first inner pleat line 822 a and second inner pleat line 822 b and outer pleat lines 826 a between inner pleat lines 822 a and 822 b . Pleat lines 822 and 826 may be areas where the shell wall 684 can be creased. Inner pleat lines 822 may be positioned radially inward from outer pleat lines 826 when the shell is collapsed as shown in FIG. 7A . Each flute 84 can be the portion of the shell wall 684 between two inner pleat lines 822 . The shell apertures 714 can be between adjacent outer pleat lines 826 and interrupt an inner pleat line 822 as shown. The apertures 714 may or may not cross an inner pleat line 822 . The apertures 714 may or may not cross an outer pleat line 826 .
[0128] FIG. 7B illustrates a section view at D-D of FIG. 7A . The portion of the section view that shows aperture 714 is highlighted with a dotted line. The width of aperture 714 at section D-D can be divided into aperture first partial width 830 and aperture second partial width 834 . Aperture first partial width 830 may be about the same as aperture second partial width 834 . For example, the aperture 714 can be centered on the inner pleat line 822 . The aperture first partial width 830 may be different than width 834 , for instance equal to one to three times width 834 , thus placing aperture 714 off center from inner pleat line 822 . Aperture 714 can be wholly between two adjacent outer pleat lines 826 , for instance between outer pleat lines 826 a and 826 b.
[0129] FIG. 7C illustrates a section view at E-E of FIG. 7A . The central zone of the shell can have apertures or no apertures (as shown) interrupting the shell wall 684 , as shown at section E-E.
[0130] FIG. 7D illustrates that the pleated shell 678 or annular balloon structure 682 can be collapsed into a compact form with a reduced diameter. Pleating may allow the shell 678 or structure 682 to collapse and expand in a repeatable and regular way. In this collapsed state, apertures 714 may be wholly (as shown) or partially covered or concealed by collapsed flutes 84 , for instance second flute 84 b may cover or conceal aperture 714 . Covering the apertures 714 may give the collapsed shell 678 or annular balloon 682 an outer surface free of interruptions from the apertures 714 . The diameter of the structure can be minimized and the apertures can be covered by the structure surface before and during insertion of the structure into the body during a medical procedure.
[0131] Annular balloon structure 682 may be subjected to a first cycle and a second cycle of inflation and deflation. Annular balloon structure 682 may have the same number of pleats after first and second cycles of inflation and deflation. For example, the fold position angle of the pleats, and the number and location of the pleats can remain about constant after an inflation and deflation cycle.
[0132] A material, such as a gas or a liquid, may flow from the shell exterior 49 through shell apertures 714 on one taper of the shell (for instance, the distal taper 42 ), pass through the shell interior 47 and flow out of shell apertures 714 on the other taper of the shell (for instance, the proximal taper 34 ) to the shell exterior 49 . FIG. 8 shows that apertures 714 may be fitted with shell aperture unidirectional flow valves or flaps 718 , for instance apertures 714 may be fitted with shell aperture flaps 718 on proximal taper 34 . Shell aperture flaps 718 may be configured so that they will partially or completely cover apertures 714 when there is no material flowing through the shell interior 47 to the proximal end, for example, of the shell exterior 49 . When material is urged to flow with sufficient pressure from the shell interior 47 to the shell exterior 49 , flaps 718 may open to allow flow through apertures 714 . When pressure is reduced or removed, flaps 718 may partially or completely cover apertures 714 . Flaps 718 may act as one-way or two-way valves. For example, flow and flow pressure (e.g., of a body fluid such as blood) through the apertures 714 may be generated by a beating heart during a medical procedure. Flaps 718 may be a temporary or permanent replacement for a heart valve (such as the aortic valve) during a medical procedure. Flaps may be made of a polymer film or be made similar to the shell wall 684 described herein or be made of a compliant material such as, for instance, an elastomer. The flap may be made integral to the shell by cutting the aperture 714 but omitting the circumferential cut, for example leaving a hinge 719 .
[0133] FIG. 9A shows a pattern for a marker wire 190 . Marker wire 190 may be wound around the shell 678 . The marker wire 190 can partially cover the distal and proximal ends of the central section 38 of the shell 678 .
[0134] FIG. 9B shows that marker wire 190 may be wound around the shell on both the distal 42 and proximal tapers 34 of the shell 678 . The marker wire 190 may be wound up to the distal and proximal borders of the central section 38 without any substantial amount of the wire being placed in the central section 38 . The marker wire may be wound in a helical pattern in both directions on the shell or be wound in a single direction. The marker wire crossing angle 191 between two layers of marker wire may be less than 20 degrees, more narrowly less than 10 degrees, still more narrowly less than 6 degrees.
[0135] FIG. 9C illustrates that the shell 678 can have a marker wire 190 wrapped over approximately the entire length of central section 38 . The marker wire 190 may be centered on the central section 38 . The marker wire 190 may cover only a portion of the central section 38 . For instance, the marker wire 190 may cover more than 70% of the central section 38 , more narrowly more than 80%, still more narrowly more than 90%. The marker wire 190 may cover a portion of the distal tapers 42 and proximal tapers 34 . For example, the marker wire 190 may cover 100% of the distal tapers 42 and proximal tapers 34 , more narrowly more than 50%, still more narrowly more than 25%. The marker wire 190 may be a latitudinal reinforcement fiber 86 a.
[0136] FIG. 9D illustrates that the shell 678 can have a marker wire 190 wrapped over substantially the whole length of the shell 678 .
[0137] The pitch of the marker wire 190 may be less than about 150 winds per 1 inch (25.4 mm), more narrowly less than about 75 winds per 1 inch (25.4 mm), still more narrowly less than about 25 winds per 1 inch (25.4 mm), still more narrowly less than about 10 winds per 1 inch (25.4 mm). The pitch of the marker wire 190 may be about 6, 5, 4, 3 or 2 winds per 1 inch (25.4 mm).
[0138] FIG. 10A illustrates that the shell wall 684 at section B-B or at other sections taken through a single wall of the shell can have a layer 72 that can have a fiber matrix. The fiber matrix can have one or more monofilaments 274 and one or more adhesives 208 . The adhesive can remain flexible when cured or melted to form an annular balloon structure 682 . A fiber matrix may comprise a layer 72 or a panel 196 .
[0139] The reinforcement fiber 85 , 86 and 87 can be a monofilament 274 and/or a tow 270 . A tow 270 may contain one or more monofilaments 274 . Reinforcement fiber 86 can be a marker wire 190 . A fiber matrix may have one, two or more reinforcement fibers 86 running substantially parallel to each other and embedded in an adhesive 208 . The substantially parallel reinforcement fibers 86 may be positioned within the adhesive such that they are touching each other along their length. The substantially parallel reinforcement fibers 86 may be positioned such that there is adhesive separating each fiber along its length.
[0140] FIG. 10A illustrates a layer 72 with a fiber matrix having a layer width 210 in cross-section. The layer width 210 can include a number of monofilaments 274 . The layer 72 can have a linear quantity fiber density measured, for example, as the number of fibers 86 per unit of layer width 210 . The linear quantity fiber density can be equal to or greater than about 500 monofilaments 274 per inch, more narrowly equal to or greater than about 1000 monofilaments 274 per inch, more narrowly equal to or greater than about 2000 monofilaments 274 per inch, yet more narrowly equal to or greater than about 4000 monofilaments 274 per inch. For example, the liner quantity monofilaments 274 density can be from about 1,000 monofilaments 274 per inch to about 2,000 monofilaments 274 per inch.
[0141] The layer 72 with a fiber matrix can have a layer thickness 216 from about 1 μm (0.00004 in.) to about 50 μm (0.002 in.), more narrowly from about 8 μm (0.0003 in.) to about 25 μm (0.001 in.), yet more narrowly from about 10 μm (0.0004 in.) to about 20 μm (0.0008 in.). Monofilaments 274 or fibers 86 may have a non-circular cross section, for instance an oval cross-section.
[0142] Part or all of the shell wall 684 can have a volumetric quantitative density of monofilaments 274 measured, for example, as the number of monofilaments 274 per unit of area. The area quantity monofilaments 274 density can be equal to or greater than about 100,000 monofilaments 274 per square inch, more narrowly equal to or greater than about 250,000 monofilaments 274 per square inch, more narrowly equal to or greater than about 1,000,000 monofilaments 274 per square inch, yet more narrowly equal to or greater than about 4,000,000 monofilaments 274 per square inch. The area quantity of fiber can be about 25% of the area of a wall cross section, more narrowly about 50%, more narrowly about 75%.
[0143] The ratio of the volume of a fiber matrix to the volume of the monofilaments 274 can be about equal to or greater than about 15%, more narrowly equal to or greater than about 30%, more narrowly equal to or greater than about 50%, yet more narrowly equal to or greater than about 75%.
[0144] FIG. 10B illustrates that the outer layer 72 a and the inner layer 72 b can be polymer films, for example as described infra. In any variation, the polymer films can be the same or different polymers, or any combination thereof. The first middle layer 72 c can have a fiber matrix, for example with the fibers oriented as longitudinal fibers 86 b . The second middle layer 72 d can have a fiber matrix, for example with the fibers oriented as latitudinal or hoop fibers 86 a . The third middle layer 72 e can be an adhesive. The fourth middle layer 72 f can be a radiopaque layer, such as a metal foil or wire.
[0145] FIG. 11A is a cross section taken at C-C in FIG. 3C . FIG. 11A illustrates that the outer layer 72 a and the inner layer 72 b can be polymer films, for example as described infra. The first middle layer 72 c can have a fiber matrix, for example with the fibers oriented as longitudinal fibers 86 b . The second middle layer 72 d can have a fiber matrix, for example with the fibers oriented as latitudinal or hoop fibers 86 a . The third middle layer 72 e , the fourth middle layer 72 f and the fifth middle layer 72 g can be shell taper reinforcements 862 . Shell taper reinforcements may be of unequal longitudinal lengths as shown in FIG. 11A . An adhesive may be placed between any of the layers 72 shown. Any of the layers 72 shown in FIG. 11A may be omitted.
[0146] As shown in FIG. 11A , proximal taper 34 or distal taper 42 may have a first wall average shell thickness 686 a . Central section 38 may a second wall average shell thickness 686 b . First wall average thickness 686 a may be greater than second wall average thickness 686 b.
[0147] The shell wall 684 of the proximal taper 34 and/or distal taper 42 can be the same or more stiff per unit of area than the shell wall 684 of the central section 36 . For example, the shell wall 684 of the proximal taper 34 and/or distal taper 42 can have a measured bending stiffness of about two, about three, or about five times greater per unit of area than the shell wall 684 of the central section 36 .
[0148] FIG. 11B is a cross section taken at C-C in FIG. 3C . FIG. 11A illustrates that shell taper reinforcements 862 may be placed nearer to inner layer 72 b than outer layer 72 a.
[0149] A layer 72 can be a panel 196 . Layers 72 and/or panels 196 may comprise a polymer. The polymer may be a film. The thickness of the polymer films can be from about 2 μm to about 50 μm, more narrowly from about 2 μm to about 18 μm, yet more narrowly from about 4 μm to about 12 μm. Films may be metalized or coated to change their surface properties. Metallization or coating may take place before or after a film is formed. Films may be treated chemically or via plasma or via corona treating or by combinations thereof in order to modify their bondability. A layer 72 and/or a panel 196 and/or a film may comprise polyamide, co-polyamide, polyester, co-polyester, ECTFE, Solef, EPTFE, FEP, Kapton, Pebax, HDPE, LDPE, PET, Mylar, micrton, nylon, PEEK, PEN (polyethylene Napthalate), Tedlar, PVF, Polyurethane, Thermoplastic Polyurenthane (TPU), Parylene or combinations thereof.
[0150] The reinforcement fibers 86 can be high strength and inelastic. Inelastic fibers may have a strain to failure of less than 10%, more narrowly less than 5%. High strength fibers may have an ultimate tensile strength greater than 1.8 GPa (260 ksi), more narrowly greater than 2.4 GPa (350 ksi), still more narrowly greater than 2.9 GPa (420 ksi).
[0151] The reinforcement fibers 86 can have a fiber or monofilament diameter 212 , for example, from about 1 μm to about 50 μm, for example less than about 25 μm, more narrowly less than about 20 μm.
[0152] The reinforcement fibers 86 may be a wire or wires. The reinforcement fibers 86 may be a metal. Wire may have a strain to failure of less than 10%, more narrowly less than 5%, still more narrowly less than 2%. The wire may be annealed or tempered to adjust its mechanical properties. The wire may have a breaking strength of greater than 150KSI, more narrowly greater than 250KSI, more narrowly greater than 400KSI
[0153] Wire may be ductile and have a strain to failure of greater than 20%, more narrowly greater than 40%, still more narrowly greater than 80%. Ductile wire may allow the shell 678 the fold without fracturing the wire.
[0154] The wire may be less than 25 um in diameter. The wire may be substantially rectangular and less than 25 um in thickness 1068 , more narrowly less than 15 um in thickness 1068 when integrated into the wall of the balloon. The ratio of the width 1072 of the wire to the thickness 1069 of the wire may be greater than or equal to about 3, more narrowly greater than or equal to about 5, more narrowly greater than or equal to about 10. The wire may be a foil wherein the ratio of the width 1072 of the wire to the thickness 1069 of the wire may be greater than or equal to about 100, more narrowly greater than or equal to about 300, more narrowly greater than or equal to about 500. The density of the wire may be greater than about 2.4 g/cm̂3, more narrowly greater than about 6.9 g/cm̂3, more narrowly greater than about 15 g/cm̂3.
[0155] The reinforcement fiber 86 or wire may be substantially radiopaque when used under a flourosocpe as part of a medical procedure in the human body. The use of radiopaque material, such as radiopaque fibers 86 , may allow the physician to use an inflation medium, such as saline, which is not radiopaque when inflating a balloon 650 or annular balloon structure 682 . The use of radiopaque material, such as radiopaque fibers 86 may allow the physician to visualize how well pleated or folded the balloon structure 682 is when placed in the human body. The fibers 86 may be substantially radiolucent. A fiber matrix can have the same or different sizes and materials of fibers 86 within the same fiber matrix.
[0156] The reinforcement fibers 86 or wires may be coated. The coating may enhance adhesion. The coating may be an adhesive 208 . The adhesive 208 may be melted as part of the process of applying reinforcement fibers 86 to a shell 678 .
[0157] A reinforcement fiber 86 may comprise Vectran, PBO (p-phenylene-2,6-benzobisoxazole), Zylon, Spectra, Dyneema, UHMWPE, Conex, Technora, Twaron, Dacron, Polyester, Compet, Nylon, PEEK, PPS, Boron, Cermic, Kevlar, aramid, Carbon, Carbon Fiber, Inorganic Silicon, glass, fiberglass, Tungsten and its alloys, Tantalum and its alloys, Molybdenum and its alloys, bismuth and its alloys, gold and its alloys, silver and its alloys, platinum and its alloys, iridium and its alloys, stainless steel (for instance, alloys 302, 304, 316, 440), Nickel and its alloys, cobalt and its alloys, Titanium and its alloys, copper and its alloys, Barium and its alloys, bismuth and its alloys, Iodine and its alloys, Nitinol alloys or combinations thereof.
[0158] Adhesive 208 can be an thermoset material, a thermoplastic material, or a combination thereof. Adhesive 208 can be elastomeric. Adhesive 208 can be a polymer or a monomer or combinations thereof. The adhesive 208 can be a urethane, a polyurethane, a thermoplastic polyurethane (TPU), a thermoplastic, a cyanoacrylate, a UV curing adhesive, a polyester, a nylon, a polyamide, a silicone, a polypropylene, a polyolefin, ULDPE, VLPDE, LDPE, an epoxy, a pebax, Tefzel, an EVA, Solef, a parylene or combinations thereof. The adhesive 208 can be a resin or a glue.
[0159] Any of layers 72 or panels 196 can be leak proof, water tight, air tight, MMA (Methyl methacrylate)-resistant, MMA-releasing, or combinations thereof.
[0160] Magnetic resonance visualization enhancement materials, such as magnetic contrast agents, can be added to the adhesive 208 or any layer 72 or panel 196 . The magnetic resonance visualization enhancement materials can enhance the visualization of the balloon during an magnetic resonance imaging (MRI) procedure. For example, the magnetic resonance visualization enhancement material can be gadolium, Omniscan, Optimark, ProHance, Magnevist, Multihance, or combinations thereof.
[0161] Any of the layers 72 , for example the outer layer 72 a , can be tinted or dyed a visible spectrum color. For example, a pigment, coloring additive, dispersions or other coloring agents, such as a coloring additive from Plasticolors (Ashtabula, Ohio) can be added. A paint or coating can be added to the outer surface of the shell 678 .
[0162] The color can be selected for branding, market differentiating, as an indication of the type of device, the size of the device, or combinations thereof. For example, devices having a selected diameter, length, pressure rating, clinical indication or efficacy, other common performance metric, or combinations thereof, can be dyed a specific color (e.g., green for a first type of device, red for a second type of device).
[0163] The layers 72 can have one or more optical fibers. The fiber optic can be a strain sensor. The strain sensor can monitor mechanical status in real time. The fiber optic can guide light delivery into the body. The fiber optic can visualize a target site (e.g., gather light from the body to produce a visual image).
[0164] FIG. 12 shows that a balloon 650 can have a balloon main diameter 662 , a balloon length 666 and a balloon wall thickness 658 . The balloon may have a balloon taper section 652 at either end. The taper sections may connect the balloon diameter to the balloon inflation/deflation ports 654 . The balloon 650 may be inflated by putting a pressurized fluid, such as saline, contrast, water or a gas, into both inflation/deflation ports or by putting fluid into one of the inflation/deflation ports 654 while closing the other inflation/deflation ports 654 .
[0165] Balloon 650 may have a main diameter 662 of about 1 mm to about 15.3 mm, more narrowly about 4 mm to about 12 mm, still more narrowly about 6 mm to about 10 mm. The balloon wall thickness 658 may be about 5 μm to about 50 μm, more narrowly about 8 μm to about 25 μm, still more narrowly about 8 μm to about 15 μm. The balloon length 666 may be about 125 mm to about 635 mm, more narrowly about 200 mm to about 500 mm, still more narrowly about 250 mm to about 380 mm.
[0166] FIG. 13 shows that balloon 650 can have balloon segments 656 a - 656 f . Balloon segments 656 a - 656 f may form a continuous internal inflation/deflation lumen. Each balloon segment 656 may be joined by a balloon flexion section 670 a - 670 e to the adjacent balloon segment 656 . The balloon flexion sections 670 may have a smaller balloon flexion section diameter 664 than the balloon main diameter 662 (i.e., of the balloon segments 656 ). Balloon 650 may have a balloon flexion section diameter 664 of about 1 mm to about 10 mm, more narrowly about 2 mm to about 6 mm, still more narrowly about 2.5 mm to about 5 mm. Balloon 650 may have a balloon flexion section diameter 664 of about 3.3 mm. Multi-segment balloon taper section 653 can connect the balloon flexion sections 670 to the balloon segments 656 . The balloon 650 can bend or flex at the balloon flexion sections 670 before bending at the balloon segments 656 , for example, when the balloon 650 is inflated. The balloon 650 could have 4, 5, 6, 7, 8, 9, 10 or more balloon segments 656 .
[0167] The balloon 650 may be made of one polymer, or use several layers or a mix of different polymers. Polymers such as Nylon, PEBAX, PET, parylene and/or polyurethane may be used to make the balloon 650 . The balloon 650 may be fabricated by blow molding. The balloon may comprise a layer 72 , a panel 196 or a film as described supra.
[0168] Heat shrink tubing may be used to form the balloon 650 . For instance, the balloon 650 could be formed by placing heat shrink tubing over a removable mandrel, heating the tubing and then removing the mandrel. The mandrel may be removed mechanically, with a solvent such as water, by the application of heat, or combinations thereof.
[0169] The balloon 650 may be formed by depositing a material either onto a mandrel or into a cavity mold. The mandrel may be removed as described above or a mold may be opened to remove the balloon 650 . Deposition could be by various techniques of physical vapor deposition, dipping, coating or spraying. Parylene may be deposited using a physical vapor deposition process. The balloon 650 may be deposited directly onto a mandrel with the shape shown in FIGS. 15 , 16 , 17 and 18 . The mandrel could then be removed.
[0170] The balloon may comprise a fiber and be designed and fabricated as described in U.S. Provisional Application No. 61/363,793, filed 13 Jul. 2010, and in PCT Application No. PCT/US2011/43925, filed Jul. 13, 2011, both of which are incorporated by reference herein in their entireties.
[0171] FIG. 14A shows a balloon with balloon restraints 674 wrapped around the length of balloon 650 . FIG. 14B shows a balloon with balloon restraints 674 wrapped around the portions of the length of the balloon. The balloon restraints 674 may be bonded to the outside of the balloon. The restraints 674 may be knotted or tied around the balloon. The balloon restraints 674 may serve to narrow and bunch the balloon at the point they are applied, thus creating a balloon flexion section 670 . A balloon flexion section 670 could also be created by locally twisting the balloon.
[0172] FIGS. 15 and 16 show a balloon 650 after balloon segments 656 have been formed into an annular balloon structure 682 and inflated. The balloon segments can form a ring with a clear or hollow passageway or channel in the center. The annular balloon structure working length 680 can be the about equal to the longitudinal length of the largest diameter constant diameter section of each balloon segment 656 . Working length 680 may be about 12 mm to about 100 mm, more narrowly about 25 mm to about 75 mm, still more narrowly 32 mm to 65 mm. Working length 680 may be about 45 mm. The balloon segments 656 may be attached to each other with adhesive, solvent, the application of heat or combinations thereof. FIG. 15 shows that the local balloon diameter of the flexed or relaxed (i.e., unfllexed) flexion section 670 can be less than the main balloon diameter of the balloon segments 656 . FIG. 16 shows a flexion section 670 where the balloon has been bent or folded with no previous narrowing of the balloon diameter. The balloon may be inflated by putting pressure into balloon inflation/deflations ports 654 a and 654 b . The inflation/deflation ports 654 a and 654 b may be joined into a single inflation/deflation port.
[0173] First balloon segment 656 a may have a first balloon segment longitudinal axis 657 a . Second balloon segment 656 b may have a second balloon segment longitudinal axis 657 b . Balloon segment longitudinal axis angle 659 may be the angle between first balloon segment longitudinal axis 657 a and second balloon segment longitudinal axis 657 b . Balloon segment longitudinal axis angle 659 may be zero degrees to 200 degrees, more narrowly, 160 degrees to 200 degrees, for example 180 degrees. The longitudinal axis angle 659 can be the angle formed by the opposite terminal ends of the balloon flexion section 670 adjacent to the respective balloon segments 656 .
[0174] FIG. 17 shows a group of inflated balloons 650 arranged into an annular balloon structure 682 . Rather than sharing an inflation/deflation lumen, each balloon has two inflation/deflation ports 654 . FIG. 18 shows a balloon design with one inflation/deflation port and the other end closed. The balloon in 8B could be arranged into an annular balloon structure 682 similar to that shown in FIGS. 15 , 16 and 17 . Balloons 650 may have their interior volumes connected together by piercing or punching holes in the wall of each balloon and then aligning the holes in each balloon before bonding the balloons 650 together.
[0175] FIG. 19 shows one method of forming the balloon 650 into an annulus. Adhesive 208 or a solvent may be applied to the outside of the balloon. The balloon 650 may be threaded around pins 676 . The balloon flexion section 670 may be twisted about the balloon longitudinal axis, for instance 45 or 90 degrees. A compression fixture, for instance a balloon assembly fixture compression sleeve 898 (e.g., a non-stick tube such as one made out of fluorinated ethylene propylene (FEP), such as Teflon) may be slid over the balloon 650 in order to hold and radially compress the balloon segments 656 together. The balloon assembly fixture compression sleeve 898 may have an inside diameter smaller than the outside diameter of the annular balloon structure 682 shown in, for instance, FIG. 15 , 16 or 17 . A cross section of balloon 650 in balloon assembly fixture compression sleeve 898 may look similar to FIG. 24B with shell 678 being replaced by balloon assembly fixture compression sleeve 898 . Heat may be applied to cure the adhesive 208 or to melt and fuse the segments 656 together.
[0176] FIG. 20A shows a balloon 650 after having been formed into a spiral to make an inflated annular balloon structure 682 . That is, the balloon 650 forms a spiral ring with a central fluid passage 692 in the center. The coils of the spiral may be attached to each other with adhesive, solvent, the application of heat or combinations thereof. The balloon may be inflated by putting pressure into balloon inflation/deflations port 654 . Multiple spiral coils may be interleaved to form one annular balloon structure.
[0177] FIGS. 20B and 20C shows a spiral forming tool 742 . The spiral forming tool has a spiral groove 746 . A nominally straight balloon 650 may be wrapped around the spiral groove and pressurized. The pressurized assembly may be placed in the oven. The balloon dimensions may gradually creep until the balloon has been formed into the spiral shown in 11 a.
[0178] FIG. 21 shows that the balloons 650 can have toroidal configurations. The balloons 650 can be stacked to make an annular balloon structure 682 . The balloons 650 can form a ring with a clear passageway in the center. The balloons 650 may be attached to each other with adhesive, solvent, the application of heat or combinations thereof. The balloons 650 may be inflated by putting pressure into the balloon inflation/deflations port 654 (not shown). The lumens of each balloon 650 may be in fluid communication with one or more (e.g., all) of the other lumens and connected to one or more (e.g., all) of the other lumens internally.
[0179] FIGS. 22A and 22B show the balloon 650 can be attached to a balloon strap 672 . The balloon 650 can be in a spiral configuration. The balloon strap 672 may be removed during a medical procedure such that the balloon 650 may unwind along the first hollow shaft 2000 a . This may make it easier to extract the balloon 650 thru an introducer after a procedure.
[0180] An annular balloon structure may comprise a balloon 650 and a shell 678 .
[0181] FIG. 23A shows that the inflated annular balloon structure can have a shell 678 . The shell 678 may wrap, encircle or enclose the balloon segments 656 . The shell 678 may entirely or partially (as shown) cover the balloon segments 656 .
[0182] FIG. 23B shows a cross section F-F thru the center of the inflated annular balloon structure 682 in FIG. 23A . The annular balloon structure 682 can have a central fluid passage 692 that may allow the annular balloon structure 682 to perfuse when used in a lumen in the body. The annular balloon structure 682 can have an inside radius 690 . This inside radius 690 can be ½ the maximum circular diameter that can pass through central fluid passage 692 of the annular balloon structure 682 . For example, the inside radius might be from about 2.5 mm to about 10 mm, more narrowly from about 5 mm to about 7.5 mm. The inside radius may be about 6.4 mm.
[0183] FIGS. 23B and 24B illustrate that the annular balloon structure 682 may have a first balloon cell 691 a and a second balloon cell 691 b . FIGS. 23B and 24B show a total of 8 balloon cells 691 . Balloon cells 691 a and 691 b may be joined by balloon contact line 710 . Similar balloon contact lines may exist between adjacent balloon cells 691 in FIGS. 23B and 24B . The annular balloon structure 682 may have a balloon contact inner radius 694 and a balloon contact outer radius 698 . These radii are aligned with the innermost and outermost extent of the contact between balloon cells 691 a and 691 b . The difference between the inner and outer contact radii can be about zero. For example the balloon cells 691 a and 691 b can be touching only at a point of tangency. The balloon contact inner radius and outer radius may be about 3.8 mm to about 15 mm, more narrowly about 7.5 mm to about 11.5 mm. The balloon contact inner radius and outer radius may be about 9.5.
[0184] The balloon radius 704 can be the radius of the circle intersecting all of the center axes of each balloon cell 691 . The balloon radius 704 may be about 5 mm to about 15 mm more narrowly about 5 mm to about 13 mm. The balloon radius 704 may be about 10 mm. The shell wall 684 may have a shell average thickness 686 of about 7 μm to about 65 μm, more narrowly about 13 μm to about 38 μm, still more narrowly about 20 μm to about 30 μm. The shell outside radius 708 may be the shell inside radius 706 plus the shell thickness. The shell outside radius 708 may be equal to one half of the shell central section outer diameter 50 .
[0185] The balloon radius 702 may be about 0.5 mm to about 7.6 mm, more narrowly about 2 mm to about 5.8 mm, still more narrowly about 3 mm to about 5 mm. The balloon radius 702 may be about 3.8 mm.
[0186] The balloon cells 691 may have about zero contact with each other and with the inside of the shell 678 (as shown in FIG. 23B at shell contact line 712 ). The leakage area 700 between the inner wall of the shell and the balloon contacts 710 may be 12-22% of the total area enclosed by the shell cross section, more narrowly about 17%. The leakage area may be greater than 10%, more narrowly greater than 15%.
[0187] FIG. 24A shows an inflated annular balloon structure 682 with a shell 678 . The shell 678 may entirely or partially (as shown) cover the balloon segments 656 . The balloon 650 shown in FIG. 24A may have similar or identical dimensions to the balloon 650 shown in FIG. 23A . The shell 678 shown in FIG. 24A may have a smaller shell outside radius 708 than the shell 678 shown in FIG. 23A . The shell 678 in FIG. 24A may be placed over the balloon segments 656 . The shell may compress or squeeze balloon segments 656 such that the balloon segments 656 may be deformed and driven closer to the shell longitudinal axis 26 . The shell 678 may be in tension when the balloon segments 656 are inflated
[0188] FIG. 24B shows a cross section G-G thru the center of the inflated annular balloon structure 682 in FIG. 24A . The annular balloon structure can have a central fluid passage 692 . The central fluid passage 692 can be an open channel along the entire length of the inflated annular balloon structure 682 . The central fluid passage 692 may fluidly connect to apertures 714 in proximal taper 34 and distal taper 42 . When the annular balloon structure 682 is placed in a body lumen, for example in the vasculature, fluid (such as blood) or gas (such as air) in the lumen can flow through the central fluid passage 692 . For example, the balloon can perfuse when in the vasculature or in an airway.
[0189] The annular balloon structure may have a second hollow shaft 2000 b in the central fluid passage 692 . There may be a flow area gap 693 between the second hollow shaft 2000 b and the balloon 650 . The flow area gap 693 might be from about 2 mm to about 10 mm, more narrowly from about 4 mm to about 7 mm, for example 5.5 mm. Second hollow shaft 2000 b is not shown in FIGS. 23A , 23 B and 24 A.
[0190] The inside radius 690 of annular balloon structure 682 shown in FIG. 24B may be, for example, about 2.5 mm to about 10 mm, more narrowly about 3 mm to about 5.6 mm, for example about 4.3 mm. The area of the circle defined by the inside radius 690 may be about 0.091 inches squared or about 0.59 centimeters squared.
[0191] The balloon cells 691 a and 691 b may be joined by balloon contact line 710 , for example with a bond. The annular balloon structure 682 may have a balloon contact inner radius 694 and a balloon contact outer radius 698 . These radii are aligned with the innermost and outermost extent of the balloon contact 710 between balloon cells 691 a and 691 b . The balloon contact inner radius 694 may about 1 mm to about 20 mm, more narrowly 2.5 mm to about 13 mm, more narrowly about 5 mm to about 7.5 mm. The balloon contact inner radius may be about 6.4 mm. The balloon contact outer radius 698 may be about 2 mm to about 20 mm, more narrowly 5 mm to about 15 mm, more narrowly about 7.6 mm to about 12.7 mm. The balloon contact outer radius may be about 10 mm. Balloon contact line 710 can have a contact length about equal to the inner radius subtracted from the outer radius
[0192] The balloon cell perimeter 696 is about equal to the total length of the dotted line 696 shown in FIGS. 23B and 24B (the dotted line matches the wall of the balloon cell 691 ). Balloon cells 691 may have a balloon cell perimeter 696 of about 3 mm to about 48 mm, more narrowly about 12.7 mm to about 37 mm, still more narrowly about 19 mm to about 32 mm, for example about 24 mm.
[0193] The length of the balloon contact line 710 may be greater than about 5% of the balloon cell perimeter 696 , more narrowly greater than about 10%, still more narrowly greater than about 12%, for example about 16%.
[0194] The balloon outer radius 702 a may be about 0 mm to about 5 mm, more narrowly about 0.5 mm to about 3 mm, still more narrowly about 1 mm to about 2.5 mm, for example about 1.5 mm. The balloon inner radius 702 b may be about 0.5 mm to about 7.5 mm, more narrowly about 1 mm to about 5 mm, still more narrowly about 1.5 mm to about 3.8 mm, for example about 2.5 mm.
[0195] The leakage area 700 between the inner wall of the shell 678 and the balloon contact line 710 may be less than about 15% of the total area enclosed by the shell cross section, more narrowly less than about 10%, still more narrowly less than about 5%, for example 2%.
[0196] The leakage area 700 can be sealed (no fluid communication) from central fluid passage 692 . The leakage area 700 can be connected to a pressure source accessible by the physician. Leakage area 700 may contain a fluid, for instance, a drug. Shell wall 684 may have pores, for instance holes less than 0.005 mm in diameter. Shell wall 684 may perfuse from shell interior 47 to shell exterior 49 . Pressurizing the fluid in leakage area 700 may cause the fluid in area 700 to travel from shell interior 47 to shell exterior 49 .
[0197] The arc length of the shell contact line 712 may be about 1.3 mm to about 10 mm, more narrowly about 3.3 mm to about 8.4 mm, still more narrowly about 4 mm to about 7.5 mm, for example about 5.8 mm.
[0198] FIG. 24 b illustrates that the balloon cells 691 at the shell contact line 712 can be concentric with the shell 678 , for example with the shell inner perimeter. The length of the wall of the balloon cells 691 at the shell contract line 712 can be equal to or greater than about 5%, more narrowly equal to or greater than about 10%, yet more narrowly equal to or greater than about 20%, of the balloon cell perimeter 696 (i.e., the total length of the wall of the balloon cells in lateral section, i.e., the section shown in FIG. 24 b ).
[0199] The shell inner perimeter in a plane can be about equal to the shell inside radius 706 multiplied by 2 multiplied by pi. The sum of the arc lengths of all the shell contact lines 712 in a plane in the annular balloon structure 682 may be greater than 30% of the shell inner perimeter, more narrowly greater than 45%, still more narrowly greater than 55%, for example 61%.
[0200] A bond may be formed between the balloon segment 656 and the shell 678 at the shell contact line 712 with adhesive, solvent, heat or combinations thereof. The shell 678 may have adhesive 208 on the shell inside surface, for instance a thermoplastic or a thermoset.
[0201] The arc length of the shell contact line 712 may be greater than 10% of the balloon cell perimeter 696 , more narrowly greater than 15%, still more narrowly greater than 20%, for example 24%.
[0202] FIG. 25 a shows an inflated spiral balloon 650 (such as shown in FIG. 20 a ) with a shell 678 . The shell 678 may wrap, encircle or enclose the balloon 650 . The shell 678 may entirely or partially (as shown) cover the balloon 650 . FIG. 25 b shows a longitudinal cross-section H-H of the annular balloon structure 682 shown in FIG. 25A .
[0203] FIG. 26 a shows an inflated spiral balloon with a shell 678 . The balloon 650 shown in FIG. 26A may have similar or identical dimensions to the balloon 650 shown in FIG. 25A . The shell 678 shown in FIG. 26A may have a smaller shell outside radius 708 than the shell 678 shown in FIG. 25A . The shell 678 in FIG. 26A may be placed over the balloon 650 . The shell may compress or squeeze balloon 650 such that the balloon 650 may be deformed and driven closer to the shell longitudinal axis 26 . The shell 678 may be in tension when the balloon 650 is inflated. FIG. 17 b shows a longitudinal cross-section of a spiral balloon with a shell 678 . Shell contact line 712 may be oriented in the longitudinal direction. Shell leakage area may be shaped like a spiral.
[0204] FIGS. 27A and 27B illustrate that the shell 678 can have a balloon 650 in the shell interior 47 . Shell strut 716 may contain additional elements not included in the shell central section 38 . For example, shell strut 716 may comprise additional longitudinally aligned fiber and/or additional fiber at other angles to the longitudinal axis and/or an additional polymer film and or shell taper reinforcements 862 . The polymer film may have a low coefficient of friction on the outermost surface, for example it may have a coefficient of friction of less than 0.25, more narrowly less than 0.15, still more narrowly less than 0.1. Proximal taper 34 and distal taper 42 may help to introduce and withdraw the annular balloon structure 682 through a standard vascular introducer. For instance, the tapers 34 and 42 may protect the balloon 650 from being damaged by rubbing on the vascular introducer or features, such as calcifications, in the body. The tapers 34 and 42 may guide the annular balloon structure 682 thru the introducer.
[0205] FIG. 27B shows cross section K-K of an inflated annular balloon structure 682 . FIG. 27D shows a closeup of a portion of FIG. 27B . Balloon segments 656 can be compressed by shell 678 . The annular balloon structure 682 can have a second hollow shaft 2000 b , a third hollow shaft 2000 c and a fourth hollow shaft 2000 d . As shown in FIGS. 27B and 27D , fourth hollow shaft 2000 d can fit over the outsides of shafts 2000 b and 2000 c to make shafts 2000 b and 2000 c approximately coaxial. Shafts 2000 b and 2000 c may slide within in the inside diameter of shaft 2000 d . Shafts 2000 b and 2000 c may be in fluid communication. A hollow shaft gap 2002 is formed between the distal end of shaft 2000 b and the proximal end of shaft 2000 c.
[0206] FIG. 27C shows FIG. 27B with the annular balloon structure 682 in a deflated state. FIG. 27E shows a closeup of a portion of FIG. 27C . FIG. 27E shows that shafts 2000 b and 2000 c move within the inside diameter of shaft 2000 d when the annular balloon structure 682 is deflated. Hollow shaft gap 2002 increases when the annular balloon structure 682 moves from an inflated to a deflated state. The second hollow shaft 2000 b , third hollow shaft 2000 c and fourth hollow shaft 2000 d can form an inner lumen 154 a . The inner lumen 154 a can extend thru the center of the annular balloon structure 682 . A guidewire may be inserted into inner lumen 154 a to locate the balloon during a medical procedure. Third hollow shaft 2000 c and fourth hollow shaft 2000 d may be omitted and second hollow shaft 2000 b may be extended to catheter tip 838 .
[0207] First hollow shaft 2000 a may be in fluid communication with hollow shaft distal port 54 and balloon inflation/deflation ports 654 . The addition of fluid or gas into ports 654 may cause balloon segments 656 to inflate and for the annular balloon structure 682 to expand. Removal of fluid or gas from ports 654 may cause balloon segments 656 to deflate and for the annular balloon structure 682 to return to a pleated state, for example as shown in FIG. 7C .
[0208] FIG. 28A shows cross section K-K of an inflated annular balloon structure 682 . FIG. 28C shows a closeup of a portion of FIG. 28A . The annular balloon structure can have a second hollow shaft 2000 b that slidably fits into catheter tip 838 . A hollow shaft gap 2002 is formed between the distal end of shaft 2000 b and the catheter tip pocket bottom 840 . The catheter tip 838 may have a catheter tip exit 841 . Fluid flow 870 (shown with a dashed line in FIG. 28A ) may pass through shell apertures 714 on the distal taper 42 or proximal taper 34 , into central fluid passage 692 and through shell apertures 714 on the proximal taper 34 or distal taper 42 .
[0209] FIG. 28B shows FIG. 27A with the annular balloon structure 682 in a deflated state. FIG. 28D shows a closeup of a portion of FIG. 28B . FIG. 28D shows that shaft 2000 b moves within the catheter tip 838 when the annular balloon structure 682 is deflated. Hollow shaft gap 2002 increases when the annular balloon structure 682 moves from an inflated to a deflated state. The second hollow shaft 2000 b can form an inner lumen 154 a . Inner lumen 154 a may be in fluid communication with the catheter tip exit 841 .
[0210] FIG. 28A shows that balloon flexion sections 670 may stay within the volume enclosed by shell central section 38 with central length 40 . FIG. 27B shows that balloon flexion sections 670 may touch the shell wall 684 in taper sections 42 and 34 .
[0211] FIGS. 29 and 30 show that the annular balloon structure 682 can have 2, 3, 4, 5, 6, 7, 8 or more support members 722 and/or support sheets 726 . The support members 722 and/or support sheets 726 may cross the central fluid passage 692 . Support members 722 and/or sheets 726 may be anchored to balloon segments 656 and/or second hollow shaft 2000 b . Sheets 726 may be notched or forked so that they may pass by each other. Support members 722 and/or sheets 726 may be constructed similarly similar to the shell wall 684 and be substantially non-compliant. Support members 722 and/or sheets 726 may be semi-compliant, compliant or highly compliant. Support members 722 and/or sheets 726 may made of an elastomer such as urethane. Support members 722 and/or sheets 726 may comprise a fiber. Support members 722 and/or sheets 726 may have a strain to failure of less than about 10%. Support members 722 and/or sheets 726 may be in tension when the annular balloon structure 682 is inflated and serve to control the maximum diameter of the annular balloon structure 682 when inflated. When pressure is withdrawn from the annular balloon structure 682 , support members 722 and/or sheets 726 may help to collapse the structure 682 in a way that helps pleats or flutes to re-form. The re-forming of pleats or flutes may make the collapsed balloon easier to withdraw through body lumens, for example through the vasculature and through an introducer.
[0212] FIG. 31A show that a valve 730 may be placed in central fluid passage 692 . FIGS. 31A and 31B show the valve 730 in a closed position. FIG. 31C shows the valve 730 in an open position. The valve leaflets 734 may be anchored to the balloon segments 656 or the inside of the shell wall 684 . The valve leaflets can be thin and flexible. The valve leaflets may contact the outside of second hollow shaft 2000 b when in a relaxed state.
[0213] Referring to FIG. 31A , central fluid passage 692 may be filled with a liquid or a gas. When the pressure in the liquid or gas is higher in the distal taper 42 than the proximal taper 34 , valve leaflets 734 may open (as shown in FIGS. 31A and 31C ) to allow fluid flow 870 through the central fluid passage. When the pressure difference in the liquid or gas between the distal taper 42 and the proximal taper 34 is reduced or removed the valve leaflets 734 may shut and reduce or eliminate fluid flow in central fluid passage 692 . Valve leaflets 734 may act as a one way valve. A pressure difference in the liquid or gas between the distal taper 42 and the proximal taper 34 pressure may be generated by a beating heart during a medical procedure. Valve leaflets 734 may serve as a temporary replacement for a heart valve (such as the aortic valve) during a medical procedure. Valve leaflets 734 may be made of a polymer film or be made similar to the shell wall 684 or be made of a highly compliant material such as, for instance, an elastomer.
[0214] The exterior of shell wall 684 may be coated with a drug, such as paclitaxel. The drug may be delivered to the body when the annular balloon structure 682 is inflated during a medical procedure. Layer 72 or panel 196 may comprise a drug. For instance, Layer 72 or panel 196 could be a film soaked in a drug, a film with pores to hold drugs, a fiber matrix holding drugs or combinations thereof. Layer 72 may be an outer layer 72 a , an inner layer 72 b or a middle layer, such as 72 c.
[0215] FIG. 32A shows a capsule 874 . Capsule 874 may be an annular balloon structure 682 . FIG. 32B shows a cross section of the capsule 874 in FIG. 32A . Capsule 874 may have a capsule length 878 , a capsule diameter 882 and capsule inside diameter 890 .
[0216] FIG. 32C shows a capsule 874 with hourglass shape on the outer diameter. FIG. 32D shows a cross section of the capsule 874 in FIG. 32C . Capsule 874 may have a capsule waist diameter 886 .
[0217] The capsule length 878 divided by the capsule diameter 882 may form a capsule length to width ratio. The capsule length to width ratio may be from about 10:1 to about 1:1, more narrowly from about 5:1 to about 1:1, more narrowly still from about 3:1 to 1:1. The capsule waist diameter 886 may less than about 90% of capsule diameter 882 , more narrowly less than about 80% of capsule diameter 882 , still more narrowly less than about 70% of capsule diameter 882 .
[0218] FIG. 33A shows a capsule 874 with capsule taper section 894 and capsule inflation port 896 . Providing material, such as a liquid or a gas, at capsule inflation port 896 may cause capsule 874 to inflate. Withdrawing material at capsule inflation port 896 may cause capsule 874 to deflate.
[0219] FIG. 33B shows that a first capsule 874 a and a second capsule 874 b may be aligned concentrically and in contact to form an annular balloon structure 682 with an hourglass shape. First capsule 874 a may be inflated or deflated at first inflation port 896 a . Second capsule 874 b may be inflated or deflated at second inflation port 896 b . The internal lumens of capsules 874 a and 874 b may be connected over a portion of the area where the capsules touch. Three, Four, Five or more capsules 874 may be joined to form an annular balloon structure 874 .
[0220] FIG. 34 shows a capsule 874 in a pleated condition. Capsule 874 may have a distal taper 42 with a distal taper length 44 of about 0 mm.
[0221] Capsule wall 876 may comprise a fiber matrix, a layer 72 a panel 196 or combinations thereof. FIG. 35 a shows a fiber matrix with fiber 86 and adhesive 208 . The fiber matrix in FIG. 35 a may be referred to as a unidirectional fiber matrix. FIG. 35 b shows a fiber matrix with reinforcement fiber 86 a and reinforcement fiber 86 b at an angle of about 90 degrees to each other. FIG. 35C shows a fiber matrix with reinforcement fiber 86 a and reinforcement fiber 86 b placed at layer angle 738 to one another. Layer angle 738 may be from 45 to 70 degrees, more specifically 45, 50, 55, 60, 65, or 70 degrees. FIG. 35D shows that the fiber matrix shown in FIG. 35D may be combined with another unidirectional fiber matrix. Capsule 874 may have a non-compliant capsule diameter 882 when inflated.
[0222] FIG. 36 illustrates that the shell 678 can be partially or completely manufactured in a pressure chamber 219 . The pressure chamber 219 can be in a pressure chamber case 218 . The pressure chamber case 218 can have a case top 220 a separable from a case bottom 220 b . The case top 220 a can have a case top port 222 . The case bottom 220 b can have a case bottom port 224 . The case top port 222 can be in fluid communication with the top of the pressure chamber 219 . The case bottom port 224 can be in fluid communication with the bottom of the pressure chamber 219 .
[0223] The case top can screw or otherwise tightly join to the case bottom. The pressure chamber case can have one or more o-rings (not shown) in o-ring seats 226 .
[0224] The pressure chamber can have a mandrel seat 228 . The mandrel seat 228 can be configured to receive a mandrel 230 . The mandrel seat 228 can have holes or pores. The holes or pores in the mandrel seat 228 can allow pressure from the case bottom port and the bottom of the pressure chamber to reach the top surface of the mandrel seat around the mandrel and/or directly under the mandrel.
[0225] The mandrel 230 can have the inner dimensions of the shell 678 .
[0226] The mandrel 230 may be made from a low melting point wax or metal, a foam, some collapsing structure or an inflatable bladder. The mandrel 230 can be made from a eutectic or non-eutectic bismuth alloy and removed by raising the temperature to the melt point of the metal. The mandrel 230 can be a water soluble mandrel. The mandrel 230 can be made from aluminum, glass, sugar, salt, corn syrup, hydroxypropylcellulose, ambergum, polyvinyl alcohol (PVA, PVAL or PVOH), hydroxypropyl methyl celluslose, polyglycolic acid, a ceramic powder, wax, ballistic gelatin, polylactic acid, polycaprolactone or combinations thereof.
[0227] A panel 196 a may be positioned over the mandrel 230 . The panel 196 a may be a single layer or multiple layers. For instance, the panel 196 a could be a layer of film and meltable adhesive 208 . The panel 196 a can be positioned with film on the side that touches the mandrel and adhesive on the radially outer side.
[0228] FIG. 37A illustrates that a positive pressure can be applied to the top 220 a of the pressure chamber (e.g., through the case top port 222 ) and/or a negative pressure or differential pressure or suction or vacuum applied to the bottom 220 b of the pressure chamber (e.g., through the case bottom port 224 ). The panel 196 A can get sucked and/or pressed down and/or formed onto the mandrel 230 . The first panel 196 A can be smoothly fitted to the mandrel 230 and adhered to the mandrel at the first adhesive 208 A. The first panel 196 A can stretch and/or yield and or/deform. The first panel 196 A can be have thinner after being stretched, yielded or formed. The first adhesive 208 a can be water soluble. The first adhesive 208 a can be sugar syrup. Heat may be applied to panel 196 a before forming onto mandrel 230 . Forming of one panel 196 a may be done more than once on different sized mandrels before the panel 196 a reaches the form shown in FIG. 37A .
[0229] Forming of panel 196 a may also be accomplished with a mechanical die. The mechanical die may be heated and conform closely to the shape of the mandrel 230 . The mechanical die may have a shape similar to the mandrel seat 228 .
[0230] The mandrel 230 and panel 196 a can be mounted into a trimming jig. Any excess portion of the first panel 196 a extending from the mandrel 230 can be trimmed with a blade, with a laser, with a water jet cutter, with a die cut tool or combinations thereof. The trimming jig can cover the mandrel 230 and the first panel 196 a attached to the mandrel. Several panels 196 a and/or layers 72 can be formed over the mandrel 230 and cut. The panels 196 a and/or layers 72 may be trimmed at the same time or one at time.
[0231] FIG. 37B illustrates that the mandrel can have the excess area of the first panel 196 A removed in preparation for attachment of the second panel 196 b.
[0232] A second adhesive 208 b can be applied to the first panel 196 a around the perimeter of the second panel's 196 b contact area with the first panel 196 a . The mandrel 230 can be seated in the mandrel seat 228 with the first panel 196 a in the mandrel seat.
[0233] FIG. 37C illustrates that after the case top 220 a is secured to the case bottom 220 b , the positive and/or negative pressures can be applied to the pressure chamber as described infra. The second panel 196 b can be smoothly fitted or pressure formed to or against the mandrel 230 and adhered to the first panel 196 a at the second adhesive 208 b . Adhesion can be accomplished by the application of heat. The first and second panels ( 196 A and 196 B) can form the inner layer 72 b or bladder 52 of the shell wall 684 . The inner layer may be leaktight. The inner layer may be capable of sustaining pressure. Multiple layers can be made by repeating the method described infra. The pressure chamber can be heated, for example, to decrease the viscosity of and decrease the modulus of the panels 196 .
[0234] FIG. 37D shows cross section L-L with the mandrel 230 omitted. Bladder 52 may have first internal seam 69 a , second internal seam 69 b inner layer first panel 74 a , inner layer second panel 74 b and inner layer 72 b . The bladder 52 may be leaktight.
[0235] FIG. 38A shows the bladder 52 after being fit over a mandrel 230 (mandrel 230 is inside bladder 52 and not directly shown in FIG. 38A ). The bladder 52 may be made slightly larger in diameter and/or longer in length than the mandrel 230 onto which the bladder 52 is fit. This may allow the bladder 52 to be re-assembled on the mandrel 230 with an internal seam 66 that may be sealed. FIG. 38A shows a longitudinal seam 66 running the length of the bladder 52 . The seam 66 may be sealed with adhesive, by fusing, by heating, with a solvent or combinations thereof. The sealed bladder 52 may form the inner layer 72 b of a shell 678 and be leak-tight. Seam 66 may be an external seam 66 a or internal seam 66 b.
[0236] FIG. 38B illustrates that the first bladder portion 52 a can overlap at a lap joint or overlap (as shown), abut at an abutment, or flange with the second bladder portion 52 b at the seam 66 . Seam 66 may be angled, vertical or a spiral or combinations thereof.
[0237] FIG. 39A shows a cross section of a tow 270 . The tow 270 may contain about 6, 25, 100, 500 or 1500 monofilaments. The tow 270 may have a tow height 271 and a tow width 272 . The tow 270 may be approximately circular. For example, the tow height 271 and tow width 272 may be about 0.025 mm (0.001 in) to about 0.150 mm (0.006 in), more narrowly about 0.050 mm (0.020 in) to about 0.100 mm (0.040 in), still more narrowly about 0.075 mm (0.003 in). The tow 270 may be loosely held together by a polymer finish (not shown).
[0238] FIG. 39B shows that tow 270 may contain a marker wire 190 . Marker wire 190 may be circular, as shown, and radiopaque.
[0239] FIG. 39C shows the tow 270 after the tow 270 has been spread. The tow 270 may be flattened or spread by passing the tow 270 through a closely spaced set of rollers that form a narrow pinch gap. The tow 270 may be spread by pulling the tow 270 under tension over a set of rollers or pins. After spreading, the tow 270 may have a tow height 271 less than about twice the fiber height 1068 , for example about the same as fiber height 1068 . The fiber height 1068 and fiber width 1072 may be substantially unchanged after spreading. For example, the fiber width 1072 and fiber height 1068 may be about 15 μm (0.0006 in), tow width 272 may be about 210 μm (0.008 in) and tow height 271 may be about 15 μm (0.0006 in). The marker wire 190 is not shown in FIG. 39C but may be present after the tow 270 has been spread.
[0240] FIG. 40A illustrates that a layer of fiber matrix can be made on a roller 232 . The roller 232 can be configured to rotate about a roller axle 234 . The roller 232 may have a diameter from about 100 mm to about 1,000 mm. The roller 232 may be made or coated with an anti-stick material such as a fluoropolymer.
[0241] FIG. 40B illustrates that a releaser 236 , such as a release layer, can be placed around the circumference of the roller 232 . The release layer can be a low friction film or coating. The release layer may be a thin and/or flexible fluoropolymer sheet.
[0242] FIG. 40C shows that an adhesive 208 can be placed on the releaser or directly onto the roller 232 (e.g., if no releaser 236 is used). The adhesive 208 may be a thermoplastic film. The adhesive 208 may be a thermoset adhesive. The adhesive 208 may be a solvated thermoplastic or thermoset. The adhesive 208 may have a backing film, such as paper.
[0243] FIG. 40D shows the application of the reinforcement fiber 86 to the roller 232 . The fiber 86 may be unwound from a spool (not shown) and rolled onto the top surface of the adhesive 208 . Before winding, the fiber 86 may be infused or coated with an adhesive 208 , a solvent, or both. The coating may be a thermoplastic. The fiber 86 may have been previously flattened as detailed supra. The fiber 86 may have a non-circular cross section, such as a rectangle or an ellipse. Any coating or sizing on the fiber may have been removed using a solvent. The fiber 86 may be placed with a gap between each successive fiber wrap. The gap may be less than about 200 μm (0.008 in), more narrowly less than about 5 μm (0.0002 in). A heat source or a solvent may be used to fix the fiber 86 to the adhesive 208 (i.e., tack the fiber 86 in place on the adhesive 208 ), to melt or solvate a material onto the release layer 236 , to melt or solvate a material on the fiber 86 or combinations thereof. For example, a separate resistive heater, a laser, a source of hot air, or an RF welder may be used. A solvent such as methyl ethyl ketone or tetrahydrofuran may be used. The fiber 86 can be wound with a pitch of 3000 to 30 turns per 1 inch (25.4 mm). The pitch can be chosen based on the total size of the fiber 86 or tow 270 being applied and the chosen gap between each subsequent fiber 86 or tow 270 on the roller 232 . Applications of a single monofilament 274 , which may be a wire, can have pitches from about 2000 to about 100 turns per 1 inch (25.4 mm).
[0244] FIG. 40E shows reinforcement fiber 86 on top of adhesive 208 on top of release layer 236 . FIG. 40E may show a cross section after the operation shown in FIG. 40D is performed.
[0245] FIG. 40F illustrates that the roller can be placed between a vacuum top sheet 238 a and a vacuum bottom sheet 238 b , for example in a vacuum bag. A vacuum seal tape 240 can surround the roller 232 between the vacuum bottom and top sheets 238 b and 238 a , respectively. Air can be removed from between the vacuum top and bottom sheets 238 a and 238 b and within the vacuum seal tape, for example by suction from a suction tube 242 . Inside and/or outside of the vacuum bag, the roller 232 can be heated, for example to melt or cure the adhesive 208 . Roller 234 can be removed from the vacuum bag, for example after melting or curing of the adhesive is complete.
[0246] FIG. 40G shows the removal of the panel 196 . For instance, a cut may be made substantially perpendicular to the fiber. The panel 196 may be peeled away from the release layer. The panel 196 may be substantially foldable and/or flexible.
[0247] FIG. 40H illustrates that the panel 196 of fiber matrix can be removed from the roller 232 . For example, the panel 196 can be peeled off the releaser 236 . The panel 196 can be repositioned on the roller 232 at about 90 degrees to the layer's previous angle and additional reinforcement fibers 86 can be applied as shown in FIG. 39D . This may result in a panel 196 with fibers 86 running perpendicular to each other (e.g., a “0-90” layer, so called for the angle the two layers of fiber make with respect to each other). The panel 196 can be cut into a smaller panel. For instance, the panel 196 can be cut with a trimming jig, a laser, a water jet cutter, a die cut tool, or a combination thereof.
[0248] FIG. 41A shows that a panel 196 may have reinforcement fibers 86 b oriented substantially parallel to panel longitudinal edge 332 . The panel 196 can have a panel width 334 . The panel width 334 can be about equal to the circumference of the shell 678 in the central section 38 . The panel 196 can have a panel length 335 . The panel length 335 can be greater than the shell length 28 . The panel 196 can have a panel rectangular section 336 and one or more panel serrations 338 a , 338 b and 338 c . Each panel serration 338 a , 338 b and 338 c can have a portion of the panel 186 that forms a portion of the stem 30 or 43 and taper 34 or 44 . Each serration 338 a , 338 b and 338 c can have a serration edge 339 a , 339 b and 339 c , respectively. The angle between the serration edges 339 and a line parallel to the reinforcement fibers 86 b can be a panel serration angle 340 . The panel serration angle 340 can be about 30°, about 20°, about 10°, or about 0°. A first panel serration 338 a can be substantially in line with a second panel serration 338 b . One or more fibers 86 b may run from the terminal end of the first serration 338 a to the terminal end of the second serration 338 b.
[0249] FIG. 41B illustrates that longitudinal reinforcement fiber 86 b can be parallel with longitudinal edge 332 . Second longitudinal reinforcement fiber 87 b can be parallel with the fiber 86 b . Fibers 86 b and 87 b can be separated by fiber separation areas 614 . The fiber separation areas 614 may separate fibers 86 b and 87 b by about 2 mm, more narrowly less than about 1 mm, still more narrowly less than about 0.25 mm. The fiber separation areas 614 may be distributed on the panel such that no area 614 substantially overlaps any other area in the X and/or Y direction. The fiber separation areas 614 may be positioned in the X and Y directions on the panel 196 in a pattern sufficient to prevent any fiber from reaching all the way across the panel rectangular section in the X direction. The shell 678 in FIG. 5 may be built in part with the panel 196 shown in FIG. 41B . Fibers 86 b and 87 b may have fiber lengths 88 less than about 80% of the shell length 28 more narrowly less than about 75% as long, more narrowly less than about 70% as long, still more narrowly less than about 65% as long, still more narrowly less than about 60% as long.
[0250] FIG. 41C shows that a panel 196 can have a panel rectangular section 336 and one or more panel serrations 338 a , 338 b and 338 c . Panel serration 338 b can be oriented in the Y direction substantially midway between panel serrations 338 a and 338 c . Panel serration 338 b can be oriented in the Y direction substantially closer to either panel serrations 338 a or 338 c . The longest reinforcement fiber length 88 in panel 196 may be less than about 75% of the length 28 of the shell, more narrowly less than about 70%.
[0251] FIG. 42A shows that panel 196 may contain reinforcement fibers 85 a and 85 b arranged in a woven pattern. A woven pattern can have fibers 85 a and 85 b that alternately pass over and under each other.
[0252] FIG. 42B shows that the panel 196 may contain reinforcement fibers 85 in a braided configuration.
[0253] FIG. 42C shows that the panel 196 may contain reinforcement fibers 85 of various lengths in random orientations, sometimes referred to as chopped or chopper fiber.
[0254] FIGS. 43A and 43B illustrate that a panel 196 may be applied to a mandrel 230 with none, one or more layers 72 on the mandrel 230 . The panel 196 may be joined to layers 72 by the application of adhesive or by heat or by combinations thereof. The panel 196 , when folded onto the shape of the mandrel 230 may give a substantially complete coverage of the mandrel 230 with minimal or no overlap of the panel 196 . Panel rectangular section 336 may cover the shell central section 38 . Panel serrations 338 may cover proximal taper 34 , distal taper 42 , proximal stem 30 and distal stem 43 .
[0255] A die may be used to press the panel 196 onto the shell 678 . The die may be heated and the panel 196 may contain a thermoplastic. The die may melt the thermoplastic and adhere the panel 196 to the shell 678 . The die may be shaped to match the mandrel 230 shape. After attaching two serrations 338 (one serration at each end of the mandrel 230 . See FIG. 43A ), the mandrel 230 may be rotated about its longitudinal axis to advance the next set of serrations 338 into place under the die. The die may again press two serrations 338 into place on the shell 678 . Subsequent use of the die in this manner may attach substantially the entire panel 196 to shell 678 as shown in FIG. 43B .
[0256] FIG. 44 illustrates that fiber 86 can be wound over the mandrel 230 or over shell 678 . The fiber 86 may be continuous or discontinuous. The mandrel can be rotated, as shown by arrow 252 , about the mandrel longitudinal axis 250 or shell longitudinal axis. The first spool 244 a can be passively (e.g., freely) or actively rotated, as shown by arrow 254 , deploying fiber 86 (shown) or tow 270 . Before or during winding, the fiber 86 may be infused or coated with an adhesive, a solvent, or both. The coating may be a thermoplastic. A fiber distal end can fix to the shell 678 or directly to the mandrel 230 .
[0257] The fiber 86 a may be wound with a gap between each successive fiber wind. The gap can be less than about 200 μm (0.008 in), more narrowly less than about 5 μm (0.0002 in).
[0258] The fiber 86 can be wound with a pitch of about 3000 to about 30 winds per 1 inch (25.4 mm). The pitch can be chosen based on the total size of the fiber 86 or tow 270 being applied to the part from first spool 244 a and the chosen gap between each subsequent fiber 86 or tow 270 on the part. Applications of a single monofilament 274 , which may be a wire, can have pitches from about 2000 to about 100 turns per 1 inch (25.4 mm).
[0259] A tool arm 246 can be attached to a rotating tool wheel 248 . The tool arm 246 can rotate and translate, as shown by arrows 256 and 258 , to position the tool wheel 248 normal to and in contact with the shell 678 . A second tool wheel 248 ′ (attached to tool arm 246 ′) can have a range of motion sufficient to apply pressure normal to the surface of a shell taper section.
[0260] The tool wheel 248 can press the fiber 86 or tow 270 against the shell 678 and spread the monofilaments 274 . The tool wheel 248 may help to adhere the tow 270 to the shell, for example by applying pressure and following closely the surface of the shell. The tool wheel 248 can be heated to soften or melt the material on the surface of the shell 678 . Another heat source or a solvent may be used to tack the fiber in place, to melt or solvate a material on the shell, to melt or solvate a material on the fiber or combinations thereof. A separate resistive heater, a laser, a UV light source, an infrared light source, a source of hot air, or an RF welder may be used with our without the tool wheel 248 to attach the fiber. A solvent such as methyl ethyl ketone or tetrahydrofuran or alcohol or combinations thereof may promote adhesion of the fiber 86 and may be used with our without the tool wheel 248 . The tool wheel 248 can be made of or coated with a non-stick material. The tool wheel 248 may not rotate. The tool wheel 248 may comprise a hard surface, for example carbide.
[0261] A second spool 244 b may deploy marker wire 190 during a winding operation. Second spool 244 b may also deploy a reinforcement fiber 85 (not shown). Marker wire 190 (or reinforcement fiber 85 ) may be applied simultaneously with fiber 86 and/or tow 270 to the shell. Marker wire 190 may interleave with reinforcement fiber 86 to form a single fiber layer on shell 678 . Marker wire 190 may be deposited on top bellow another existing fiber layer.
[0262] The resulting layer deposited in FIG. 44 can have a layer thickness 216 of from about 1 μm (0.00004 in) to about 50 μm (0.002 in), more narrowly from about 8 μm (0.0003 in) to about 25 μm (0.001 in).
[0263] The techniques described in FIGS. 36 , 37 A, 37 B and 37 C may be used to apply additional panels 196 or layers 72 to shell 678 . For example, two panels 196 may be applied to form an outer layer 72 a on the shell 678 as shown in FIG. 45A .
[0264] FIG. 45B shows that a panel 196 e can applied to the proximal end of the balloon. Similarly, a panel 196 f can be applied to the distal end of the balloon. The panels 196 e and 196 f could be like those shown in FIGS. 46A and 46B .
[0265] FIG. 46A shows a panel 196 with panel cutout 842 and panel lobe 846 . Panel cutout 842 can be aligned on a shell 678 to form an aperture 714 . Panel lobe 846 can be placed on a shell 678 to form a shell reinforcement lobe 866 .
[0266] FIG. 46B shows a panel 196 with a panel cut 850 . Panel cut 850 may allow the panel to form over shell 678 .
[0267] FIG. 47 illustrates that a wash tube 264 can be inserted into a mandrel washout port 262 . A dissolving or solvating fluid can be delivered through the wash tube and into the washout port 262 . The mandrel can be removed by delivery of a fluid solvent such as water, alcohol or a ketone. The solvent may be applied during the consolidation process such that the solvent melts or partially softens the mandrel and concurrently pressurizes the bladder. The mandrel 230 can be removed by raising the mandrel to a melting temperature for the mandrel. The mandrel 230 can be removed by deflating the mandrel or by collapsing an internal structure.
[0268] FIG. 48A illustrates that the shell 678 may be placed in a shell mold 622 containing a shell pocket 624 . The shell mold 622 may be porous such that substantial amounts of gas may be drawn from shell pocket 624 thru the wall of shell mold 622 and out into the surrounding atmosphere. The shell 678 may have a tube (not shown) placed in its inner volume that may extend out either end of the shell 622 . The tube may be thin and very flexible. The tube may be a silicon rubber.
[0269] A coating may be sprayed into mold 622 that bonds to the shell 678 during cure and forms an outer layer 72 a on the shell 678 .
[0270] FIG. 48B illustrates that the shell mold 622 may be closed around the shell 678 . Pressure may be applied thru shell second fluid port such that the shell expands to contact the inside of shell pocket 624 . Alternately, the tube (not shown) extending out either end of the shell may be pressurized to force the shell into contact with pocket 624 .
[0271] FIG. 48C shows Pressure P inside the shell volume pressing the shell wall 684 outwards. Mold 622 may be placed in an oven and heated. Mold 622 may have built in heaters. The shell mold 622 may be placed under vacuum or placed in a vacuum chamber during heating. The shell mold 622 may have a texture, such as a texture created by abrading or sand blasting or bead blasting the shell mold 622 . The texture may impart a texture to the outer layer 72 b of the shell.
[0272] Heating the shell under pressure may cause one or more layers 72 to melt and/or fuse and/or bond with adjoining layers 72 . Melting under pressure may remove voids in the shell wall. The inner and outer films may not melt. Heating the shell under pressure may cause the walls of the shell 678 to fuse or laminate into one continuous structure. The shell outer layer 72 a may be substantially smoothed by this process. The shell outer layer 72 a may be permeable or perforated such that gas or other material trapped in the shell wall 684 during manufacture may escape when the shell is heated under pressure.
[0273] The shell outside radius 708 may be very accurate and repeatable. For instance, at a given pressure, the outside radius 708 of a group of shells 678 may all be within about 2% (+/−1%) of each other. For instance, if the nominal dimension of the outside radius 708 of the shell is about 12 mm at about 60 psi (414 kPa), all shells may have an outside radius 708 of about 11.88 mm to about 12.12 mm.
[0274] A shell 678 can be clamped in a pleating tool with two, three, four, five or more removable pleating blocks. Heating the pleating blocks to about 80C and then pressing them against the shell 678 for about 1 minute causes the shell to become pleated or fluted. Commercial pleating machines such as folding machinery from Interface Associates (Laguna Niguel, Calif.) can also be used. A small amount of wax may be used to hold the pleated and folded shell into its desired shape.
[0275] As shown in FIGS. 49A and 49B , a balloon 650 may be placed in an insertion tool 854 . Before being placed in the insertion tool 854 , the balloon 650 may be coated in an adhesive 208 or a solvent. The insertion tool 854 may comprise a tube that will not adhere to most adhesives, for example the tube may comprise a fluoropolymer.
[0276] FIG. 49C shows that apertures 714 may be cut in the shell 678 , for example with a laser 858 . A shell 678 may be fabricated with apertures 714 already in place. FIG. 49D shows that insertion tool 854 may be inserted through aperture 714 into shell interior 47 . Insertion tool 854 may be inserted through the interior volume of shell proximal stem 30 or shell distal stem 43 or any other orifice in the shell 678 . A cut in the shell 678 may be made to allow the insertion tool 854 into shell interior 47 . FIG. 49E shows that the insertion tool 854 can be removed leaving balloon 650 in the shell interior 47 . FIG. 49F shows that balloon 650 can be inflated inside shell 678 . Adhesive 208 or a solvent or the application of heat may bond balloon 650 to the inner wall of shell 678 forming annular balloon structure 682 .
[0277] FIG. 50 illustrates a balloon catheter. Inflation fluid may be provided by detachable syringe 472 thru catheter Y-fitting 634 . Inflation fluid may flow between the inside wall of first hollow shaft 2000 a and the outside wall of second hollow shaft 2000 b . Inflation fluid may flow into the balloon 650 to inflate the annular balloon structure 682 . A guide wire may be inserted at guidewire port 632 and pass thru the interior of the second hollow shaft 2000 b.
[0278] FIG. 51 illustrates a cross section of an annular balloon structure 682 in a substantially deflated and pleated or folded configuration. The annular balloon structure 682 is shown in a tube 428 with a tube inside diameter 436 and a tube inside diameter cross sectional area 434 . The annular balloon structure 682 may be inserted into the tube 428 without damaging the annular balloon structure 682 . The tube 428 may be, for instance, an introducer or a balloon protection sleeve used to store the balloon.
[0279] The compression ratio of the annular balloon structure 682 can be from about 3:1 to about 10:1, more narrowly from about 5:1 to about 7:1. The compression ratio can be the ratio between twice the shell outside radius 708 of the substantially inflated annular balloon structure 682 and tube inside diameter 436 . For instance, an annular balloon structure 682 with shell outside radius 708 equal to about 12.2 mm can be inserted into a tube 428 with a tube inside diameter 436 of about 4.8 mm, more narrowly about 4 mm, still more narrowly about 3.6 mm.
[0280] The annular balloon structure 682 can have a packing density equal to or greater than about 40%, more narrowly greater than or equal to about 55%, yet more narrowly equal to or greater than about 70%. The packing density can be the percentage ratio between the cross sectional area of the walls of the annular balloon structure 682 and the tube inside diameter cross sectional area 434 .
[0281] The packing density and compression ratios for the annular balloon structure 682 can remain substantially constant and the wall strength of the annular balloon structure 682 can remain substantially constant with repeated insertions or withdrawals from tube 428 and/or inflations and deflations of the annular balloon structure 682 , for example 10 or 20 or 40 insertions and withdrawals or inflations and deflations.
[0282] The annular balloon structure 682 can have an unsupported burst pressure. The unsupported burst pressure is the pressure at which the annular balloon structure 682 ruptures when inflated in free air without any external constraint on the walls at about 1 atm external pressure and about 20° C. temperature. The unsupported burst pressure can be from about 2 atm to about 20 atm, more narrowly from about 3 atm to about 12 atm, still more narrowly about 4 atm to about 8 atm, for example 5 atm, 6 atm or 7 atm.
[0283] The annular balloon structure 682 can be non-compliant or inelastic. For example, the annular balloon structure 682 can have a failure strain of less than about 0.30, more narrowly less than about 0.20, still more narrowly less than about 0.10, yet more narrowly less than about 0.05.
[0284] The failure strain of the annular balloon structure 682 is the difference between the shell outside radius 708 when the balloon is inflated to 100% of the burst pressure and the shell outside radius 708 when the balloon is inflated to 5% of the burst pressure (i.e., to expand from a deflated state without stretching the wall material) divided by the shell outside radius 708 when the balloon is inflated to 100% of the burst pressure.
[0285] The annular balloon structure 682 can have a compliance of less than about 2% per atmosphere, more narrowly less than about 1% per atmosphere, still more narrowly less than about 0.7% per atmosphere, yet more narrowly less than about 0.4% per atmosphere.
[0286] The annular balloon structure 682 can be inflated to a pressure A and a pressure B. Pressure B may be a higher pressure than pressure A. Pressures B and A may be positive pressures. Pressures B and A may be greater than 1 atm. Delta pressure may be pressure B minus pressure A. Delta radius may be the shell outside radius 708 when annular balloon structure 682 is inflated to pressure B minus the shell outside radius 708 when annular balloon structure 682 is inflated to pressure A. Compliance may be Delta radius divided by the shell outside radius 708 when annular balloon structure 682 is inflated to pressure B divided by Delta pressure.
[0287] A shell 678 can be constructed with fiber 85 patterns similar to those shown in FIG. 4 . For example, fiber reinforcement member 85 c can be omitted and fiber 85 a can be placed at +20 degrees and fiber 85 b can be placed at −20 degrees to the shell longitudinal axis. First reinforcement fibers 85 A may form a layer angle 738 with respect to and second reinforcement fibers 85 b . The layer angle 738 can be about 40 degrees. As shell 678 is placed under tension by balloon 650 , the angle between the fibers will gradually increase until the layer angle 738 is about 70 degrees. This is the angle 738 where the fibers balance the longitudinal and hoop loads in the shell. The fibers may change their angle with respect to each other by straining the adhesive. Shell 678 may rapidly expand to a first diameter where the a layer angle 738 is, for example, about 40 degrees and then slowly expand in diameter 50 as internal pressure on the shell 678 from balloon 650 is increased. By choosing the initial diameter 50 and layer angle 738 , a shell 678 can be designed that allows for a variety diameters 50 to be achieved.
[0288] FIG. 52 shows a cross section of the heart 562 . The heart 562 has an aorta 568 , a left ventricle 570 and an aortic valve 564
[0289] FIG. 53 is a graph that shows how the percent stenosis creates acceptable, difficult and critical flow conditions in both the rest and stress conditions in a patient. The acceptability of a stenotic condition would further vary as a function of the time spent in each condition.
[0290] FIGS. 54A and 54B illustrate that a guidewire 572 can be inserted through the aorta 568 and positioned in the left ventricle 570 of the heart 562 . The annular balloon structure 682 can be slidably inserted over the guidewire through the aorta 568 . The annular balloon structure 682 may be in a deflated or pleated state when first placed in the aortic valve 564 . The annular balloon structure 682 can be positioned to align along the balloon longitudinal axis with the aortic valve leaflets 566 . The annular balloon structure 682 can also be rotated about the balloon longitudinal axis to align with the aortic valve 564 , for example when cutting apart attached leaflets 566 in a bicuspid aortic valve with a flange, a vane, a blade, other cutting element described herein, or combinations thereof. Fluid flow 870 may pass out of the left ventricle 570 through aortic valve leaflets 566 and into the aorta 568 . Fluid flow 870 may comprise blood flow.
[0291] FIG. 54C shows the annular balloon structure 682 in an inflated configuration. The annular balloon structure 682 can be non-compliant and open the aortic valve 564 to a precise dimension (for example, about 20 mm or about 24 mm). The annular balloon structure 682 can fixedly reconfigure and press the aortic valve leaflets 566 against the outer wall or annulus 582 of the aortic valve 564 . The annular balloon structure 682 can radially expand the aortic valve annulus 582 .
[0292] Fluid flow 870 may pass through shell apertures 714 on the distal taper 42 , into central fluid passage 692 and through shell apertures 714 on the proximal taper 34 thus allowing for perfusion of blood while the balloon structure 692 is inflated. The central fluid passage 692 could have a cross sectional area of 0.3 to 1.2 centimeters squared, more narrowly 0.5 to 0.8 centimeters squared.
[0293] When annular balloon structure 682 is inflated, there may be a pressure differential between left ventricle 570 and aorta 568 . For instance, the pressure differential may be from about 5 mm Hg to about 50 mm Hg, more narrowly from about 10 mm Hg to about 40 mm Hg, still more narrowly, from about 10 mm Hg to about 25 mm Hg.
[0294] Perfusion may allow the physician to leave the balloon structure inflated in the aortic valve 564 for longer than would be allowed with a balloon that did not perfuse while still avoiding significant harm to the patient or the patient's hemodynamics. Increasing inflation time may allow for a more careful and accurate remodeling of the vasculature, such as that done during a valvuloplasty or a PCTA procedure.
[0295] One or more segments 656 of balloon 650 may employ a compliant material. Raising and lowering the pressure in these compliant segments 656 may cause the segment volume to change. A change in the segment 656 volume may cause the area of the central fluid passage 692 to change. A physician may initially place the annular balloon structure 682 and then adjust pressure in the balloon 650 or balloon segments 656 to adjust the flow area gap 693 . The compliant balloon segment 656 may be an additional balloon enclosed by shell 678 with an inflation lumen separate from the one used to inflate balloon 650
[0296] The physician may inflate the annular balloon structure 682 until the structure 682 makes contact with the aortic valve 564 or the valve leaflets 566 or other vascular structures. This contact with the vasculature may be confirmed by the use of small bursts of radiopaque contrast. Once the annular balloon structure 682 is in contact with the vasculature, increases in the pressure delivered to annular balloon structure 682 can be used to make changes in central section outside diameter 50 of the annular balloon structure and thus change the shape of the patient's vasculature. The change in shape of the vasculature can be monitored by ultrasound, fluoroscope or other methods known in the art. Changing the shape of the patient's vasculature via this method may take more than 10 seconds, more narrowly more than 30 seconds, still more narrowly more than 60 seconds while not adversely affecting patient health.
[0297] The heart 562 may be allowed to beat at its normal rhythm during the procedure. The heart 562 may be forced to beat at an elevated rhythm during the procedure.
[0298] FIG. 54D illustrates that the annular balloon structure 682 can be deflated, contracted and withdrawn from the aortic valve leaflets 566 .
[0299] FIG. 54 FE shows the aortic valve leaflets 566 with a larger opening than before the procedure.
[0300] Instead of using a guidewire, an IVUS or OCT system can be inserted in the inner lumen 154 a . These systems may allow visualization of the aortic valve 564 , for instance the positioning of the valve leaflets 566 at any point during the procedure detailed in FIGS. 54A-54F .
[0301] The method described in FIG. 54 above can be performed on an aortic, mitral, pulmonary, tricuspid or vascular valve. This method may be described as balloon valvuloplasty or balloon aortic valvuloplasty. This procedure may be described as pre-dilation when it used to prepare the aortic valve for the implantation of a prosthetic valve. This procedure may also be employed after a prosthetic valve is in place in order to better seat the valve into the patient's anatomy. In this case, it is often referred to as “post-dilation”.
[0302] Referring now to FIGS. 55A-55F , the annular balloon structure 682 can be used to deploy a prosthetic valve in, for instance, the aortic valve 564 near the coronary ostia 583 . A guidewire 572 may first be introduced thru the aorta 568 into the left ventricle 570 as shown in FIG. 55A . Next, as shown in FIG. 55B , a balloon catheter carrying prosthetic heart valve 626 and deflated annular balloon structure 682 may be introduced over guidewire 572 into aortic valve 564 . In FIG. 55C , annular balloon structure 682 is inflated to expand the prosthetic heart valve 626 into the aortic valve 564 . While the annular balloon structure 682 is inflated, fluid (for example, blood) flow 870 may pass through shell apertures 714 on the distal taper 42 , into central fluid passage 692 and through shell apertures 714 on the proximal taper 34 . In FIG. 55D , the annular balloon structure 682 is deflated and separated from valve prosthesis 626 , leaving the valve prosthesis 626 implanted in the aortic valve 564 . FIGS. 55E and 55F show the prosthetic valve closing ( 55 E) and opening ( 55 F) immediately after the annular balloon structure 682 is withdrawn.
[0303] FIG. 56A illustrates that the annular balloon structure 682 can be positioned over a guidewire 572 or stylet in a body lumen 574 having a constriction 576 on the interior of the lumen wall 578 . A stylet may be stiffer than a guidewire.
[0304] FIG. 56B illustrates that the annular balloon structure 682 can be inflated and expanded. The annular balloon structure 682 can remodel the body lumen 574 , pushing the constriction 576 radially away from the shell longitudinal axis 26 . The annular balloon structure 682 can deploy a stent to the constriction 576 . While the annular balloon structure 682 is inflated, fluid (for example, blood) flow 870 may pass through shell apertures 714 on the proximal taper 34 , into central fluid passage 692 and through shell apertures 714 on the distal taper 42 .
[0305] FIG. 56C illustrates that the annular balloon structure 682 can be deflated, contracted and removed from the body lumen 574 . The body lumen 574 can remain patent after the annular balloon structure 682 is removed, for example restoring blood flow past a treated atherosclerotic length.
[0306] Body lumen 574 may be a vessel or an airway. Constriction 576 may be a atherosclerotic plaque or a local narrowing of the body lumen 574
[0307] The annular balloon structure 682 can be implanted in the body semi-permanently or permanently.
[0308] The annular balloon structure 682 , can be used for Kyphoplasty, angioplasty including CTO dilation, stent delivery, sinuplasty, airway dilation, valvuloplasty, drug or other fluid delivery through the balloon, radiopaque marking, incising the inside of a vessel (e.g., to open or expand a vessel), brachytherapy, intentionally obstruct a vessel, or combinations thereof. The annular balloon structure 682 can be used to deliver one or more stents and/valves and/or emboli filters to the coronary blood vessels (e.g., arteries or veins), carotid artery, peripheral blood vessels, the GI tract, the biliary ducts, the urinary tract, the gynecologic tract, and combinations thereof.
[0309] The reinforcement fibers 85 , 86 and 87 can be identical to or different from each other.
[0310] Any elements described herein as singular can be pluralized (i.e., anything described as “one” can be more than one), and plural elements can be used individually. Any species element of a genus element can have the characteristics or elements of any other species element of that genus. The term “comprising” is not meant to be limiting. The above-described configurations, elements or complete assemblies and methods and their elements for carrying out the invention, and variations of aspects of the invention can be combined and modified with each other in any combination. | An inflatable structure for use in biological lumens and methods of making and using the same are disclosed. The structure can have an inflatable balloon encircled by a shell. The shell can have proximal and distal tapered necks, longitudinally-oriented flutes, and apertures at the proximal and distal ends of the shell. The apertures can be recessed in the flutes in the necks. The shell can also have fiber reinforced walls. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
Reference is made to commonly-assigned, copending U.S. patent application Ser. No. 09/473,248, filed Dec. 27, 1999 entitled “Ink Jet Printing Method”, by Martin;
U.S. patent application Ser. No. 09/472,484, filed Dec. 27, 1999 entitled “Additive for Ink Jet Ink”, by Erdtmann et al.; and
U.S. patent application Ser. No. 09/472,577, filed Dec. 27, 1999 entitled “Additive For Ink Jet Ink”, by Martin.
FIELD OF THE INVENTION
This invention relates to an ink jet printing method which employs an additive for a pigmented ink jet ink to improve printing reliability.
BACKGROUND OF THE INVENTION
Ink jet printing is a non-impact method for producing images by the deposition of ink droplets on a substrate (paper, transparent film, fabric, etc.) in response to digital signals. Ink jet printers have found broad applications across markets ranging from industrial labeling to short run printing to desktop document and pictorial imaging. The inks used in ink jet printers are generally classified as either dye-based or pigment-based.
A dye is a colorant which is molecularly dispersed or solvated by a carrier. The carrier can be a liquid or a solid at room temperature. A commonly used carrier is water or a mixture of water and organic co-solvents. Each individual dye molecule is surrounded by molecules of the carrier. In dye-based inks, no particles are observable under the microscope. Although there have been many recent advances in the art of dye-based ink jet inks, such inks still suffer from deficiencies such as low optical densities on plain paper and poor light-fastness. When water is used as the carrier, such inks also generally suffer from poor water fastness.
In pigment-based inks, the colorant exists as discrete particles. These pigment particles are usually treated with addenda known as dispersants or stabilizers which serve to keep the pigment particles from agglomerating and settling out of the carrier. Water-based pigmented inks are prepared by incorporating the pigment in the continuous water phase by a milling and dispersing process. Pigmented inks require a water soluble dispersant in the pigment slurry during the milling process. Such a dispersant is necessary to produce a colloidally stable mixture and an ink that can be “jetted” reliably without clogging the print head nozzles.
Dispersing agents in an ink jet ink have the dual function of helping to break down pigments to sub-micron size during the milling process and of keeping the colloidal dispersion stable and free from flocculation for a long period of time.
A requirement in wide format ink jet printers is the delivery of at least 500 ml of ink through a printhead before nozzles begin to fail to fire ink droplets. Reproducible quantities of ink delivered prior to print cartridge failure (ink reliability) and particle size stability, over time, have been problems encountered with ink jet inks containing pigments as colorants and anionic dispersants.
U.S. patent application Ser. No. 09/351,614, filed Jul. 12, 1999, entitled “Color Pigmented Ink Jet Ink Set” discloses a typical ink jet pigmented ink. However, there is a problem with print cartridges containing those inks in that the print reliability over an extended period of time is not as good as one would desire.
U.S. Pat. No. 5,855,656 relates to an ink jet ink containing a cationic fluorocarbon material. There is a disclosure in this patent that a nonionic surfactant maybe used such as Tergitol TMN-10®. However, there is a problem with this combination used in a pigmented ink with an anionic dispersant in that the dispersion is not stable, i.e., the pigment will precipitate out.
It is an object of this invention to provide an ink jet printing method which employs an additive for a pigmented ink jet ink which would improve the print reliability. It is another object of this invention to provide an ink jet printing method which employs an additive for a pigmented ink jet ink which would be useful with a variety of pigments. It is still another object of this invention to provide an ink jet printing method which employs an additive for a pigmented ink jet ink which would not affect the dispersion stability.
SUMMARY OF THE INVENTION
These and other objects are achieved in accordance with this invention which relates to an ink jet printing method, comprising the steps of:
A) providing an ink jet printer that is responsive to digital data signals;
B) loading the printer with ink-receptive substrates;
C) loading the printer with an ink jet ink composition comprising from about 30 to about 90% by weight of water, from about 0.5 to about 30% by weight of a pigment, from about 0.125 to about 7.5% by weight of an anionic dispersant, from about 0.05 to about 2% by weight of an ethoxylated trimethylnonanol, and from about 10 to about 50% by weight of a humectant comprising a polyhydric alcohol; and
D) printing on an ink-receptive substrate using the ink jet ink in response to the digital data signals.
Use of the ethoxylated trimethylnonanol in the inks employed in this invention greatly increases the amount of ink that may be delivered before print nozzles begin to fail.
DETAILED DESCRIPTION OF THE INVENTION
As noted above, the ink jet ink composition employed in the process of the invention contains the ethoxylated trimethylnonanol at a concentration of from about 0.05 to about 2.0 weight percent. In a preferred embodiment, the concentration of the ethoxylated trimethylnonanol is from about 0.075 to about 1.0 weight percent. In another preferred embodiment of the invention, the ethoxylated trimethylnonanol has the formula C 12 H 25 O(CH 2 CH 2 O) n H, where n is from about 3 to about 10, and is made through the reaction of 2,6,8-trimethyl-4-nonanol with ethylene oxide. These materials are sold commercially as Tergitol® TMN-3, -6 and -10 (Union Carbide Corp.).
In the present invention, any of the known organic pigments can be used. Pigments can be selected from those disclosed, for example, in U.S. Pat. Nos. 5,026,427; 5,085,698; 5,141,556; 5,160,370 and 5,169,436, the disclosures of which are hereby incorporated by reference. The exact choice of pigment will depend upon the specific color reproduction and image stability requirements of the printer and application. For four-color printers, combinations of cyan, magenta, yellow and black (CMYK) pigments are used. In a preferred embodiment, the pigment set is cyan pigment, C.I. Pigment Blue 15:3; quinacridone magenta, C.I. Pigment Red 122; C.I. Pigment Yellow 155; and carbon black, C.I. Pigment Black 7.
A humectant is added to the composition employed in the process of the invention to help prevent the ink from drying out or crusting in the orifices of the ink jet printhead. Polyhydric alcohols useful in the composition of the invention for this purpose include, for example, ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, tetraethylene glycol, polyethylene glycol, glycerol, 2-methyl-2,4-pentanediol, 1,2,6-hexanetriol and thioglycol. As noted above, the humectant is employed in a concentration of from about 10 to about 50% by weight. In a preferred embodiment, diethylene glycol or a mixture of glycerol and diethylene glycol is employed a concentration of between 10 and 20 wt. %.
A co-solvent can also be employed in the composition employed in the process of the invention. The selection of a co-solvent depends on the requirements of the specific application, such as desired surface tension and viscosity, the selected pigment, drying time of the pigmented ink jet ink, and the type of paper onto which the ink will be printed. Representative examples of water-soluble co-solvents that may be selected include (1) alcohols, such as methyl alcohol, ethyl alcohol, n-propyl alcohol, isopropyl alcohol, n-butyl alcohol, sec-butyl alcohol, t-butyl alcohol, iso-butyl alcohol, fiirftiryl alcohol, and tetrahydroflirfuryl alcohol; (2) ketones or ketoalcohols such as acetone, methyl ethyl ketone and diacetone alcohol; (3) esters, such as ethyl acetate, ethyl lactate, ethylene carbonate and propylene carbonate; and (4) sulfur-containing compounds such as dimethyl sulfoxide and tetramethylene sulfone.
Dispersants which are used in the composition employed in the process of the invention include sodium dodecyl sulfate, acrylic and styrene-acrylic copolymers, such as those disclosed in U.S. Pat. Nos. 5,085,698 and 5,172,133, and styrenics, such as those disclosed in U.S. Pat. No. 4,597,794. Other patents referred to above in connection with pigment availability also disclose a wide variety of useful dispersants. In a preferred embodiment, potassium or sodium N-methyl-N-oleoyl taurate is used.
Ink Preparation
A preferred method for making the inks employed in the process of the invention is disclosed in U.S. Pat. No. 5,679,138, the disclosure of which is hereby incorporated by reference. In general, it is desirable to make the pigmented ink jet ink in the form of a concentrated mill grind, which is subsequently diluted to the appropriate concentration for use in the ink jet printing system. This technique permits preparation of a greater quantity of pigmented ink from the equipment. The mill grind can be diluted with either additional water or water-miscible solvents to make a mill grind of the desired concentration. By dilution, the ink is adjusted to the desired viscosity, color, hue, saturation density and print area coverage for the particular application.
Jet velocity, separation length of the droplets, drop size and stream stability are greatly affected by the surface tension and the viscosity of the ink. Pigmented ink jet inks suitable for use with ink jet printing systems should have a pH in the range of 5 to 9.
Acceptable viscosity's are no greater than 20 centipoise, and preferably in the range of about 1.0 to about 10.0 centipoise, more preferably from about 1.0 to about 5.0 centipoise at room temperature.
The ink has physical properties compatible with a wide range of ejecting conditions, i.e., driving voltages and pulse widths for thermal ink jet printing devices, driving frequencies of the piezo element for either a drop-on-demand device or a continuous device, and the shape and size of the nozzle.
A penetrant (0-10 wt. %) may also be added to the ink composition employed in the process of the invention to help the ink penetrate the receiving substrate, especially when the substrate is a highly sized paper. A preferred penetrant for the inks of the present invention is n-propanol at a final concentration of 1-6 wt. %.
A biocide (0.01-1.0 wt. %) may also be added to prevent unwanted microbial growth which may occur in the ink over time. A preferred biocide for the inks of the present invention is Proxel® GXL (Zeneca Colours Co.) at a concentration of 0.05-0.5 wt. %. Additional additives which may optionally be present in ink jet inks include thickeners, conductivity enhancing agents, anti-kogation agents, drying agents, and defoamers.
Ink-receptive substrates useful in ink jet printing are well known to those skilled in the art. Representative examples of such substrates are disclosed in U.S. Pat. Nos. 5,605,750; 5,723,211; and 5,789,070 and EP 813 978 A1, the disclosures of which are hereby incorporated by reference.
Commercially available ink jet printers use several different methods to control the deposition of the ink droplets. Such methods are generally of two types: continuous stream and drop-on-demand.
In drop-on-demand systems, a droplet of ink is ejected from an orifice directly to a position on the ink receptive layer by pressure created by, for example, a piezoelectric device, an acoustic device, or a thermal process controlled in accordance with digital data signals. An ink droplet is not generated and ejected through the orifices of the print head unless it is needed.
The following examples illustrate the utility of the present invention.
EXAMPLES
Example 1
Control Example 1 (C1)
Mill Grind
Polymeric beads, mean diameter
325.0
g
of 50 μm (milling media)
C.I. Pigment Yellow 155
30
g
From Clariant Corp.
Oleoyl methyl taurine, (KOMT)
7.5
g
potassium salt
Deionized water
208.0
g
Proxel GXL ®
0.2
g
(biocide from Zeneca)
The above components were milled in a 2 liter double walled vessel obtained from BYK-Gardner using a high energy media mill manufactured by Morehouse-Cowles Hochmeyer. The mill was run for approximately 8 hours at room temperature. The dispersion was separated from the milling media by filtering the millgrind through a 4-8 μm KIMAX® Buchner Funnel obtained from VWR Scientific Products. An aliquot of the above dispersion containing 2.9 g pigment was mixed with 16.0 g diethylene glycol (DEG) and additional deionized water for a total of 100.0 g.
Control Example 2 (C-2)
This composition was prepared the same as C-1 except that it contained C.I. Pigment Blue 15:3 instead of C.I. Pigment Yellow 155 and an aliquot of this dispersion was used containing 1.75 g of pigment to mix with the DEG and water.
Control Example 3 (C-3)
This composition was prepared the same as C-2 except that it contained 0.6 g of an acetylenic diol, Surfynol® 465 (Air Products Co.).
Control Example 4 (C-4)
This composition was prepared the same as C-2 except that it contained 0.6 g of a secondary alcohol ethoxylate, Tergitol® 15-S-7 (Union Carbide Corp.) which is a mixture of linear secondary alcohols reacted with ethylene oxide.
Invention Example 1 (I-1)
This composition was prepared the same as C-1 except that it also contained 0.6 g of an ethoxylated surfactant, Tergitol® TMN-10 (Union Carbide Corp.).
Invention Example 2 (I-2)
This composition was prepared the same as C-2 except that it also contained 0.3 g of an ethoxylated surfactant, Tergitol® TMN-10 (Union Carbide Corp.).
Invention Example 3 (I-3)
This composition was prepared the same as I-2 except that the Tergitol® TMN-10 was employed at 0.6 g.
Invention Example 4 (I-4)
This composition was prepared the same as I-3 except that the pigment was C.I. Pigment Red 122 at 2.9 g.
Ink Reliability Testing
An apparatus that will fire a single nozzle of a 104 nozzle ink cartridge utilized to print each colored ink in the Kodak Professional 2042 Wide Format Inkjet Printers was designed and assembled. Crossover reliability testing between wide format printers and the single nozzle test apparatus (SNTA) indicated that delivery of 1.8 to 2.0 ml of ink in the SNTA, before the nozzle failed, was equivalent to delivery of 700 to 1000+ml of ink from a cartridge in a printer before one nozzle failed. The following results were obtained:
TABLE 1
Element
Nozzle (ml)
C-1
0.83
C-2
1.75
C-3
3.55
C-4
0.02
I-1
2.08
I-2
4.51
I-3
5.57
I-4
8.24
The above results show that the inks employed in the process of the invention provide superior reliability performance (higher amount of ink delivered before failure) in comparison to C-1 and C-2 which did not contain any surfactant, and C-3 and C-4 which contained control surfactants.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. | An ink jet printing method of the steps: A) providing an ink jet printer that is responsive to digital data signals; B) loading the printer with ink-receptive substrates; C) loading the printer with an ink jet ink composition of from about 30 to about 90% by weight of water, from about 0.5 to about 30% by weight of a pigment, from about 0.125 to about 7.5% by weight of an anionic dispersant, from about 0.05 to about 2% by weight of an ethoxylated trimethylnonanol, and from about 10 to about 50% by weight of a humectant of a polyhydric alcohol; and D) printing on an ink-receptive substrate using the ink jet ink in response to the digital data signals. | 2 |
BACKGROUND OF THE INVENTION
[0001] The invention relates to geared motors for window regulators in vehicles and more particularly window regulators with a window braking and irreversibility device.
[0002] The known window regulators have means for driving a window up and down. Persons may try to open a vehicle window by applying a downward pressure to the closed or partly opened window, in order to illegally gain access to the passenger compartment of the vehicle.
[0003] A window regulator, sold by the assignee under reference number 101087, comprises an electric motor with a reduction gear; an output shaft of the motor has teeth at one end forming a worm. This worm engages with a wheel to form a wheel and worm reduction gear. The wheel transmits the movement to a cable driving drum. The cable drives a slider attached to the window up and down. In this window regulator, a wheel and worm reduction gear with transmission efficiency of the order of 40 percent is used. When pressure is applied to the window, the motor and the low efficiency transmission lock the rotation of the wheel. The irreversible driving up and down of the window by the drum is thus assured.
[0004] This device has disadvantages. Because of the low transmission efficiency, driving the drum requires the use of a motor that is oversized relative to the drive force actually applied to the drum. The motor is thus bulky and costly.
[0005] German Patent Application DE-A-3110368 discloses a window regulator comprising a drive component coupled to a drum. The drum drives a window up and down by means of a cable attached to a window slider. The drum is equipped with a mechanical locking device. A gear placed on the axis of the drive shaft is equipped with lugs projecting axially. These lugs lock against a fixed plate arranged in the structure of the window regulator. The window regulator is released when the drive shaft drives the drum and locked when the drum drives the drive shaft.
[0006] This device is complex and costly. Moreover, the drum is bulky. This device also requires the use of an additional braking system in order to stop the window from rising when an obstruction is detected.
[0007] The device sold by the assignee under reference number 101087 also comprises an anti-pinch system. The system measures the current consumed and the rotating speed of the motor. The system detects the pinching of an object between the top of the window and the window frame from variations in these parameters. The power supply to the motor is then interrupted and the driving of the window is thus stopped.
[0008] This anti-pinch device has disadvantages. The response time between the pinching of an object and the actual stopping of the movement of the window is significant. As the window is still being driven during this response time, a user may be injured. It is also more difficult to obtain approval for vehicles using this type of window regulator.
SUMMARY OF THE INVENTION
[0009] There is therefore a need for a window regulator and a geared motor that provide a solution to one or more of these disadvantages. The object of the invention is thus a window regulator comprising an electric motor having a drive shaft, a window slider, a transmission having an input driven by the drive shaft and an output driving the slider, with a piezoelectric element selectively locking the position of the slider.
[0010] According to one embodiment, the piezoelectric element acts upon the drive shaft.
[0011] According to another embodiment, the piezoelectric element has a friction surface that is able to lock the position of the slider.
[0012] According to a further embodiment, the friction surface has a coefficient of friction on the shaft greater than 0.15.
[0013] According to yet another embodiment, the transmission has a reduction gear with a speed reduction ratio between the input and the output of the geared motor of less than 1.
[0014] Provision may also be made for the reduction gear to comprise a worm wheel system, the worm being provided on the drive shaft.
[0015] According to one embodiment, the piezoelectric element forms a journal of the drive shaft.
[0016] According to another embodiment, the piezoelectric element locks the drive shaft by means of a split bearing.
[0017] According to a further embodiment, the motor comprises a housing with a journal, and the piezoelectric element has an outer surface permanently housed in the journal and an inner surface acting upon the bearing.
[0018] According to yet another embodiment, the piezoelectric element is piezostrictive.
[0019] Provision may also be made for the piezoelectric element to selectively brake the movement of the slider.
[0020] Another object of the invention is a geared motor comprising a drive shaft, a reduction gear coupled to the drive shaft with a speed reduction ratio between the input and the output greater than 1, and a piezoelectric element selectively locking the drive shaft.
[0021] According to one embodiment, the piezoelectric element has a friction surface which is able to lock the shaft, this surface preferably having a coefficient of friction with the shaft greater than 0.15.
[0022] According to another embodiment, the reduction gear has a worm wheel system, the worm being provided on the drive shaft.
[0023] According to a further embodiment, the piezoelectric element forms a journal of the drive shaft.
[0024] According to yet another embodiment, the piezoelectric element locks the drive shaft by means of a split bearing.
[0025] Provision may also be made for the geared motor to comprise a housing with a journal, the piezoelectric element having an outer surface permanently housed in the journal and an inner surface acting upon the bearing.
[0026] According to one embodiment, the piezoelectric element is piezostrictive.
[0027] According to another embodiment, the piezoelectric element selectively brakes the drive shaft.
[0028] A further object of the invention is a method for operating a window regulator comprising the steps of locking the slider position by means of the piezoelectric element when the motor is switched off and unlocking the slider position when the motor is supplied with power.
[0029] According to one embodiment, the piezoelectric element has two terminals, is piezostrictive and is not supplied with power during the slider locking step.
[0030] According to another embodiment, the method comprises the steps of the driving of the slider by the motor, obstruction detection and braking of the movement of the slider by means of the piezoelectric element.
[0031] According to a further embodiment, the method also comprises a stage of short-circuiting the power supply to the motor after an obstruction has been detected.
[0032] Other characteristics and advantages of the invention are given in the following description of embodiments of the invention, given by way of example and with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 is if a schematic representation of a window regulator comprising a geared motor according to the invention;
[0034] FIG. 2 is a longitudinal cross-section view of a geared motor according to the invention;
[0035] FIG. 3 is a transverse cross-section view of details in FIG. 2 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0036] The invention provides in particular a window regulator and a geared motor driving a window slider. A piezoelectric element locking the slider locks the position of the slider when the motor is switched off. Thus when an attempt is made to open the window by forcing it from the outside, the window stays locked in its position.
[0037] FIG. 1 shows a schematic view of a window regulator 1 according to an embodiment of the invention. The window regulator 1 comprises a slider 2 attached to a window, not shown. The slider 2 can slide for example on a guide rail 3 . A cable 4 drives the slider 2 . This cable 4 is itself driven by a drum 5 . This drum 5 is coupled to the wheel of a geared motor 6 , for example by means of a damper. The geared motor is for example fixed to a structural part 7 of the window regulator 1 .
[0038] As shown in more detail in FIG. 2 , the geared motor 6 is housed in a housing 67 . A motor 64 has a rotor 65 and a power supply and control device 66 that can be produced in a way known per se. The wheel 61 is the output element of a wheel and worm reduction gear. The wheel 61 is driven by a worm gear pair 62 made on the output shaft 63 of the motor 64 . The reduction gear ensures the transmission of mechanical power between the drive shaft 63 and the drum 5 . The reduction gear also has a speed reduction ratio between the input and the output of the geared motor greater than 1. The input speed of the reduction gear is thus greater than the output speed of the reduction gear. Although a wheel and worm reduction gear was used in the example, it is possible to use any type of appropriate reduction gear. A damper 73 connects the drum 5 and the wheel 61 . The damper in particular absorbs the shocks during the transient drive phases of the motor. The drum 5 serves as winding component for the cable 4 that drives the slider.
[0039] In this embodiment, the geared motor comprises a piezoelectric element that selectively locks the position of the slider. The use of a piezoelectric element for locking the slider permits the use of a small size locking part with a simple shape. An appropriate piezoelement is moreover easy to produce. The locking of the slider can also be selectively controlled using simple means with a piezoelectric element. The piezoelectric element can lock the slider position by braking. Braking that locks the position of the slider to a force of 500 N applied to the window is seen as locking. The slider position is selectively locked in order to ensure the irreversibility of the window regulator. Thus, the driving of the slider by the window is prevented, while the driving of the slider by the motor is permitted. Means allowing for the selective locking of the slider will be detailed later. Generally, the slider position is locked when the motor is switched off and the slider position is unlocked when the motor is supplied with power. As the irreversibility is selective, it is possible to use a reduction gear with high transmission efficiency. A less powerful motor can then be used, for example a 20-Watt motor.
[0040] The slider position is locked in the example in FIG. 2 by locking the drive shaft by means of the piezoelectric element. As shown in more detail in FIG. 3 , the piezoelectric element can be used as a journal of the motor. The geared motor can thus be kept small. Moreover, the volume of the drum is not increased. A substantially cylindrical piezoelectric element can be used. The piezoelectric element can be placed in a recess in the housing 67 or be mounted with a tight fit in a hole in the housing 67 . Generally, an outer surface of the piezoelectric element can be permanently housed in a hole in the housing. It is advantageous to arrange the piezoelectric element in the housing 67 of the geared motor 6 . The electrical connections of the piezoelectric element can thus be located in the same place as the motor power supply electrical connections. The electrical wiring of the window regulator 1 can thus be simplified.
[0041] The piezoelectric element 68 can lock the drive shaft 63 by means of a shaft rotation guide component. A split bearing 69 can for example be used for this, as shown in FIGS. 2 and 3 . In this embodiment, the split bearing 69 is housed against an inner surface of the piezoelectric element 68 . The bearing has a substantially longitudinal split 70 . The diameter of the bearing 69 can thus vary. By placing a radial load on the bearing 69 , the width of the slit 70 and the diameter of the bearing can be reduced. The brake force applied by the bearing 69 on the shaft 63 is thus increased. When the piezoelectric element 68 is in a dilated position, i.e. when its inner diameter has a minimum size, the inner surface of the piezoelectric element 68 acts upon the split bearing 69 and reduces the width of the split 70 . The rotation of the drive shaft 63 is then locked by the bearing 69 .
[0042] A piezoelectric element 68 made of quartz or barium titanate can be used. A piezostrictive material is preferably used to make the piezoelectric element. Thus, the piezoelectric element is in a dilated position or locking position when idle. When the power supply to the piezoelectric element is interrupted, due to a dead battery for example, the piezoelectric element 68 still continues to lock the slider position. A 10 mm×8 mm×5 mm piezoelectric element can be used with a reduction gear with a speed reduction ratio of 73 to ensure a locking force of 500 N on the slider. An unlocking voltage of 12 to 60 V between the electrodes releases the drive shaft.
[0043] An electrode is preferably arranged on the outer circumference of the piezoelectric element and another electrode on the inner circumference of the piezoelectric element. A greater variation of the inner diameter of the piezoelectric element is thus ensured.
[0044] A split bearing 69 made of sintered and lubricated bronze can be used. A bearing with dimensions of inner diameter 8 , a minimum thickness of 5 mm and a minimum outer diameter of 10 mm is suitable to ensure the locking of the drive shaft 63 .
[0045] Provision can also be made for the piezoelectric element 68 to act directly upon the drive shaft 63 . A piezoelectric element 68 with a friction surface with a high coefficient of friction with the drive shaft will preferably be used. A coating with a high coefficient of friction with the drive shaft can also be used. This coating can for example be applied to the surface of the piezoelectric element coming into contact with the drive shaft. A friction surface with a coefficient of friction greater than 0.15 is preferably used.
[0046] The arrangement of the piezoelectric element 68 upstream of the reduction gear, and on the drive shaft in particular, is advantageous. A piezoelectric element with reduced braking power can be used because the reduction gear multiplies the braking torque applied by the piezoelectric element on the slider.
[0047] The piezoelectric element 68 can also be used to selectively brake the movement of the slider 2 . The arrangement of the piezoelectric element on the drive shaft is also advantageous for carrying out this braking. It is possible to brake the movement of the slider when an obstruction of the window is detected. The braking using the piezoelectric element allows for the inertia of the motor to be reduced more quickly. The response time between the identification of an obstruction and the stopping of the slider and the window can thus be reduced. Moreover, a piezoelectric element that already exists to ensure that the movement of the slider is irreversible is used for this.
[0048] A piezoelectric element control shared with the control of the motor power supply can be used. Provision can be made for the control to apply different voltages to the terminals of the piezoelectric element depending on the operation to be carried out. Different braking or unlocking voltages can be used depending on the external conditions detected, such as the temperature, the power supply status of the motor or the pinching of an object.
[0049] The invention also relates to methods for operating the window regulator and the geared motor described.
[0050] According to a first method of operation, the slider position is locked by means of the piezoelectric element when the motor is switched off. The piezoelectric element can for example be kept idle during this step, for example when a piezostrictive piezoelectric element is used. The position of the slider is unlocked, for example by exciting a piezostrictive piezoelectric element, when the motor is supplied with power.
[0051] According to a second method for operating a window regulator, the steps of driving the slider by the motor are carried out. An obstruction of the window is detected by appropriate means. A braking order is then sent to the piezoelectric element for example when an obstruction is detected. The movement of the slider is then braked by means of the piezoelectric element.
[0052] According to one embodiment, the power supply to the motor is short-circuited after the detection of an obstruction. Additional braking is thus provided by a motor brake.
[0053] Of course this invention is not limited to the examples and embodiments described and shown, but is open to a number of embodiments accessible to a person skilled in the art. Although the locking of the slider position on a drive shaft has mainly been described, provision can of course be made to carry out this locking in any suitable place. For example, provision can be made to install a piezoelectric locking element placed on a slider and acting on a guide rail. Provision can also be made for a piezoelectric element on the reduction gear wheel acting upon the housing of a geared motor. | A window regulator includes an electric motor having a drive shaft, a window slider, a transmission having an input driven by a drive shaft, and an output driving the slider. A geared motor includes a drive shaft, a reduction gear coupled to the drive shaft and having a transmission ratio less than 1, and a piezoelectric element selectively locking the drive shaft. The window regulator can be used to prevent fraudulent opening of a window and to reduce the jamming force of an object between the window and the window frame. | 4 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to magnetic resonance image (MRI) imaging, and, more particularly, to methods and apparatus for assembling magnetized permanent magnetic blocks used for an MRI magnetic field generator.
[0002] A high uniform magnetic field is useful for using magnetic resonance image (MRI) and nuclear magnetic resonance (NMR) systems as a medical device or a chemical/biological device. At least some popular and low maintenance cost MRI systems currently available use a permanent magnet system that creates a middle range uniform field (0.2 to 0.5 Tesla) in a pre-determined space (imaging volume). A permanent magnet system usually uses multiple permanent magnet blocks such as NdFeB to form a single magnetic object and to achieve desire high uniform magnetic field in the imaging volume.
[0003] For a magnetic field generator for an MRI system that uses permanent magnets, the magnets used in such an apparatus are often formulated from a plurality of magnetized blocks. However, it is difficult to place un-magnetized material blocks on a yoke plate first and then magnetize each block. Therefore, in actual manufacturing, the blocks are fabricated and then magnetized. The magnetized blocks are then arranged on a yoke plate so that each of the magnet blocks has a same magnetic pole facing upward. A pole piece is then placed on the top of the magnetized blocks.
[0004] It is generally known that when a substance such as human tissue is subjected to a uniform magnetic field (polarizing field B 0 ), the individual magnetic moments of the spins in the tissue attempt to align with this polarizing field, but precess about it in random order at their characteristic Larmor frequency. If the substance, or tissue, is subjected to a magnetic field (excitation field B 1 ) which is in the x-y plane and which is near the Larmor frequency, the net aligned moment, or “longitudinal magnetization”, MZ, may be rotated, or “tipped”, into the x-y plane to produce a net transverse magnetic moment Mt. A signal is emitted by the excited spins after the excitation signal B 1 is terminated and this signal may be received and processed to form an image.
[0005] When utilizing these signals to produce images, magnetic field gradients (Gx Gy and Gz) are employed. Typically, the region to be imaged is scanned by a sequence of measurement cycles in which these gradients vary according to the particular localization method being used. The resulting set of received NMR signals are digitized and processed to reconstruct the image using one of many well known reconstruction techniques.
[0006] MRI magnets typically require not only an intensive uniform magnetic field, typically less than 10 ppm within a 40-50 cm spherical volume, but also an accurate center magnetic field value, typically less than 0.5%. For a given design of the RF coil, the bandwidth is fixed. Thus the allowable range of the center magnetic field is also fixed.
[0007] One known configuration of the magnetic field generating device for MRI is the open geometry composed of yokes opposite to each other, connected by post(s), magnetic field generating elements, such as permanent magnets and/or superconducting/resistive coils, and other field shaping components, such as pole pieces.
[0008] The magnetic field of the magnet as manufactured, is often influenced by the deviation of material properties, the tolerance of manufacturing process and the environment. For Superconducting and resistive magnets, the center field can be easily adjusted by fine tuning the current. For permanent magnet, however, this is not that easy. Mechanisms typically are built into the magnet in order to adjust the magnet center field after the magnet is finished assembly.
BRIEF DESCRIPTION OF THE INVENTION
[0009] In one aspect, a product line of MRI systems is provided. The product line includes a first MRI system including a first yoke and a plurality of magnet blocks forming a first central assembly disposed on the first yoke. The product line also includes a second MRI system including a second yoke, a plurality of magnet blocks forming a second central assembly disposed on the second yoke and shaped the same as the first central assembly, and a first set of magnet blocks mounted to the second yoke at a periphery of the second central assembly.
[0010] In another aspect, a method of manufacturing MRI systems is provided. The method includes providing a plurality of magnet blocks forming a central assembly disposed on a yoke, measuring a center magnetic field, and adding additional magnet blocks to the yoke when the center magnetic field is not within a predetermined range.
[0011] In still another aspect, a method for altering a magnetic field is provided. The method includes measuring a center magnetic field of an MRI system to obtain a center magnetic field value and regulating a temperature of at least one component of the MRI system to change the center magnetic field to a value different the measured value.
[0012] In a further aspect, a method for altering a magnetic field is provided. The method includes measuring a center magnetic field of an MRI system to obtain a center magnetic field value and using a B 0 controlled shimming to change the center magnetic field to a value different the measured value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 is a block schematic diagram of an imaging system.
[0014] [0014]FIG. 2 is a block schematic diagram of an imaging system.
[0015] [0015]FIG. 3 illustrates a central magnet assembly disposed on the yoke shown in FIG. 1.
[0016] [0016]FIG. 4 illustrates a plurality of sets of magnetic blocks disposed illustrates a plurality of sets of magnetic blocks disposed at a periphery of the central assembly shown in FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
[0017] As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural said elements or steps, unless such exclusion is explicitly recited. Furthermore, references to “one embodiment” of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.
[0018] [0018]FIG. 1 is a block schematic diagram of an imaging system 10 such as an MRI system 10 including two plate yokes 12 and a plurality of columnar yokes 14 extending between plate yokes 12 . Alternatively, an MRI system 10 with a single C shaped yoke 16 may be used as shown in FIG. 2. System 10 includes magnet blocks 18 secured to yoke surfaces, pole piece bases 20 and support rings 22 secured to magnets 18 and a pole piece 24 is secured to each pole piece base 20 and support ring 22 . A gap 25 is formed between pole pieces 24 . A body part to be imaged is inserted into gap 25 .
[0019] MRI system 10 also may contain electronics 26 and a display 28 . Electronics 26 may include a control system such as a computer, a transmitter, a receiver, an imager and/or a memory.
[0020] [0020]FIG. 3 illustrates a central assembly 30 including a plurality of magnetic blocks 18 disposed on yoke 12 . Central assembly 30 includes a periphery 31 .
[0021] In use, central assembly 30 is disposed on yoke 12 , and a measurement is taken of a center magnetic field. The measurement is compared to a desired value and if the measured value is different from the pre-determined desired value then the center magnetic field value is altered as herein described. In one embodiment, a temperature of at least one component of the finished assembly 10 is regulated such that the center magnetic field value is substantially equal to the desired value. In an exemplary embodiment, at least one heating element (not shown) is positioned to heat yoke 12 . In another embodiment, the center magnetic field value is changed to be closer to the desired value but is several percent away from the desired value falling within a range above and below the desired value. By heating at least one component of finished assembly 10 , the center magnetic field is alterable by about 1.5 percent stronger or weaker. Alternatively, the center magnetic field is changed using B 0 controlled shimming. Using B 0 controlled shimming, the center magnetic field is also alterable by about 1.5 percent stronger or weaker.
[0022] With this method, sufficient shimming of a magnet assembly such as central assembly 30 may be achieved without requiring mechanical variations to the magnet assembly after the magnet assembly has been assembled. The method, which may be carried out as a set of instructions of a computer program by one or more computers, analyzes the center magnetic field. A comparison is then made to the desired center magnet field strength, and active and/or passive shim elements may then be incorporated into the magnet assembly at different places to achieve the desired center magnetic field strength. The shimming or weighting factors are used to determine the amount of “shimming material” that is used at each place.
[0023] “Shimming material” varies according to the type of shim element. For example, for active shim elements, i.e. shim coils, the shimming material corresponds to the amount of current applied to the coils. By varying the amount of current applied to the coils, the amount contributed to the magnetic field can be varied. As a result, the shim coils can be independently controlled such that field contribution is precisely controlled. For passive shim elements, i.e. iron shims or permanent magnets, the shimming material corresponds to the amount of magnetic element that is added to the magnet assembly.
[0024] In accordance with another aspect of the present invention, a computer readable storage medium having a computer program stored thereon to develop a shimming model for a magnet assembly of an MR imaging system, the computer program representing a set of instructions that when executed by a computer causes the computer to change the center magnetic field generated by an assembled magnet assembly. The set of instructions then causes the computer to determine an amount of shimming required at each of the places such that a desired center field strength is maintained.
[0025] In an exemplary embodiment utilizing B 0 controlled shimming, upon construction of the magnet assembly, the magnet temperature is adjusted and allowed to stabilize. And after the magnet temperature has stabilized, the center field strength is measured. If the center field strength is within a pre-determined range, then a B 0 controlled shimming process is not performed, but other downstream processes may be performed, and the magnet assembly is incorporated into an MR assembly. However, if the center field strength is outside the predetermined range, then a B 0 controlled shimming process continues with the input of system and shim constraints into one or more computers programmed to determine shimming parameters.
[0026] The constraints input include the desired center field strength range and the measured center filed strength. Other inputs include magnet system geometry constraints as well as shimming constraints. The shimming constraints include the physical limitations on each type of potential shim and placement of the shims within the magnet. For example, for active shims, constraints may include the maximum or minimum acceptable current that may be applied to the shim coils or the maximum permanent magnetic material of proper polarity in each predetermined locations to control field contributions. In another example, mass constraints may be input for passive shims such as iron cores. As will be described in greater detail below, these constraints are utilized by a shimming algorithm to determine shim placement, type of shim, and amount of shim at any particular location.
[0027] One technique, which is carried out by one or more computers, begins with the reception of system and shim constraints input. From the system and shim constraints, an objective function is formulated. The objective function, which may take one of many forms, is defined to determine a minimum amount of shimming required throughout the magnet assembly such that the desired center field strength is achieved or, if applicable during a field maintenance procedure, is maintained.
[0028] From the constraints relative to the objective function, an ideal solution is determined. The ideal solution sets forth the amount of shimming required at a number of locations or target points within the magnet assembly. However, it is necessary to take into consideration that the amount of shimming identified at each location may not be precisely possible. For example, iron shims are fabricated with varying degrees of mass. As such, there may not be an iron shim having the exact particular shim value identified as “ideal”. Therefore, it is necessary to discretize the ideal solution at to address variations between the “ideal” shim values and the shim values that are available. From the discretizing process, shim locations and shim amounts are output.
[0029] As noted above, the shimming algorithm may utilize one of a number of objective functions designed to address field inhomogeneities and field strength simultaneously. For example, a Linear Programming (LP) approach or implementation may be used or a least squares method. In one LP approach, the objective function may be defined as:
Minimize Obj=ΣVi ( Ii+−Ii −)+Σ Wj*Yj (Eqn. 1).
[0030] limited or subjected to the following constraints:
− I max ≦I i − ≦0 (Eqn. 2);
0≦ I i + ≦I max (Eqn. 3);
Y L ≦Y j ≦Y U (Eqn. 4);
B L ≦AX≦B U (Eqn. 5);
[0031] Where Ii−, Ii+ are state variables for active shims, such as resistive, superconducting or permanent magnet shims. For shimming coils, these are the amount of currents of appropriate sign required in the coil. For permanent magnet shims, these are the amounts of permanent magnet material of the appropriate polarity. Yj is the state variables for passive shims. These are the amount of passive shims placed at each location. V i is the weighting factors for the active shims. W j is the weighting factors for the passive shims. A is a shim strength matrix of the active and passive at each shim location, either in terms of field contributions to each shimming points or in terms of spherical harmonics including the B 0 contribution. X is a vector of all the state variables. B L and B U are the constraint lower and upper bound vectors, in terms of field (Gauss, Tesla) or harmonics (ppm). These are the actual constraints that define the desired center field strength. It should be noted that Eqn. 5 may be characterized as |AX−B target | where B target is the target field or harmonics, and ε is the allowable tolerance vector.
[0032] [0032]FIG. 4 illustrates a plurality of sets of magnet blocks 18 mounted to yoke 12 . One set includes magnetic blocks 18 numbered 32 , another set includes magnetic blocks 18 numbered 34 , and another set includes magnetic blocks 18 numbered 36 . Still another set includes magnetic blocks 18 numbered 38 , while another set of magnetic blocks 18 includes blocks numbered 40 in FIG. 4. In an exemplary embodiment, blocks 32 and 34 are half blocks in that they are approximately one-half the size of all other blocks 18 .
[0033] In use, central assembly 30 is disposed on yoke 12 and the center magnetic field is measured. In an exemplary embodiment, the center magnetic field is measured such as with a Tesla meter or Gauss meter. The measured value is compared against a desired value and a set of blocks is disposed on yoke 12 at a periphery of central assembly 30 . Accordingly, different MRI systems have substantially the same center magnetic field strength but with different configurations of magnetic blocks to account for manufacturing differences between various blocks 18 . Also, a single MRI can have different block configurations for a top yoke 50 and a bottom yoke 52 (Shown in FIG. 1) to adjust the center magnetic field. Note that the use of half block and full block additions to central assembly 30 are typically made during an initial fabrication of MRI system 10 , while B 0 shimming and magnetic block temperature regulation as explained above are typically employed in the field or in the factory after finishing magnet assembly to recalibrate the center magnetic field and field homogeneity, but the effects are cumulative and can be employed together in all permutations of combinations. Using half blocks 32 and 34 , the center magnetic field is alterable by about 1 percent stronger or weaker. Using three sets of blocks 36 , 38 , and 40 , the center magnetic field is alterable by about 3.5 percent stronger or weaker.
[0034] The herein described methods and apparatus provide a novel approach to changing the center magnetic field. The herein described methods and apparatus also provide methods and apparatus useable during an assembly of an MRI system and after assembly.
[0035] Exemplary embodiments of methods and apparatus for changing the center magnetic field are described above in detail. The methods and apparatus are not limited to the specific embodiments described herein, but rather, components of each method and apparatus may be utilized independently and separately from other components described herein. In addition, each method and apparatus component can also be used in combination with other components described herein.
[0036] While the invention has been described in terms of various 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. | A product line of MRI systems includes a first MRI system including a first yoke and a plurality of magnet blocks forming a first central assembly disposed on the first yoke. The product line also includes a second MRI system including a second yoke, a plurality of magnet blocks forming a second central assembly disposed on the second yoke and shaped the same as the first central assembly, and a first set of magnet blocks mounted to the second yoke at a periphery of the second central assembly. | 6 |
CROSS REFERENCE TO RELATED PATENTS
This application is a continuation of U.S. non-provisional patent application Ser. No. 11/967,388 filed Dec. 31, 2007, and now abandoned herewith. Priority is claimed to U.S. Provisional application No. 60/897,883 filed Jan. 29, 2007.
BACKGROUND OF THE INVENTION
The present invention is in the field of quick connect couplers.
Quick connect couplers are well known and commonly used in connecting air powered tools to highly pressurized spraying systems. Quick connect couplers allow a user to merely push two portions of the coupler together to connect a fluid or gas line. Numerous types of quick connect couplers exist in the art. These couplers are usually designed to be freely rotatable around a center axis. The problem with such couplers is that there exist applications where minimal, or no rotatable action is desired. In some dispensers, for example, accessories exist that require the user to rotate the nozzle in order to adjust the spray pattern. Traditionally configured couplers do not allow the convenient use of such accessories in a quick connect configuration due to the fact that the coupler will rotate freely, thus not providing the resistance necessary to adjust the accessory and requiring the operator to use two hands, one to hold the work piece in position and the other to adjust the controls. Another example would be in a sprinkler system using rotating sprinkler heads, such as impact heads. The base of such heads has to be held against a rotation so that the sprinkler head will rotate as desired. If the coupler and the base of the sprinkler head are free to rotate, the sprinkler may stay in substantially one position with the sprinkler head base moving back and forth. Another example would be when connecting hose lines in pneumatic or hydraulic applications. There exist instances where it is required to orient the connector in such a manner and have it remain in the intended rotational position. Examples include the use of in-line pressure gauges, venturi valves, and other auxiliary pieces. Traditionally configured couplers do not allow the user to orient the connector in such a manner because the hose or accessory would freely self-adjust to its most natural position being influenced by the weight of gravity or the twisting influence of a hose line. Another example would be when it is required to open or close a shut-off valve after the coupler is engaged or before it is disengaged, as is the case with some industrial and medical hose lines. Once connected the coupler is rotated to open the nipple valve and allow flow.
These quick connect couplers have been known in the art for a long time and some attempts have been tried over the years to stop the natural rotation. These attempts are usually designed in such a way that require changes to both the male and female portions of the coupler, thus making them not compatible with the standard mating piece on the market. That is to say, the male portion of the recently improved components may be compatible with a standard female socket, but the features that prevent rotation may not be functional. Thus, it is desirable to provide a quick connect coupler that limits rotation and is backwards compatible with traditional configured couplers while still maintaining its additional function of rotation limitation. It is in this light that the present invention seeks to limit rotation through implementation of an improved quick connection device that interacts with the common feature of a traditional mating coupler piece in order to achieve limited rotational movement.
SUMMARY OF THE INVENTION
The present invention comprises a quick connect and disconnect coupling system which includes a respective male and female fittings having respective interlocking portions which prevent relative rotation there between in the coupled condition and a dispensing accessory. The coupling is particularly useful for applications wherein free rotation of the ends of the coupler is undesirable such as for connecting accessories such as spraying devices that require rotary action to adjust the dispensing action.
The quick connect and disconnect coupling system includes a male plug having a coupling end and an attachment end and a female socket having a coupling end with a receiving opening to receive the coupling end of the male plug. A locking mechanism is associated with and co-operable between the male plug and the female socket to secure the coupling end of the male plug when the coupling end of the male plug is inserted into the receiving opening and to release the coupling end of the male plug from the receiving opening when desired to disconnect the male plug from the female socket. The male plug includes a male component and an annular groove with integrated longitudinal ridge that engages the locking mechanism on the female socket to prevent relative rotation of the male plug and the female socket when the connectors are in a coupled condition. Such interlocking or engaging surfaces may take the form of one or more ridges extending radially from the ball receiving recess in the coupling end of the male plug to mate with at least one retaining ball located in the female socket of the locking mechanism.
The holding mechanism may include at least one ball retaining hole through the coupling end of the female socket with a ball positioned in at least one ball retaining hole. A sleeve having a first inside diameter portion and a tapered portion extending from the first diameter portion to a larger diameter portion is slidably mounted on the coupling end of the female socket over at least one ball retaining hole so that the first diameter portion or tapered portion may be selectively aligned with at least one ball retaining hole so that the first diameter portion or tapered portion may be selectively aligned with the at least one ball retaining hole. When the first diameter portion is aligned with the at least one ball retaining hole, it holds the ball in the at least one ball retaining hole in an inward position wherein the ball extends into the receiving opening. When the tapered portion of the larger diameter portion is aligned over the at least one ball retaining hole it allows the ball in the at least one ball retaining hole to move to an outward position of the receiving opening. A spring biases the sleeve to a biased position wherein the first diameter portion is aligned with the at least one ball retaining hole. A ball receiving recess in the coupling end of the male plug, receives the ball in the at least one ball retaining hole when the coupling end of the male plug is received in the receiving opening of the female socket. The male and female couplers are held together by holding the ball in the at least one ball retaining hole in inward position to extend into the ball receiving recess.
One of the primary characteristics of the improved quick connect coupler system is that only one portion of the coupler system, namely the male plug, has an improved design. The improvement applied to the male plug is intended to function within the existing design of the traditional female socket. That is, by to say that each of both the female and male couplers are interoperable with or without the improvement, thereby ensuring backwards compatibility with the traditional or non-improved designs.
Further objects and advantages of the invention will become apparent from a consideration of the drawings and ensuing detailed description.
DETAILED DESCRIPTION OF THE DRAWINGS
Brief description for carrying out the invention is illustrated in the accompanying drawings, in which:
FIG. 1A is a perspective view of a male quick connect plug attached to a dispensing accessory implementing an embodiment of the non-circular surface, or ridge, located between the ball engagement surface and the backwardly rising surface, thus bridging the two surfaces.
FIG. 1B is a side elevation view of the same male quick connect plug.
FIG. 1C is a side view of the same male quick connect plug;
FIG. 2 is an exploded perspective view of a male quick connect plug attached to a dispensing accessory and a female quick connect socket assembly;
FIG. 3A is a side view of a male quick connect plug attached to a dispensing accessory and a female quick connect socket assembly.
FIG. 3B is a perspective view of the same dispensing accessory attached to a female quick connect socket assembly;
FIG. 4A is a partial perspective view of a male quick connect plug with an alternate embodiment of the ridge located between the ball engagement surface and across toward the backwardly rising surface.
FIG. 4B is a side view of the same male quick connect plug with an alternatively designed ridge;
FIG. 5A is an exploded perspective view of an alternative design showing a quick connect plug and an attachable clip.
FIG. 5B is a perspective of a clip assembled to a male connect plug;
FIG. 6 is a lateral sectional view of FIG. 3A showing an anti-rotation ridge on the male plug and engagement surfaces of the female socket;
FIG. 7 is a transverse sectional view taken through plane A-A of FIG. 3A ;
FIG. 8 is an elevated perspective view of a sprayer accessory rotatably adjustable;
FIG. 9 is a side sectional view of a sprayer accessory threadably attached to male quick connector plug;
FIG. 10 is an elevated perspective view of multiple sprayer accessories usable with same socket.
DETAILED DESCRIPTION OF THE INVENTION
It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention. The following exemplary embodiment is provided to further illustrate the invention and is not to be construed to unduly limit the scope of the invention.
Referring to FIGS. 2, 3A and 3B , the non-rotating quick connector 10 comprises a male connector 31 , a female connector 67 , a tubular sleeve 62 , a compression spring 63 , a lock ring 60 , O-rings 61 and one or more locking balls or pins 64 .
Male connector 31 includes an internally or externally threaded portion 57 forming an attachment end integrally connected to a male plug or coupling portion or end 50 by means of a shoulder portion 54 intermediate the length of the connector 31 . Male plug 50 has an annular surface and further includes a fluid or air channel 97 which extends either partially or completely through the male connector 31 , at least one selectively annular retaining ball groove 55 about coupling portion 50 , and one or more ridges 52 purposely positioned generally longitudinal along axis 20 and extending between forwardly angled ball retention inclined surface 51 , across annular groove 55 and interconnecting to backwardly angled inclined surface 53 , ridge 52 thereby extending longitudinally and radially within groove 55 . Male connector 31 further includes a hexagonally or otherwise flattened sided shaped gripping surface 56 . A highly pressurized sprayer attachment accessory 30 is shown attached to the male connector 31 , as an example, but may comprise other forms or configurations. There exist other configurations of male plug designs that incorporate single shut-off, double shut-off and straight-through configurations which all could apply to the present invention.
Female connector 67 comprises an externally or internally threaded portion 73 forming an attachment end integrally connected to a female quick connect socket portion 66 by means of a shoulder portion 58 . Female connector 67 further comprises a hexagonally or otherwise flattened sided shaped gripping surface 72 . Female connector 67 further includes a water of air channel 71 ( FIG. 7 ) which extends partially or completely through female connector 67 , one or more tapered ball or pin recesses 65 extending through female socket portion 66 , and internal o-ring grooves (not shown) inside a shoulder portion (not shown). There exist other configurations of female socket designs that incorporate single shut-off, double shut-off and straight-through configurations which all could apply to the present invention.
Sleeve 62 includes an annular internal shoulder 15 having an annular tapered portion 70 , an axially flat annular portion 81 and a radially flat annular portion 75 , and also includes an annular exterior gripping surface 69 . Lock ring 60 is secured in annular lock ring groove 68 during assembly after sleeve 62 is slid over female coupling portion 66 with balls or pins 64 in recesses 65 . There exist other configurations of quick connect sleeve assemblies of which this invention would apply.
Compression spring 63 biases sleeve 62 against lock ring 60 and comprises a piece of wire wound around one or more turns at such a radius as to closely fit about female socket portion 66 of female socket 67 . There exist other configurations of quick connect spring assemblies of which this invention would apply.
Locking rings 60 , O-rings 61 and retaining balls or pins 64 are of standard construction known in the fluid and air flow industries, as is the construction of the ball or pin retaining recess 65 to retain balls or pins 64 therein. There exist other configurations of quick connect locking and O-ring assemblies of which this invention would apply.
Female socket portion 66 , sleeve 62 , compression spring 63 , lock rings 60 , O-rings 61 and retaining balls or pins 64 fit together as shown in FIGS. 7, 3A and 3B . Spring 63 is disposed about female socket portion 66 of female connector 67 with sleeve 62 disposed thereabout, retaining balls or pins 64 being retained within respective retaining recesses 65 by internal shoulder 15 of sleeve 62 . Sleeve 62 is retained on female connector 67 by means of lock rings 60 , which are secured in annular lock ring groove 68 about female socket portion 66 and abut internal shoulder 15 of sleeve 62 as sleeve 62 is biased by spring 63 to a forward locking position. When in locking position, retaining balls or pins 64 are retained in an inwardly biased position by contact with axially flat annular portion 81 of sleeve 62 so as to partially extend into the media channel 71 . When sleeve 62 is manually influenced against the bias of spring 63 to a rearward position by engagement between the spring and radially flat annular portion 75 , balls or pin 64 are disposed adjacent annular tapered portion 70 or larger diameter annular portion 16 of sleeve 62 , which permits balls or pins 64 to move radially outwardly so as to be removed from inside media channel 71 . O-rings 61 are disposed within respective O-ring grooves (not shown).
Male and female connectors 31 and 67 removably couple together by forcing sleeve 62 to the rearward position against the bias of spring 63 such that retaining balls or pin 64 can clear the media channel 71 when the male coupling portion 50 , which fits closely in media channel 71 , is moved into position in media channel 71 . When male and female connectors 31 and 67 are rotated relative to one another to the proper position or otherwise interconnected, anti-rotation ridge or ridges 52 each fit into a region 17 between two adjacent retaining balls or pins 64 , the respective surfaces thereof on opposite sides of region 17 being thereby engageble by ridge 52 as shown in FIG. 6 to prevent such relative rotation. Male coupling portion 50 is moved into the opening in female socket portion 66 so that groove 55 is aligned with ball or pin receiving recesses 65 and balls or pins 64 therein so that balls or pins 64 can extend into groove 55 . Sleeve 62 is then released so as to be biased back to the forward position by spring 63 such that annular flat portion 81 thereof holds retaining balls or pins 64 in ball or pin retaining groove 55 of male connector 31 . In such a coupled condition, male and female connectors 31 and 67 are locked together both longitudinally and rotationally with O-rings 61 sealing therebetween. The procedure is reversed to uncouple male and female connectors 31 and 67 , without the possible need of rotating since anti-rotation ridge or ridges 52 already align to fit in region 17 in between balls or pins 64 .
Another alternate embodiment of anti-rotation ridge 52 is illustrated in FIG. 4A and FIG. 4B where ridge 74 can be one or more longitudinally and radially extending surfaces within groove 55 and retained within forwardly inclined surface 51 and rearwardly inclined surface 53 . The ridges 74 may extend all the way across groove 55 and in line with the surface of coupler 50 or the surface of shoulder 54 , or may have any number of shapes and sizes that would prevent rotation of retention balls or pins 64 around annular surfaces 53 or 51 , or rotation within groove 55 .
Another alternate embodiment of anti-rotation ridge 52 is illustrated in FIG. 5A and FIG. 5B where ridge 77 is a separable component clip 18 and attachably held onto the male quick connector 31 . Clip 18 would snap into or within grooves 79 and 78 which could also be located in an alternate location of male quick connector 31 , for example within shoulder portion 54 . Groove 78 on the male quick connector plug would engage segment 76 of clip 18 to retain the clip 18 longitudinally and retain the clip from removal. Groove 79 would engage ridge segment 77 to prevent clip 18 against rotational movement. Ridge segment 77 would protrude into groove region 55 and thus acting in a similar manner as ridge 52 or 74 . Anti-rotation clip 18 could be either rigidly connected to male quick connector 31 or may incorporate compliant, non-rigid features in order to be moveably connected to connector 31 , but maintain the intended purposes of anti-rotation. The ridges 77 may comprise one or more locations along groove 55 .
The method of forming an anti-rotation feature as shown in ridge 52 , 74 and 77 may vary in method and design. As an example, the feature could also be threadably attached to the male quick connect plug 31 and act as the anti-rotation ridge itself or retain another such piece to act in the same. The anti-rotation feature may be constructed via various means which include standard machining methods, a separate piece fusably linked as with welding or epoxy, use of electro-discharge machining (EDM), forging, casting, swaging, or other alternate technologies known to manufacturing.
Another alternate embodiment of the anti-rotation ridge would be where the user would physically engage a button or other interface means in order to bias the anti-rotation ridge into position or out of position. In this manner the user would choose when to use the anti-rotation feature or to just allow the system to freely rotate. Examples of ridge actuation would include pivoting or sliding the ridge into position via an interlocking means back to the various interface means available.
Another alternate embodiment of the anti-rotation ridge would be where the anti-rotation feature would be configured not to fully prevent rotation, but instead to provide resistance in the turning process, only to a desired force, and then allow the ridge to release and move past the locking ball. This would result in the ability to provide an audible clicking sound while rotating, as the ridge engages each locking ball. Additionally, the operator would be provided with a resistance feedback that provides physical indication of how much the plug has rotated by counting the number of points of higher resistance.
Another alternate embodiment of the anti-rotation ridge would be where the anti-rotation feature is configured in such a way as to act as a cam surface to the retention balls and thereby gradually influencing the balls radially outward and thus initiating a disconnection of the plug to the coupler. The operator would rotate the nozzle assembly or other mechanism and thereby disengage the coupler socket from the male plug. This is particularly relevant to auto-lock coupler configurations where the user pulls back the retaining collar, and the male plug automatically ejects from the socket via a biasing spring mechanism.
A fluid accessory 30 is shown coupled to the female connector 67 via the male connector 31 in FIG. 8 . However, other fluid accessories, such as those illustrated in FIG. 10 , may be used rather than the fluid accessory in FIG. 8 , such as a fixed brush 28 , which may be coupled to the female connector 67 . The fluid accessory 29 may output a rotating spray pattern, while the fluid accessory 27 may, for example, be configured to output a wide-angle spray pattern, a narrow-angle spray pattern, or any other type of fixed (non-adjustable) spray pattern.
In addition, the fluid accessory may be configured to output a different pattern depending on the rotational position selected by the user (nozzle changeover). The adjustable nozzle assembly 30 may be adjusted by the user by axially rotating the housing. For example, the adjustable nozzle 30 housing may be axially rotated about a longitudinal axis 20 between a first position, in which the fluid accessory 30 provides a high pressure spray, and a second position, in which the fluid accessory 30 provides a low pressure spray. Further, the fluid accessory 30 of the illustrated construction includes an independently adjustable mechanism 150 for altering the spray pattern (see FIGS. 8 and 9 ). The spray pattern may be adjusted by rotating the housing about a longitudinal axis 20 , such that at a first rotational orientation, the fluid accessory 30 provides a wide-angle spray pattern, and at a second rotational orientation, the fluid accessory 30 provides a narrow-angle spray pattern. Since the spray pattern is independently adjustable for the nozzle assembly 151 , several different combinations of the spray patterns and discharge pressures exist. Nozzle 27 is fitted with a standard male plug 154 to illustrate the backward compatibility of the system. Wand 153 is shown in FIG. 10 to illustrate possible connection configuration.
While illustrated embodiments show, what is known as, a straight-through coupling assembly, the invention would apply to, what is known in the fluid and air flow industry as, one-way shut-off systems as used in compressed air & paint spray applications to name a few. Additionally, the design would apply to, what is known as, double-shutoff systems as commonly associated with use in hydraulics as well as other material such as steam, solvents, cooling water, oil and a host of other media.
The invention also includes the process for connecting a quick connect coupling by using any of the anti-rotation devices disclosed herein.
Whereas this invention is here illustrated and described with reference to embodiments thereof presently contemplated as the best mode of carrying out such invention in actual practice, it is to be understood that various changes may be made in adapting the invention to different embodiments without departing from the broader inventive concepts disclosed herein. | The invention is a quick connect and disconnect coupling system which limits the free rotation between the female socket and the male plug of the coupling with respect to one another. It comprises a male plug having a coupling end and a female socket having a coupling end with a receiving opening therein to receive the coupling end of the male plug when the connectors are in a coupled condition. A holding mechanism is associated with the coupling end. The male plug includes a non-circular surface that inter-engages the locking balls within the female quick connect socket to substantially prevent relative rotation of the male plug in relation to the female socket. The coupling is particularly useful for attaching accessories for fluid dispensing as used in highly pressurized spray applications to allow the ability to rotationally adjust the dispensing action. | 5 |
BACKGROUND OF THE INVENTION
The present invention relates to bore hole tools, and more specifically to a core sample orientation tool used for taking core impressions in bore holes.
Core drilling is employed in various fields and particularly in the mining and petroleum industries in order to secure samples of the earth's crust at predetermined depths to secure subsurface geological data for the purpose of analysis and study. Full knowledge of the characteristics of a subsurface formation can be obtained only if the precise location and orientation of the core sample, before it was taken, can be determined. Core orientation is accomplished by removing a sample of the core from a bore hole and orienting it in space in precisely the same position that it occupied in the bore hole. Normally such orientation of core samples is done for the purpose of aiding in the proper evaluation of subsurface geology and thus determining the proper drilling program for the bore hole or well. A further purpose is to facilitate the proper development of an oil field by ascertaining the dip and strike of subsurface formations, such data being of considerable importance to the geologist. The dip of a stratum is the largest angle between the plane of the stratum and a horizontal plane. The strike of the stratum is the direction that the intersection of the plane of the stratum and a horizontal plane makes with respect to north.
Although data for determining dip and strike can be obtained by other methods, as for example, a comparison of several bore holes by electric logging and bore hole profile logging techniques, such methods rely on the difference in properties between the successive strata and are sometimes not applicable where massive bodies of rock are encountered. Hence, there is a need for orienting cores to obtain the fullest information when boring a bore hole or well.
During the drilling of a bore hole in the search for oil or minerals, core samples are cut from the formations being traversed and are removed to the earth's surface for examination. Various important information can be obtained from such a core. For example, if any bedding planes are observable in the core, the strike and dip of these planes (and hence of the formation from which the core was obtained) can be determined. The true directions of strike and dip, however, can be determined only if the core can be oriented (in space) in the same way that it was oriented in its original place in the formation.
In order to ascertain the dip and strike of strata existing underground, it is first of all necessary to sink a bore hole to intersect the stratum to be investigated and to extract a piece of bore core from the lower end of the bore hole. A bore hole of any considerable depth, however, always deviates from its original vertical direction so that readings taken from the piece of bore core when mounted in a vertical position will not correctly represent the dip and strike of the selected stratum.
Geologists have long recognized the value of oriented cores. The initial and most obvious use of oriented cores is to determine the dip and strike of inclined strata which permits a more complete interpretation of structural complications. Secondary recovery programs such as water flooding have also shown that it is highly desirable to know the extent and direction of any preferential permeability which formations may exhibit. The great mass of subsurface geological data obtained over the past several years in the concerted geologic research efforts of most oil companies have amplified the need for oriented subsurface data of every type. This potential is not restricted to the petroleum industry, but is equally applicable wherever drilling cores are obtained, such as in the exploration for development of uranium, metallics, non-metallics and other minerals, the engineering and construction of dam sites, tunnels, bridges and the like, quarrying operations and many others. However, this data is of use only when drilled cores are oriented with the utmost accuracy and then only when the orientation can be accomplished economically. Many devices, methods and techniques have been employed for accomplishing core orientation. Some are complicated and time-consuming, some are of limited accuracy, and others have not been entirely satisfactory for various reasons.
One known technique employs a magnetic needle which is held fixed in the position of core orientation. Another technique scribes a mark on the core itself. Another technique includes a marker driven into a hole in the core which remains there while the core is being drilled out and brought up to the surface. Another technique injects a charge of magnetically susceptible particles adjacent to the rock to be sampled. Another technique employs a luminous ball and a light-sensative surface. Another technique subjects the rock to be sampled to a strong magnetic field of known orientation before the core is taken so that after cutting, the original orientation of the core may be ascertained by making use of the remanent induced magnetism. Another technique compares the physical property of a side wall core of known orientation with a conventional core. Still another technique uses a pin carrier ring and movable ball to determine the orientation of the core at the bottom of a bore hole. Another technique uses an orientation indicating instrument which secures the core stub thereto.
It is also known to employ a pendulum which may oscillate in all directions relative to the middle axis of the core tube and having a borer at its end to directly mark the face of a core to determine the angle of inclination of dip, see U.S. Pat. No. 2,011,979 (Martienssen). This device suffers from the same problems as the other aforementioned devices that directly mark the core, i.e., debris, water or mud in the hole which may prevent suitable marking and a separate hole survey is needed to orient the core for each core sample.
Still another technique which is used by the Bureau of Reclamation employs a putty receptacle attached to aluminum or plastic manual setting tools. Once a drill hole has been started, a mark is made at twelve o'clock on the hole collar. Next, the putty receptacle is pushed into the hole with the setting tools, maintaining constant alignment between a scribe line on the tools and the mark on the hole collar. When hole bottom is reached, the putty is pressed against the bottom and an impression is made. The setting tools and putty impression are then removed from the hole. The putty receptacle is then placed in a tray in the configuration where the scribe line is in its uppermost position (twelve o'clock). When the next length of core is removed from the hole, it is placed in the tray and matched to the impression in the putty. The drill core can now be mapped for fracture orientations and spacings. This technique requires precise matching of the scribe lines by the operator and is limited to manual application in shallow holes, i.e., approximately 200 feet.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a core sample orientation tool that is highly reliable in determining core orientation.
It is a further object of the present invention to provide a core sample orientation tool that overcomes the disadvantages of the aforementioned known techniques.
It is a further object of the present invention to provide a core sample orientation tool for wire line applications, i.e., beyond the limits of manual operation.
It is a further object of the present invention to provide a core sample orientation tool which eliminates false markings due to accidental shocks during insertion of the tool into a bore hole.
It is a still further object of the present invention to provide a core sample orientation tool for orienting a previously drilled core or core to be drilled next.
It is a still further object of the present invention to provide a core sample orientation tool which enables the strike and dip of planar core features to be translated into actual attitude in space when combined with logging techniques.
Briefly, the core sample orientation tool of the present invention includes a sleeve having a putty cup and mark receiving member removably attached to the lower end of the sleeve and a pendulum-oriented marker slidably arranged within the sleeve to mark the mark receiving surface indicating a chosen directional reference of the core impression taken by the putty cup. Advantageously, hydraulic damping means may be employed, particularly in wire line applications, to control the downward movement of the pendulum-oriented marker allowing it to stabilize prior to marking the mark receiving member.
Other objects, aspects and advantages of the present invention will be apparent when the detailed description of the preferred embodiment of the invention is considered in conjunction with the drawings, which should be construed in an illustrative and not in a limiting sense, as follows:
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view illustrating a manual core sample orientation tool in accordance with the present invention for coupling to a push rod bore hole extension member;
FIG. 2 is a partial cross-sectional view of the core sample orientation tool of FIG. 1 at the bottom of a bore hole before scribing;
FIG. 3 is a partial cross-sectional view similar to FIG. 2, but with the scribe member in its down or collapsed position;
FIG. 4 is a side elevational view of the removable putty cup assembly of the core sample orientation tool;
FIG. 5 is a partial cross-sectional view illustrating a wire line core sample orientation tool in accordance with the present invention at the bottom of a bore hole before scribing; the tool is capable of being coupled to an overshot and packer for up-hole use or an overshot and sinker bar for down-hole use; and
FIG. 6 is a partial cross-sectional view similar to FIG. 5, but with the scribe member in its down or collapsed position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, a core sample orientation tool in accordance with the present invention is illustrated generally as 10. The core sample orientation tool includes an elongated body member or sleeve 12 with a lower end 14 and an upper end 16. A putty cup 18 is mechanically coupled to the lower end 14 of the elongated body member 12. A pendulum coupling member or tail piece 20 extends outwardly from the upper end 16 for mechanically coupling to tail mount 21 which is coupled to a bore hole extension member, here shown as a push rod 22. Preferably, the pendulum tail piece 20 includes a spring 24 concentrically mounted thereon, which will be described in more detail with reference to FIGS. 2 and 3. The elongate body member 12 also includes opposing slots 26 (only one of which is shown in FIG. 1) which receive projections shown as cap screws 28 (only one of which is shown in the drawing). The function of slots 26 and cap screws 28 will be described in more detail with reference to FIGS. 2 and 3.
Advantageously, the putty cup 18 and tail mount 21 include bushings 30 and 32, respectively, which serve as guide members and bearing surfaces as the tool 10 is lowered or raised through a bore hole or hollow drill bit in a bore hole, as desired.
Referring to FIGS. 2 and 3, the putty cup 18 includes a blade end 34 for engaging a core. The putty cup 18 includes putty 36, and grooves (not shown) on its interior surface 38; the exposed surface 35 of the putty 36 is well oiled. The upper end 40 of the putty cup 18 opposite the blade end 34 includes circumferential threads 42. A plug member 44 having a lower threaded surface 46 with circumferential threads 48 mates with circumferential threads 42 of the putty cup 18. Circumferentially mounted about the plug member 44 is the bushing 30, preferably made of nylon. The plug member 44 includes an upper end 50. The upper end 50 includes upper threaded surface 52 with circumferential threads 54 arranged therein. Adjacent the lower ends of the threads 54 is an o-ring groove 56 for receiving an o-ring 58. The upper end 50 of the plug member 44 includes a recess 55 for receiving a mark receiving member shown as scribe receiving cylinder 59, preferably formed of plexiglass.
The elongate body member 10 includes a lower threaded portion 60 having circumferential threads 62 arranged therein. The circumferential threads 62 mate with threads 54 in the upper end 50 of the plug member 44 for removably coupling the putty cup 18 and scribe receiving cylinder 59 to the elongate body member 10.
Slidably and sealingly received within the elongate body member 10 is a pendulum assembly 64, preferably made of nonreactive material such as nylon or stainless steel, which includes the pendulum tail piece 20. The pendulum assembly 64 also includes a head piece 66 and intermediate tube 68 which connects the head piece 66 and tail piece 20 and which houses a pendulum 70. The tail piece 20 has an enlarged diameter portion 72 and a reduced diameter portion 74. The enlarged diameter portion 72 has an o-ring groove 76 to receive an o-ring 78. Adjacent the o-ring groove 76 is threaded surface 80 having circumferential threads 82 formed therein.
The reduced diameter portion 74 has threaded screw holes 84 and 86 to receive cap screws 28 and 28A, respectively. The reduced diameter portion 74 extends outwardly from the upper end 16 of the elongate body member 10 through a rear flange 90, preferably nylon, coupled to circumferential threads 88 on the interior surface of the upper end 16 of the elongate body member 10. The spring 24 concentrically mounted about the tail piece 20 extends between the rear flange 90 and the tail mount 21 and is biased to hold the pendulum assembly 64 in the upward position shown in FIG. 2.
The head piece 66 of the pendulum assembly 64 includes an upper surface 92 having circumferential threads 94 arranged therein. Adjacent to the circumferential threads 94 is an o-ring groove 96 for receiving an o-ring 98. The head piece 66 and tail piece 20 of the pendulum assembly are mechanically coupled together by the intermediate tube 68 to sealingly house the pendulum 70 therein. The intermediate tube 68 has upper and lower circumferential threads 100 and 102 formed on its interior surface for mating with threads 82 of the enlarged diameter portion 72 of the tail piece 20 and threads 94 of the head piece 66, respectively.
The head piece 66 also includes an axial bore 103 extending therethrough. A bearing recess 104 is formed in the head piece 66 at its upper end and concentric with the axial bore 103. The enlarged diameter portion 72 of the tail piece 20 includes an axial bore 106 extending therein at its lower end 108 with a bearing recess 110 formed therein concentric with the axial bore 106.
The pendulum 70 which is housed in the pendulum assembly 64 includes a shaft 112 with an eccentric weight 114 affixed thereto and bearings 116 and 118 mounted on the shaft 112 on opposite sides of the eccentric weight 114. The bearings 116 and 118 are received in bearing recesses 104 and 110, respectively. The bottom end 120 of the shaft 112 extends beyond the lower end 122 of the head piece 66. Fixedly coupled to the bottom end 120 of the shaft 112 is a marking member shown as a scribing bar 124 having a scriber 126 formed thereon. The scribing bar 124 includes a bore 128 therein to receive the bottom end 120 of the shaft 112. A tapped hole 130 is formed in the scribing bar 124 in communication with the bore 128 for receiving a set screw 132 to fixedly couple the scribing bar 124 to the shaft 112.
In operation, the manual core sample orientation tool 10 is coupled to the push rod 22 and inserted into a bore hole 129 here through a hollow drill rod and bit 27 in the bore hole 129. Manual operation is generally limited to bore holes having a depth of about 200 feet. At the end of the bore hole 129, the putty 36 receives an impression from the upper surface or face 31 of the core (rock) 33 whose orientation is desired. After a short time lapse to allow the pendulum 70 to rotate to a stable "bottom" position, which will occur in all off-vertical bore holes, a manual force applied to the push rods 22 telescopes or slides the pendulum assembly 64 downwardly within the elongate body member 10 allowing the scriber 126 to mark or scratch the tube 59 indicating the "down" directional reference, see FIG. 3. The downward movement and return of the pendulum assembly 64 within the elongate body member is limited by engagement of the cap screws 28 and 28A with the lower ends 134 and 136 of slots 26 and 138, respectively.
As shown in FIG. 4, the putty cup 18, plug member 44, and scribe receiving cylinder 59 may be removed from the tool 10 after removal from the bore hole 129 and the scribe mark 135 on the scribe receiving cylinder 59 used to orient a previously drilled core or the core to be drilled next. The scribe mark 135 and the putty core impression 133 can be positioned in a tray in the predesigned attitude. When matched to the drill core, fracture orientation and spacings can be measured. Further, when hole survey data is available and the core is laid out on a table in its proper up-down relationship, the strike and dip of planar core features can be translated into actual attitude in space.
Referring to FIGS. 5 and 6, a wire line core sample orientation tool in accordance with the present invention is illustrated generally as 10A. The core sample orientation tool includes an elongate body member or sleeve 12A with a lower end 14A and an upper end 16A. A putty cup 18A is mechanically coupled to the lower end 14A of the elongate body member 12A. A pendulum coupling member or tail piece 20A extends outwardly from the upper end 16A for mechanically coupling to tail mount 21A which is coupled to a bore hole extension member, here shown as an overshot 22A. Advantageously, the putty cup 18A and tail mount 21A include bushings 30A and 32A, respectively, which serve as guide members and bearing surfaces where the tool 10A is lowered or raised through a hollow drill rod and bit 27A positioned in a bore hole 129A.
The putty cup 18A includes a blade end 34A for engaging a substrate. Preferably, the putty cup 18A includes putty 36A and grooves (not shown) on its interior surface 38A; the exposed surface 35A of the putty 36A is well oiled. The upper end 40A of the putty cup 18A opposite the blade end 34A includes circumferential threads 42A. A plug member 44A which includes a lower threaded surface 46A having circumferential threads 48A mates with threads 42A of the putty cup 18A. Circumferentially mounted about the plug member 44A is the bushing 30A, preferably made of nylon. The plug member 44A includes an upper end 50A remote from the lower threaded surface 46A. The upper end 40A includes upper threaded surface 52A with circumferential threads 54A arranged therein. Adjacent the lower ends of the threads 54A is an o-ring groove 56A for receiving an o-ring 58A. The upper end 50A of the plug member 44A includes a recess 55A for receiving a mark receiving member shown as a scribe receiving cylinder 59A hand press-fitted therein; the scribe receiving cylinder 59A is preferably of plexiglass.
The elongate body member 12A includes a lower threaded portion 60A having circumferential threads 62A arranged therein. The circumferential threads 62A mate with threads 54A in the upper end 50A of the plug member 44A for removable coupling of the putty cup 18A and scribe receiving cylinder 59A to the elongate body member 12A.
Slidably and sealingly received within the elongate body member 12A is a pendulum assembly 64A, preferably made of nonreactive material such as nylon or stainless steel, which includes the pendulum tail piece 20A. The pendulum assembly 64A also includes a head piece 66A and intermediate tube 68A which connects the head piece 66A and tail piece 20A and which houses a pendulum 70A.
The tail piece 20A includes a reduced diameter portion shown as a rod member 69 which is mechanically coupled to an enlarged diameter portion or front piece 71 via cap screws 73 and 75 received in transverse tapped hole 77 of the rod member 69. Front piece 71 has an o-ring groove 76A to receive an o-ring 78A. Adjacent the o-ring groove 76A is threaded surface 80A having circumferential threads 82A formed therein.
The rod member 69 extends outwardly from the upper end 16A of the elongate body member 10A through a rear mounting cap 79 mechanically coupled to the threaded upper end 16A of the elongate body member 12A. The rear mounting cap 79 includes a lower threaded surface 81 with threads 83 arranged therein for mating with circumferential threads 85 at the end 16A of the elongate body member 12A. Adjacent to the threaded surface 81 at the upper end is an o-ring groove 87 for receiving an o-ring 89. A hydraulic fluid fill hole 91 extends through the rear mounting cap 79 for communication with the interior of the elongate body member 12A and the exterior of the rear mounting cap 79. A set screw 93 seals the hydraulic fluid fill hole 91. The rod member 69 has an o-ring groove 95 for receiving an o-ring 97 which slides along a portion of the longitudinal extent of the rear mounting cap 79.
The head piece 66A of the pendulum assembly 64A includes an upper surface 92A having circumferential threads 94A arranged therein. Adjacent to the circumferential threads 94A is an o-ring groove 96A for receiving an o-ring 98A. The head piece 66A and front piece 71 of the tail piece 20A of the pendulum assembly are mechanically coupled together by the intermediate tube 68A to sealingly house the pendulum 70A. The intermediate tube 68A has upper circumferential threads 100A and lower circumferential threads 102A formed on its interior surface for mating with threads 82A of the front piece 71 of the tail piece 20A and threads 94A of the head piece 66A, respectively. The head piece 66A also includes an axial bore 103A extending therethrough. A bearing recess 104A is formed in the head piece 66A at its upper end and concentric with the axial bore 102A. The front piece 71 also includes an axial bore 106A extending therein at its lower end 108A with a bearing recess 110A formed therein concentric with the axial bore 106A.
The pendulum 70A which is housed in the pendulum assembly 64A includes a shaft 112A with an eccentric weight 114A affixed thereto and bearings 116A and 118A mounted on the shaft 112A on opposite sides of the eccentric weight. The bearings 116A and 118A are received in bearing recesses 104A and 110A, respectively.
The bottom end 120A of the shaft 112A extends beyond the lower end 122A of the head piece 66A. Fixedly coupled to the bottom end 120A of the shaft 112A is marking member shown as a scribe bar 124A having a scriber 126A formed thereon. The scribe bar 124A includes a bore 128A therein to receive the bottom end 120A of the shaft 112A. A tapped hole 130A is formed in the scribe bar 124A in communication with the bore 128A for receiving a set screw 132A to fixedly couple the scribe bar 124A to the shaft 112A.
Adjacent to the rear end 99 of the front piece 71 is a flange 101. The flange 101 has an upper threaded surface 103 with circumferential threads 105 on its exterior surface which mate with circumferential threads 107 on the interior surface of a rear portion 109 of the elongate body member 12A. Adjacent to the lower extent of the upper threaded surface 103 is an o-ring groove 111 for receiving an o-ring 113. The flange 101 also has a lower threaded surface 115 with circumferential threads 117 on its exterior surface which mate with circumferential threads 119 on the interior surface of the front portion 121 of the elongate body member 12A.
The flange 101 has an enlarged diameter portion 123 and reduced diameter portion 125. Flow passageways 127 extend longitudinally through the enlarged diameter portion 123. Arranged in the rod member 69 juxtaposed to the enlarged diameter portion 123 is an o-ring groove 131 for receiving an o-ring 133 for sliding movement of the rod member 69 relative to the enlarged diameter portion 123.
Spaced from the upper end 134 of the reduced diameter portion 125 of the flange 101 is a piston member 136. The piston member 136 includes an enlarged diameter portion 138 and a reduced diameter portion 140. The piston member 136 is fixedly coupled to the rod member 69 via cap screws 142 and 144 coupled to the enlarged diameter portion 138 and received in transverse tapped hole 146 of the rod member 69. Adjacent to the cap screws 142 and 144 and arranged in the exterior surface of the enlarged diameter portion 138 of the piston member 136 is an o-ring groove 148 for receiving an o-ring 150. Flow passageways 152 extend longitudinally through the enlarged diameter portion 138 of the piston member 136.
A spring 156 is concentrically mounted on rod member 69. One end 158 of the spring 156 abuts the stepped surface 160 formed between the enlarged diameter portion 123 and reduced diameter portion 125 of the flange 101. The other end 162 of the spring 156 abuts the stepped surface 164 formed between the enlarged diameter portion 138 and reduced diameter portion 140 of the piston member 136. The spring 156 is biased to normally maintain the pendulum assembly 64A in the position shown in FIG. 5 relative to the elongate body member 12A.
Further, hydraulic fluid, for example, oil, is introduced into the interior of the elongate body member 12A through the fill hole 91. With the pendulum assembly 64A in the position as shown in FIG. 5 within the elongate body member 12A, an upper chamber 166 is formed in the space between the lower end 168 of the rear mounting cap 79 and the juxtaposed upper end 170 of the piston member 136. Oil flows into the chamber 166 and then through passageways 152 to a main chamber 172 formed in the space between the reduced diameter portion 125 and stepped surface 160 of the flange 101 and the juxtaposed reduced diameter portion 140 and stepped surface 164 of the piston member 136. Flow passageways 127 provide fluid flow passageways to a lower chamber 174 formed in the space between the rear end 99 of the front piece 71 and the juxtaposed lower end 176 of the flange 101. In the position of the pendulum assembly 64A as illustrated in FIG. 5, the volume of the main chamber 172 is substantially greater than the volume of the upper and lower chambers 166 and 174, respectively, so that substantially all of the oil within the elongate body member 12A is in the main chamber 172.
In operation, the core sample orientation tool 10A is coupled to an overshot 22A, with packer (not shown) in up-hole use or sinker bar in down-hole use, as shown in FIGS. 5 and 6. The tool 10A is inserted through the hollow drill rod and bit 27A in a bore hole 129A. In the up-hole applications, hydraulic pressure is applied to the packer to pump the tool 10A into position. In down-hole applications, a sinker bar is inserted between the apparatus 10A and the overshot 22A. The sinker bar length may be chosen such that the tool 10A, sinker bar and overshot 22A will latch into the core barrel position in the drill rod with the putty cup 18A protruding through the hollow drill bit. At the end of the bore hole 129A the hydraulic pressure on the packer, or pressure on the drill rod, or weight of the sinker bar activates the pendulum assembly 64A. The putty cup 18A receives an impression from the upper surface or face 31A of the core (rock) 33A whose orientation is desired, and the pendulum 70A seeks to attain "bottom" (rotate to a stable position) which occurs in off-vertical bore holes. The force applied to the tool 10A by hydraulic pressure applied to the packer or the bar weight telescopes or slides the pendulum assembly 64A downwardly within the elongate body member 12A allowing the scriber 126A to mark or scratch the scribe receiving cylinder 59A indicating the "down" or "up" directional reference, or other orientation, as desired. The downward movement of the pendulum assembly 64A within the elongate body member 12A is controlled by the internal hydraulic chambers 166, 172 and 174 allowing the pendulum 70A to gradually move downwardly and assume a stable position before a directional mark is made on the scribe receiving cylinder 59A, and assuring that accidental shocks during insertion of the tool 10A into the bore hole 129A do not cause false markings. As an external force is applied to the pendulum assembly 64A through the packer or bar weight, the spring 156, and advantageously the hydraulic fluid within the main chamber 172 resist the downward movement of the pendulum assembly 70A within the elongate body member 12A. These resisting means are eventually overcome as the piston member 136 moves downwardly forcing the oil simultaneously through the flow passageways 127 and 152 into expanding lower chamber 174 and expanding upper chamber 166, respectively, thereby providing a damping or cushioning action to the downward movement of the pendulum assembly 64A providing time for gradual damping movement and stabilization thereof. The downward limit of movement of the pendulum assembly 64A relative to the elongate body member 12A is controlled by the lower end 182 of the piston member 136 which abuts the upper end 134 of flange 101.
As with the tool 10 shown in FIG. 4, the putty cup 18A, and plug member 44A and scribe receiving cylinder 59A of the tool 10A may be removed from the tool 10A after removal from the bore hole 129A. This removed putty cup assembly may be used in the same way as explained with reference to FIG. 4.
It should be understood that although the present invention has been illustrated to indicate a "down" directional reference or down side of the core, as shown in FIGS. 3 and 4, and an "up" directional reference in FIGS. 5 and 6, other directional references can be provided with a slight loss in pendulum efficiency by mounting the scribe bar to indicate such other orientation of the core. Advantageously, smooth upper threaded surfaces may be provided on the interior of the elongate body member or sleeve so that the o-rings of the pendulum assembly are easily received in the elongate body member without damage.
It should be understood by those skilled in the art that various modifications may be made in the present invention, without departing from the spirit and scope thereof as described in the specification and defined in the appended claims. | A core sample orientation tool for coupling to push rods or wire lines for use in obtaining core impressions in bore holes. The tool includes a putty cup and mark receiving surface which are removably attached to a sleeve housing a pendulum-oriented marker which marks the mark receiving surface when a core impression is taken to indicate a chosen directional reference. The removed putty cup and mark receiving surface can be used to orient a previously drilled core or the core to be drilled next, and when the core is laid out on a table in the proper up-down relationship, and considered in conjunction with bore hole logging techniques, the strike and dip of planar core features can be translated into actual attitudes in space. | 4 |
FIELD OF THE INVENTION
[0001] This invention relates in general to strengthening a structure, and more specifically to a composite coating that can be applied to an existing structure in the field to increase its strength and resistance to explosive, seismic, or other forces.
BACKGROUND OF THE INVENTION
[0002] Structures that must bear great weight, such as pillars, walls, or bridge spans, are often constructed from concrete. Concrete is very strong under compression, so can support its own weight as well as the weight of other structural elements, people, vehicles, and equipment.
[0003] Concrete is not strong under tension, though, and is a brittle material. Iron reinforcing rods are often embedded in concrete to increase the overall tensile strength. Even reinforced concrete needs to be very thick to withstand the forces generated by a moderate or large explosion, such as can happen in a refinery, cereal mill, power plant, or chemical plant.
[0004] Explosion forces often radiate in all directions and may change directions during the course of the blast. Thus, the forces from an explosion are not necessarily along vectors where typical load forces were expected.
[0005] Earthquakes, too, can generate large lateral forces that change direction. Many existing structures are not strong enough to withstand a large earthquake and need to be strengthened to meet current standards of safety.
[0006] Other structures that may need to withstand extreme, violent forces are the piping and tanks for holding and transporting petroleum products and other potentially explosive chemicals. Because large weights are not supported, tanks and pipes are generally not made of concrete. They are more typically made of a metal, chosen to be unreactive with the contents, nonporous, and much more ductile than concrete, such as iron, steel, or copper. The ductility of metals makes them easy to form into complex shapes, but metals, unless very thick, are generally not greatly resistant to moderate explosions. Most metals are not nearly as brittle as concrete; however, they stretch under force and eventually rupture. Extreme heat, such as can be generated by an explosion or a resulting fire, weakens most metals.
[0007] Some structures, such as water storage tanks or airplane bulkheads, were not expected to require high strength when they were designed, but are later found to need strengthening, such as to harden them against deliberate attack with explosives.
[0008] Some technology exists for strengthening structures already built, such as wrapping bridge pillars with epoxy-impregnated fiberglass panels to make them less likely to collapse in an earthquake. Some large structures can have additional concrete sprayed onto their surfaces.
[0009] Another way of rendering a building more explosion-resistant is to pile sandbags against the walls or on the roof to absorb and diffuse the forces. This is used in wartime or when an explosion is expected, as at a bomb-testing site, but is impractical for routine use and does not lend itself to all structures.
[0010] In a laboratory that uses potentially explosive chemicals, barriers of thick polycarbonate or similar material are often erected around reaction vessels. Another strategy used in laboratories and chemical plants is to include an easily knocked-down wall or roof in the design of the building. Shields and blast walls protect the personnel outside them from blasts, but do nothing to confine the explosion reactants and products to their vessel. Fire, secondary explosions, and widespread chemical contamination are common after a chemical explosion in a lab or plant and often cause more property damage and casualties than the blast itself does.
[0011] There is an increasing need for a way to strengthen structures against explosion, seismic, and other forces other than by making them extremely thick and massive. Such a means should help the structure keep its integrity, at least long enough for persons to evacuate or for hazardous materials to be removed. Preferably, such a means is applicable to complex structures and to those already built and in use.
SUMMARY OF THE INVENTION
[0012] The present invention is a composite coating that may be applied to many structures, such as buildings, bridges, storage tanks, airplane bulkheads, walls, columns, beams, and piping to increase their resistance to explosive, seismic, and other forces.
[0013] The composite consists of two layers of rubbery polymer, or elastomer, with a layer of textile embedded between the layers of elastomer. One preferred elastomer is polyurethane, which may be sprayed on as a blend of two precursor components. A mixing gun mixes the two components in the correct ratio so that the components mix in flight and begin to cure into rubbery polyurethane immediately.
[0014] A layer of mixed precursor is applied to the structure and a piece of textile is pressed onto the still tacky surface. The viscous fluid holds the textile in place. Another layer of mixed precursor is sprayed over the textile, covering it and bonding to the initial coat of polyurethane through the openings between the yarns. Each layer of cured polyurethane is in the range of 0.03 to 0.25 inch thick, with a maximum preferred total thickness of 0.5 inch. Interior corners are preferably radiused; a coving pre-cast from the same or compatible elastomer as the first and second layers may be glued into the corner to radius it before the first layer is sprayed.
[0015] The textile used is typically cloth woven of fiberglass, graphite fiber, or polyaramid (Kevlar). The textile may also be knit. The openings between yarns are in the range of 0.06 inch to 1.0 inch across. Fiber type and weave density are chosen to achieve the desired combination of elongation, stiffness, tensile strength, and cost. The weave orientation may be straight, 45° bias, or another variation.
[0016] Multiple layers of textile may be used for some applications. An additional layer of polyurethane is applied before each layer of textile, preferably keeping the total coating thickness less than 0.5 inch.
[0017] Because the loosely-woven textile is very flexible and the elastomer is typically sprayed on, this composite coating can be used on complex shapes. The coating is thin and light-weight, making it practical even for airplane bulkheads and similar applications.
[0018] Many polymers, including polyurethane and epoxy, decompose into toxic gases when burned, so a fire-resistant paint is preferably applied as the top surface of the composite coating. In some applications, it is preferable to use an elastomer/textile combination that is inherently fire resistant, such as silicone/fiberglass.
[0019] The composite, formed-in-place coating of the present invention may be installed more quickly than wrapping with pre-impregnated panels. Quick installation lowers labor cost and is an advantage when reinforcing structures that are inhabited or in use.
[0020] The finished coating is relatively light-weight and thin, making it especially applicable to airplane bulkheads and piping. The coating of the present invention can be used where there is not enough clearance for sandbags, shields, sprayed-on concrete, or similar brute force protection.
[0021] The invention will now be described in more particular detail. Many modifications and variations of the present invention are possible; it is to be understood that within the scope of the appended claims the invention may be practiced otherwise than as specifically described.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] [0022]FIG. 1 is an environmental view of the composite coating being applied to a wall.
[0023] [0023]FIG. 2 is a cross-sectional view of the composite coating applied to an interior corner in a structure.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The present invention is a composite coating 10 and method of application of coating 10 for reinforcing structures 100 such as buildings, bridges, storage tanks, piping, walls 101 , floors 103 , columns, and airplane bulkheads to increase their resistance to unusual forces. The potential forces may be those anticipated from explosion of hazardous materials such as petroleum products, steam, munitions, or reactive chemicals, may result from sabotage or terrorist attack, or may be due to an earthquake. FIG. 1 is an environmental view of coating 10 being applied to a wall 101 .
[0025] Coating 10 includes two layers of rubbery polymer, or elastomer, such as polyurethane 27 , with a layer of loosely woven or knit textile 40 embedded between the layers of polyurethane 27 . The combination of polyurethane 27 and strong but very flexible textile 40 gives composite coating 10 high elongation and tensile strength. Composite coating 10 , applied to a structure, increases the apparent ductility and elongation of the structure.
[0026] The elastomer is applied in the form of a fluid precursor that crosslinks (cures) under ambient conditions to form a solid rubbery layer that adheres strongly to most building materials, including concrete, wood, and metal. Epoxy, silicone, urethane, polyurea, neoprene, butyl rubber, and natural rubber (latex) are examples of materials that can be formulated to be rubbery when cured and that adhere to many other materials. Other elastomers can be used for this invention, also. If the structure to be strengthened is of an unusual material not spontaneously wetted by common elastomers, an adhesion-promoting primer may be preapplied.
[0027] The selected elastomer is preferably one that cures without addition of heat and without evolving solvent vapors, so that it can be applied in the field, such as outdoors or in an inhabited room. Generally, elastomers that cure within these limitations are two-component systems, that is, crosslinking results from reaction between two different chemical components. Both components may end up as part of the elastomer, or one component may act as a catalyst to enable the other component to react within itself to form crosslinks, which solidify the fluid into a solid.
[0028] RTV silicone cures upon absorption of water vapor from the air, but this reaction is generally slower than is preferable for the present invention. A thermoplastic elastomer may be applied warm and allowed to “cure” simply by cooling. An emulsion or solution of an elastomer that “cures” by evaporation of the solvent may be used, but the advantage of being able to install the reinforcing coating rapidly in an inhabited area would be largely lost.
[0029] One preferred elastomer is polyurethane 27 , preferably sprayed on as a two-part mix. Mixing gun 90 mixes the two components 22 , 23 , often called Part A and Part B, in the correct stoichiometric ratio so that Part A 22 and Part B 23 mix in flight and begin to cure into a rubbery solid immediately.
[0030] The mixed precursor 24 is fluid for a short time, then becomes a gel as crosslinks start to form. A gel does not run or slump, but is plastically deformed by small forces. After all available crosslinks have formed, polyurethane 27 is cured and considered a solid, although it is rubbery.
[0031] In another preferred embodiment, not depicted, Part A 22 and Part B 23 are premixed in a container and the mixture is applied to the surface of the structure by brush or roller. In this embodiment, a formulation is used that gels somewhat slower than a formulation used for spray application.
[0032] A preferred sprayable formulation of polyurethane 27 has been found to have typical elongation of 600-700%, Shore D hardness between 35 and 50, and tensile strength of over 4000 psi. This formulation gels in around 5 seconds, is nontacky after about 20 seconds, and achieves full cure after 24 hours. The mixing ratio of Part A 22 and Part B 23 is one to one and no volatile organic solvents are released.
[0033] In FIG. 1, first layer 20 is already applied to a structure 100 , such as wall 101 of a building, and has crosslinked so as to be gelled polyurethane 26 . Textile 40 , such as woven cloth 41 , is shown already affixed over gelled polyurethane 26 of first layer 20 . Woven cloth 41 includes yarns 44 and openings 45 .
[0034] Mixing gun 90 uses gas, such as compressed air from tank 91 , to draw Part A 22 and Part B 23 of a two-part system from their respective containers and mix them in the stoichiometric blend that will result in proper curing. Mixed fluid precursor 24 is sprayed from mixing gun 90 onto wall 101 .
[0035] Fluid precursor 24 is applied so as to yield a cured polyurethane 27 of 0.03 to 0.25 inch thick, with a preferred total thickness of about 0.5 inch. First and second layers 20 , 30 are preferably thick enough to fully embed cloth 41 . It is essential that first layer 20 not be thicker than 0.25 inch thick, so that the properties of first layer 20 and cloth 41 combine. In other words, in the event of an explosion, wall 101 should interact with coating 10 as a composite, not with elastomer first and cloth 41 soon afterward.
[0036] Polymers typically shrink as they cure, so applied fluid precursor 24 should be slightly thicker than the desired cured polyurethane 27 . For a formulation of a given viscosity, coating thickness is mainly controlled by the speed of travel of mixing gun 90 , so training and practice are required to operate gun 90 .
[0037] One skilled in the art will realize that surface 102 oof wall 101 must be fairly clean and sound before application of first layer 20 . Grease, water, or other deposits on surface 102 will decrease the adhesion of coating 10 to structure 100 . Thick dust or a crumbly or peeling texture of surface 102 will decrease the overall cohesive strength of reinforced structure 100 .
[0038] It is generally not necessary to apply a porosity-reducing primer before application of first layer 20 , nor is vacuum treatment of applied first layer 20 required.
[0039] After a first layer 20 of fluid precursor 24 is applied to structure 100 , a piece of textile 40 is pressed against gelled coating 26 . Gelled coating 26 is tacky enough that simply placing textile 40 against it causes textile 40 to adhere.
[0040] Textile 40 , such as woven cloth 41 or a knit fabric, is woven or knit from yarns 44 of a fibrous material such as fiberglass, carbon, or polyaramid. Other types of fiber, including nylon; polyester; natural fibers such as cotton, wool, linen, or silk; or synthetic forms of natural fibers, such as synthetic spider silk; may also be used. More than one type of fiber may be combined within yarns 44 or cloth 41 . To improve the adhesion of cloth 41 to elastomer 27 , it is preferred that cloth 41 be treated with a coupling agent, such as a nearly monomolecular layer of a polysiloxane.
[0041] The openings 45 between yarns 44 are in the range of 0.06 inch to 1.0 inch across. Fiber type and weave density are chosen to achieve the desired combination of elongation, stiffness, tensile strength, and cost. The orientation of yarns 44 also affects the properties of woven cloth 41 . Yarns 44 may intersect each other at angles of 90°, 45°, or other angles. For example, cloth 41 may be woven with vertical yarns 44 of nylon fiber, horizontal yarns 44 of glass fiber, with yarns 44 of cotton passing diagonally through cloth 41 . It is advantageous for some applications to design cloth 41 so that certain of yarns 44 break predictably sooner than other yarns 44 .
[0042] The piece of cloth 41 may be precut before application of fluid precursor 24 , so that cloth 41 may be affixed without delay. Thus, anchors or fasteners are not needed on flat surfaces.
[0043] Although this invention is described and illustrated as a single piece of cloth 41 embedded between first and second layers 20 , 30 , additional layers of elastomer and cloth may be installed using the same technique as described above.
[0044] [0044]FIG. 2 is a cross-sectional view of coating 10 installed in an interior corner of a building where wall 101 meets floor 103 . First layer 20 was applied to surface 102 of wall 101 and to surface 104 of floor 103 . In this case, “interior” does not mean the corner must be inside a building, but rather that floor 103 meets wall 101 at a dihedral angle of less than 180°.
[0045] Edge portion 42 of a piece of cloth 41 is defined here as the outermost eight inches from the periphery of cloth 41 ; the central portion 43 being the remainder of cloth 41 , within edge portion 42 . For maximum strength of the reinforced building, layout of cloth 41 should be planned so that interior corners, such as where wall 101 and floor 103 meet, are covered by central portion 43 . Cloth 41 preferably curves concavely over the corner. Opposite edge portions 42 are affixed to opposite members of the corner.
[0046] In the case of exterior corners, that is, corners where two walls, a wall and ceiling, a wall and a floor, or other members meet with a dihedral angle of greater than 180°, the corner is preferably covered by central portion 43 but a radius is not preferred. A joint without an angle, such as a seam where two precast portions of wall are butted together, is also preferably covered by central portion 43 .
[0047] In the case of the interior corner of wall 101 and floor 103 depicted in FIG. 2, the radius of the curve described by cloth 41 is preferably 0.4 inch or greater and is typically about 2 inches. For an interior corner in a small structure 100 , such as a blast resistant seat for a person, cloth 41 would curve with a typical radius of 0.125 to 0.4 inch.
[0048] It is preferred that the edge portions 42 of pieces of cloth 41 affixed adjacent each other should overlap by about 6 to 12 inches instead of being butted against each other.
[0049] It is preferred, but not essential, that anchors, such as disclosed in U.S. Pat. No. 5,649,398, be used to strengthen the attachment of edge portions 42 on opposite sides of the corner in applications where especially high strength is desired.
[0050] To aid the persons installing coating 10 achieve the correct radius in an interior corner, coving 50 is pre-cast, preferably from the same polyurethane 27 as is being used for coating 10 . Coving 50 is installed in the corner and may be glued into place with any appropriate adhesive 51 known to the trade, to fill in the vertex segment of the dihedral angle, and define a radius. First layer 20 is sprayed over coving 50 . Coving 50 also prevents a void from forming between cloth 41 and first layer 20 .
[0051] Casting coving 50 from the same polyurethane 27 as first layer 20 is preferred for good adhesion between coving 50 and first layer 20 . Materials with different thermal expansion properties tend to separate from each other when exposed to thermal cycles, including diurnal or seasonal variation.
[0052] Also, it is generally preferred that first layer 20 and second layer 30 be of the same polyurethane 27 . That way, first layer 20 and second layer 30 will share the same hardness, chemical nature, and thermal expansion characteristics. Different elastomers can be used for first layer 20 and second layer 30 if the two elastomers are sufficiently compatible.
[0053] Most of the above-cited examples of preferred elastomers and textiles are flammable and some evolve toxic fumes when burned. A composite of silicone elastomer and glass fiber is inherently fire-resistant, and polyimide fiber can withstand fairly high temperatures without decomposing. For most composites, though, including the most-preferred polyurethane/glass combination, a means for increasing the fire-resistance of coating 10 is included in second layer 30 . Fire-resistant paint 32 can be applied over second layer 30 , or second layer 30 may include an admixture of intumescent powder, or both. Similarly, second layer 30 may include reflective or filtering components to increase the resistance of the composite to ultraviolet light or an ultraviolet resistant paint can be applied over second layer 30 .
[0054] The invention has been shown and described with reference to certain specific embodiments, however, it is to be understood that modifications and substitutions can be made by a person skilled in the art without departing from the spirit and scope thereof. | Composite coating ( 10 ) improves the resistance to blast or seismic forces of a structure ( 100 ), such as wall ( 101 ). Coating ( 10 ) includes a first layer ( 20 ) of elastomeric polyurethane in contact with and adhering to wall ( 101 ), a second layer ( 30 ) of elastomeric polyurethane in contact with and adhering to first layer ( 20 ), and a layer of textile ( 40 ) embedded between first layer ( 20 ) and second layer ( 30 ). | 8 |
TECHNICAL FIELD
[0001] Embodiments relate to a technique for monitoring an information system.
BACKGROUND ART
[0002] Conventionally, for system monitoring, thresholds are set for a server to be monitored and monitoring items capable of being monitored by the server and the thresholds are monitored for the monitoring items, respectively, thereby detecting an abnormality. However, a proper threshold for each monitoring item is difficult to set and a setting work load is heavy, and thus PTL 1 discloses a technique “comprising a load model data creating means 14 for creating load model data indicating a temporal transition of system loads based on past load information of a computer system 1, a threshold data creating means 16 for adding designated threshold correction data to the load model data and time-sequentially calculating threshold data, and an abnormal load detecting means 17 for detecting an abnormal load of the system by comparing current load information of the system 1 with threshold data at a corresponding time thereto.
CITATION LIST
Patent Literature
[0003] PTL 1: Publication of Patent No. 2001-142746
SUMMARY OF INVENTION
Technical Problem
[0004] With the technique disclosed in PTL 1, it is difficult to monitor a system for providing a service to a client computer via a network. The difficulty is the following (1) or (2), for example.
[0005] (1) When components in a system (service execution infrastructure) for providing a network service are monitored, monitoring values can change depending on request contents from a terminal (such as request type or the number of requests per unit time), but the past monitoring values are not managed as baselines in consideration of the request contents in PTL 1, and thus many errors in abnormality detection occur.
[0006] (2) When an abnormality is detected in the service execution infrastructure, an event occurring in the system cannot be rapidly analyzed.
Solution to Problem
[0007] In order to solve the above problems, particularly (1), a monitoring system for monitoring a service execution infrastructure manages baselines of monitoring values of components per load of a service provided by the infrastructure, and uses the baselines depending on a current service load. In order to solve (2), when detecting an abnormality of a service monitoring value or component monitoring value with a baseline, the monitoring system compares events up to predetermined minutes ago from now with events in a baseline time zone thereby to specify a differential event (or non-normal latest event).
Advantageous Effects of Invention
[0008] According to the present invention, it is possible to effectively monitor a service execution infrastructure for providing a network service.
BRIEF DESCRIPTION OF DRAWINGS
[0009] [ FIG. 1 ] FIG. 1 is a diagram illustrating an information system according to a first embodiment.
[0010] [ FIG. 2 ] FIG. 2 is a diagram illustrating a hardware structure of a computer according to the first embodiment.
[0011] [ FIG. 3 ] FIG. 3 is a diagram illustrating a structure of a service monitoring server according to the first embodiment.
[0012] [ FIG. 4 ] FIG. 4 is a diagram illustrating a performance analysis processing flow of a service monitoring manager using a stream data processing system according to the first embodiment.
[0013] [ FIG. 5A ] FIG. 5A illustrates exemplary configuration information according to the first embodiment.
[0014] [ FIG. 5B ] FIG. 5B illustrates an exemplary structure of a Web system as an exemplary system execution infrastructure according to the first embodiment.
[0015] [ FIG. 6 ] FIG. 6 is a diagram illustrating contents of a service monitoring information stream and a work information-mounted service monitoring information stream for a service of the system execution infrastructure according to the first embodiment.
[0016] [ FIG. 7 ] FIG. 7 is a diagram illustrating contents of a system monitoring information stream and a work information-mounted system monitoring information stream for a component of the system execution infrastructure according to the first embodiment.
[0017] [ FIG. 8 ] FIG. 8 is a diagram illustrating contents of an event monitoring information stream and a work information-mounted event information stream for the system execution infrastructure according to the first embodiment.
[0018] [ FIG. 9 ] FIG. 9 is a diagram illustrating an event information table, a differential event information table and a similar event information table as storage destinations of the work information-mounted event information stream according to the first embodiment.
[0019] [ FIG. 10 ] FIG. 10 is a diagram illustrating a service performance information table as a storage destination of a work information-mounted service performance information stream according to the first embodiment.
[0020] [ FIG. 11 ] FIG. 11 is a diagram illustrating a system performance information table as a storage destination of a work information-mounted system performance information stream according to the first embodiment.
[0021] [ FIG. 12 ] FIG. 12 is a diagram illustrating a service group performance abstract information table as a storage destination of a work information-mounted service group baseline information stream according to the first embodiment.
[0022] [ FIG. 13 ] FIG. 13 is a diagram illustrating a system performance abstract information table as a storage destination of a work information-mounted system baseline information stream according to the first embodiment.
[0023] [ FIG. 14 ] FIG. 14 is a diagram illustrating a service catalog table and a system operating information table based on the service catalog according to the first embodiment.
[0024] [ FIG. 15 ] FIG. 15 is a flowchart of a performance analysis processing unit according to the first embodiment.
[0025] [ FIG. 16 ] FIG. 16 is a flowchart of a similar event detection processing according to the first embodiment.
[0026] [ FIG. 17 ] FIG. 17 is a diagram illustrating a monitor screen according to the first embodiment.
[0027] [ FIG. 18 ] FIG. 18 is a diagram illustrating a monitor screen according to the first embodiment.
[0028] [ FIG. 19 ] FIG. 19 is a diagram illustrating an information system according to a second embodiment.
[0029] [ FIG. 20 ] FIG. 20 is a diagram illustrating a performance analysis processing flow of the service monitoring manager using the stream data processing system according to the second embodiment.
[0030] [ FIG. 21 ] FIG. 21 is a diagram illustrating information for handling an incident according to the second embodiment.
[0031] [ FIG. 22 ] FIG. 22 is a flowchart of the similar event detection processing according to the second embodiment.
[0032] [ FIG. 23 ] FIG. 23 is a flowchart of an incident search processing according to the second embodiment.
[0033] [ FIG. 24 ] FIG. 24 is a diagram illustrating a monitor screen according to the second embodiment.
DESCRIPTION OF EMBODIMENTS
[0034] The contents of embodiments will be described below. The following terms will be used in the following description, and the meanings thereof are substantially as follows.
[0035] Stream: a flow of information indicating a temporal transition of over-time changeable information such as event or measurement value.
[0036] Baseline: a statistically-processed past monitoring value or monitoring value on which abnormality determination is based.
[0037] Information on the present invention will be described by use of the expressions such as “aaa table”, “aaa list”, “aaa DB” and “aaa queue” in the following description, but the information may be expressed by other than the data structure such as table, list, DB and queue. Thus, “aaa table”, “aaa list”, “aaa DB”, “aaa queue”, and the like may be called “aaa information” in order to indicate non-dependence on the data structure.
[0038] Further, the expressions such as “identification information”, “identifier”, “name” and “ID” are used for describing the contents on each item of information, but they are replaceable with each other.
[0039] The description may be made below by use of a subject of “program”, but the program is executed by a processor thereby to perform predefined processings by use of a memory and a communication port (communication control device), and thus the description may be made by use of a subject of processor. The processings disclosed with a subject of program may be performed by a computer such as management server, or an information processing device. Part or all of the entire programs may be realized in dedicated hardware.
[0040] Various programs may be installed in each computer via a program distribution server or computer readable storage medium. In this case, the program distribution server includes a CPU and storage resources, and the storage resources store a distribution program and programs to be distributed therein. Then, the CPU executes the distribution program so that the CPU in the program distribution server distributes a program to be distributed to other computer.
First Embodiment
[0041] FIG. 1 is a structure diagram of an information system including a monitoring system. A Web system 101 of a service execution infrastructure, and a service used by an end user from each terminal 102 via a network 104 by use of a Web browser 103 are to be monitored. The monitoring system monitors a plurality of Web systems and services available thereon. In the present embodiment, Web is illustrated as an exemplary service, but the services include other file sharing services and network services.
[0042] The Web system 101 is a service execution infrastructure configured of a server (configured of a processor, storage resources, a network and the like), OS, and a physical or logical component such as middleware. When the Web system 101 is monitored, for example, an OS monitoring agent 105 or middleware monitoring agent 106 , which is resident in a server to be monitored and is directed for monitoring an operation performance of the OS or middleware, monitors the same. Alternatively, an OS remote monitor 108 or middleware remote monitor 109 in a system remote monitoring server 107 monitors an operation performance of the OS or middleware in the server configuring the system. The OS monitoring agent 105 , the middleware monitoring agent 106 , the OS remote monitor 108 , and the middleware remote monitor 108 transmit the monitoring values for predetermined monitoring items of the components to be monitored to a service monitoring server 113 , respectively.
[0043] With the service monitoring using Web access, transmission/reception packets of the Web system 101 are mirrored from a mirror port of a network switch 110 , and are sent to a traffic monitoring server 111 . A traffic monitoring agent 112 mounted on the traffic monitoring server 111 analyzes Http packets and calculates a response time. The traffic monitoring server 111 transmits the outline of the Http packets and the response time as monitoring results to the service monitoring server 113 . Herein, a plurality of traffic monitoring servers 111 may be present, and may collect and analyze packets from connection destination switches, respectively. Not only the traffic monitoring server 111 , any server having a function of collecting packets flowing on a network, analyzing Http packets, calculating a response time, and outputting the Http packet information and the response time may be provided. The service monitoring method may employ a method for adding a program capable of calculating a response time to a Web server of the service execution infrastructure, for example, other than the above method.
[0044] An event monitoring manager 116 in an event monitoring server 115 acquires all the event information notified from the Web system 101 to be monitored or various monitoring servers 107 and 111 . Types of events occurring in the service execution infrastructure (or detected (received) by the event monitoring server) assume when a monitoring value of a component failure or alert, or a component performance exceeds a predetermined reference, when a processing starts in the service execution infrastructure (such as virus scanning, garbage collection, and defragmentation), and the like, and other exemplary cases are possible.
[0045] A service monitoring manager 114 mounted on the service monitoring server 113 compares a component monitoring value with a baseline thereby to make an abnormality determination, and notifies an abnormality notification to the event monitoring manager 116 in the event monitoring server 115 . Further, it compares a response time and a baseline per service to be monitored based on the outline of the Http packets and the response time thereby to make an abnormality determination, and notifies an abnormality notification event to the event monitoring manager 116 in the event monitoring server 115 .
[0046] Herein, when the component monitoring value or service performance is abnormal, events in a normal time zone employed for the baseline and an abnormal time zone are compared among the events on the service and its related system, thereby detecting a differential event or a combination of events appearing during abnormal time. Then, a search is made as to whether the differential event and similar event or a combination of events is contained in the past events.
[0047] Further, numerical values for standardizing a response time are calculated, and a baseline is set based on the monitoring results.
[0048] The service monitoring result can be remotely viewed by use of a Web browser 118 of a terminal 117 . Of course, the terminal 117 displaying the service monitoring result thereon maybe the same as or different from the terminal 102 provided with a service.
[0049] The monitoring system for monitoring the service execution infrastructure according to the present embodiment is configured of the three servers including the traffic monitoring server 111 , the service monitoring server 113 and the event monitoring server 115 , but the traffic monitoring and the service monitoring described later may be processed by at least one server. Further, the terminal 117 meeting the above spirit may be included in the monitoring system if its display or input is described in Claims. To the contrary, the terminal may not be included in the monitoring system if a server for performing a traffic monitoring or service monitoring processing, such as service monitoring server, performs display or input. Further, if the monitoring processing is distributed in a plurality of servers for higher reliability, parallelization or distribution of the monitoring processing, the servers for the processing are put together in the monitoring system.
[0050] The description will be made below by way of a component monitoring value as performance value, but may be applied to other monitoring values (such as the number of access retries to component, packet loss rate, the number of context switches, request queue length to component, and the number of times of queue overflow).
[0051] FIG. 2 illustrates a hardware structure of a computer other than the terminal 102 , the servers included in the Web system 101 , the traffic monitoring server 111 , the system remote monitoring server 107 , the event monitoring server 115 and the terminal 117 according to the embodiment. As illustrated in FIG. 2 , the computer includes a processor 201 , a memory 202 , a storage device 203 , and a communication interface 204 , which are communicated with each other. The computer may include an input device 206 and an output device 207 as needed. The servers and terminals are illustrated together in FIG. 2 , but the computer does not necessarily have the same hardware. The programs indicated in corner-rounded squares in the respective computers in FIG. 1 are stored in the memory 202 or the storage device 203 (which will be collectively called storage resources below) and are executed by the processor 201 .
[0052] FIG. 3 is a diagram illustrating the information and programs stored in the storage resources in the computer illustrated in FIG. 2 . In the Figure, the service monitoring manager program 114 (which will be simply called service monitoring manager below) is stored in the memory 202 , and other items of information are stored in the storage device 203 , but each program and item of information may be stored in any of the storage resources. The service monitoring manager 114 includes a screen display processing unit 301 and a performance analysis processing unit 303 . The storage device 203 stores therein configuration information 304 , performance information 305 , baseline information 306 , event information 307 and system operating information 308 . I/O information exchanged with the terminal 117 via the Web browser 118 , component monitoring value information received from the Web system 101 or the system remote monitoring server 107 , Http packet information received from the traffic monitoring server 111 , and event information received from the event monitoring server 115 are input and output via the communication interface 204 . An input device and an output device are illustrated as separate devices in FIG. 2 and FIG. 3 , but they may be assumed to be used as a server or terminal by a computer such as Smartphone or tablet computer, and thus one device may serve as both an input device and an output device.
[0053] FIG. 4 illustrates an exemplary structure and exemplary processing flow of the service monitoring manager 114 inside the service monitoring server 113 . The service monitoring manager 114 has the performance analysis processing unit 303 using a stream data processing system 302 . A query repository 406 stores therein execution codes of processing contents of the performance analysis processing unit 303 . The technique disclosed in Japanese Patent Application Laid-Open No. 2006-338432 publication may be employed for a method for receiving stream data inside the stream data processing system and a method for analyzing a received query or registering an optimized or generated query execution form. The present invention may not necessarily be accomplished as in Japanese Patent Application Laid-Open No. 2006-338432 Publication, and other accomplishing systems capable of updating or creating the baseline information 306 , the performance information 305 and the event information 307 from input streams described below may be employed.
[0054] The stream data processing system 302 receives a service monitoring information stream 401 from the traffic monitoring server 111 , a system monitoring information stream 402 from the Web system 101 or the system remote monitoring server 107 , and an event monitoring information stream 403 from the event monitoring server 105 . The input streams (monitoring information streams) 401 to 403 are subjected to a performance analysis processing by use of a query processing engine 405 via a stream data flow manager 404 . The performance analysis processing unit 303 is performed in the order of a work identification processing 410 , an abnormality determination processing 411 , a similar event detection processing 412 , and then a baseline setting processing 413 .
[0055] In the work identification processing 410 , work information-mounted monitoring information streams are generated in which work information made of service and system of the configuration information 304 is added to the input streams (monitoring information streams) 401 to 403 , respectively. A work information-mounted event information stream 407 is stored in the event information 307 .
[0056] In the abnormality determination processing 411 , the performance values of the work information-mounted service performance streams within a predetermined time (one minute, for example) are subjected to a statistic processing (of calculating an average value, a maximum value, a minimum value and a dispersion value) per service, and their statistic values are compared with service performance abstract information on a baseline use time/date per work-based service group of the baseline information 306 to determine whether they are within a baseline permitted range, and a service performance information stream 408 including a determination result is stored in the performance information 305 . The performance value of the work information-mounted system monitoring information stream is compared with server performance abstract information of an agent-based monitoring item of each host on a baseline use time/date per work-based system of the baseline information 306 to determine whether it is within a baseline permitted range, and the system performance information stream 408 including a determination result is stored in the performance information 305 . Herein, when the service performance and the system performance are determined as abnormal, it is notified to the event monitoring server 115 .
[0057] When the service performance or the system operating performance exceeds a baseline permitted range, the similar event detection processing 412 extracts and compares an event in an abnormal time zone and an event in a normal time zone used for a baseline for the work from the event information 307 , and detects a differential event appearing only during abnormal time. A search is made as to whether an event similar to the differential event is present in the past events for the work in the event information 307 . When a similar event is not present in the work, a system similar to the system configuration of the work is detected from the system operating information 308 , and event information on the work for the similar system among the event information 307 is also to be searched. As a result of the processing, the differential event information 407 and the similar event information 407 are stored in the event information 308 .
[0058] In the baseline setting processing 413 , the performance values of the work information-mounted service performance streams within a predetermined time (one hour, for example) are subjected to a statistic processing (of calculating an average value, a maximum value, a minimum value and a dispersion value) per service group to be stored in the baseline information 306 . The performance values of the work information-mounted system performance information streams within a predetermined time (one hour, for example) are subjected to a statistic processing (of calculating an average value, a maximum value, a minimum value and a dispersion value) per agent-based monitoring item of each host to be stored in the baseline information 306 . A time/date when the average value of throughput/minute and the value of throughput/minute in the same time zone in past stored in the baseline information 306 are close to each other is detected per service group in units of predetermined time (one hour, for example), and a work-based baseline use time/date in a next time zone is stored as a next time zone on the detection date in the baseline information 306 .
[0059] FIG. 5A is a schematic diagram illustrating the configuration information 304 . The configuration information 304 stores therein information on components including work groups included in the Web system (such as component setting information or attribute information) or relationships between components (such as communication relationship or inclusion relationship). FIG. 5 illustrates that configuration information 502 , service group information 503 , system information 504 , and service information 505 are included in the configuration information 304 by way of example.
[0060] The contents of the work information 502 are work name 502 a, service group name 502 b, and system name 502 c. The contents of the service group information 503 are service group name 502 b and URI path 503 a. The contents of the service information 505 are service group name 502 b, service name 505 a , service contents 505 b, URI path 505 c, and URI query 505 d. The contents of the system information 504 are system name 502 c , host name 504 a, and IP address 504 b.
[0061] FIG. 5B is a diagram illustrating an exemplary structure of the Web system. The work group 501 is made of a plurality of works 502 . The work 502 is made of service group 503 and system 504 . The service group 503 is made of a plurality of services 505 . The system 504 is made of a plurality of hosts 506 . The host 506 is made of a plurality of agents. If a plurality of works are not handled in one monitoring system and a Web system, a work group may not be present. Similarly, if a plurality of services are not provided, a service group may not be present.
[0062] FIG. 6 illustrates the service monitoring information stream 401 and a work information-mounted service monitoring information stream 605 as an output result of the work identification processing 410 .
[0063] The service monitoring information stream 401 is made of time 601 , request information 602 , response information 603 , and response time 604 . The contents of the request information 602 are source IP address 602 a, method 602 b, URI path 602 c , and URI query 602 d. The contents of the response information 603 are HTTP status code 603 a and transfer data amount 603 b.
[0064] The work information-mounted service monitoring information stream is made of time 601 , work name 502 a, service group name 502 b, service information 505 , request information 602 , response information 603 , and response time 604 . The contents of the service information 505 are service name 505 a and service contents 505 b.
[0065] FIG. 7 illustrates the system monitoring information stream 402 , and a work information-mounted system monitoring information stream 706 as an output result of the work identification processing 410 .
[0066] The system monitoring information stream 402 is made of time 701 , host information 702 , agent name 703 , monitoring item 704 , and performance value 705 . The contents of the host information 702 are host name 702 a and IP address 702 b. The contents of the monitoring item 704 are record name 704 a and field name 704 b.
[0067] The work information-mounted system monitoring information stream 706 is made of time 701 , work name 502 a , system name 502 c, host information 702 , agent name 703 , monitoring item 704 , and performance value 705 .
[0068] FIG. 8 illustrates the event monitoring information stream 403 as well as a work information-mounted service event information stream 407 a and a work information-mounted system event information stream 407 b as output results of the work identification processing 410 .
[0069] The event monitoring information stream 403 is made of time 801 , event information 802 , object type 803 , and object information 804 . The contents of the event information 802 are severity 802 a, registration time 802 b, event ID 802 c , source 802 d, message 802 e, and action 802 f. The object type 803 is information for identifying an event issue source, such as service information, system information or job information.
[0070] The work information-mounted service event information stream 407 a is made of time 801 , work name 502 a, service group name 502 b , service information 505 , and event information 802 .
[0071] The work information-mounted system event information stream 407 b is made of time 801 , work name 502 a, system name 502 c, host information 702 , and event information 802 .
[0072] FIG. 9 illustrates the table structures of an event information table 307 a inside the event information 307 storing the work information-mounted event information stream 407 , as well as a differential event information table 307 b and a similar event information table 307 c storing the work information-mounted event monitoring information streams of a differential event and a similar event in the similar event search processing 412 . Each of the event information tables 307 a, 307 b, and 307 c has the same table structure, and is made of time 801 , work name 502 a, service group name 502 b, service information 505 , system name 502 c, host information 702 , and event information 802 .
[0073] FIG. 10 illustrates a service performance information table 305 a inside the performance information 306 which stores a service performance information stream 408 a as a result of baseline determination of a statistic value found in the abnormality determination processing 411 for the work information-mounted service monitoring information stream 605 . The work information-mounted service performance information stream 408 a is made of time 1001 , work name 502 a, service group name 502 b, service information 505 , determination 1002 , response time statistic value per minute 1003 , throughput cumulative value per minute 1004 , and error rate cumulative value per minute 1005 . The contents of the service performance information table 305 a are time 1001 , work name 502 a, service group name 502 b, service information 505 , determination 1002 , response time statistic value per minute 1003 , throughput cumulative value per minute 1004 , and error rate cumulative value per minute 1005 .
[0074] FIG. 11 illustrates a system performance information table 305 b inside the performance information 306 for storing a system performance information stream 408 b as a result of baseline determination in the abnormality determination processing 411 for the work information-mounted system monitoring information stream 706 . The work information-mounted system performance information stream 408 b is made of time 1101 , work name 502 a, system name 502 c , host information 702 , agent name 703 , monitoring item 704 , performance information 705 , and determination 1102 . The contents of the system performance information table 305 b are time 1101 , work name 502 a, system name 502 c, host information 702 , agent name 703 , monitoring item 704 , performance information 705 , and determination 1102 .
[0075] FIG. 12 illustrates a service group performance abstract information table 306 a of the baseline information 306 for storing a work information-mounted service group baseline information stream 409 a, in which a statistic value of service performance per service group is found in a predetermined time (one hour, for example) and a date for which a throughput average value per minute is the closest thereto in the same service group and in the same time zone is detected to assume a next time zone of the detection date as a work-based baseline use time/date in the next time zone in the baseline setting processing 413 for the work information-mounted service performance information stream 408 a. The work information-mounted service performance baseline information stream 409 a is made of time 1201 , work name 502 a, service group name 502 b, throughput (statistic value) 1202 , error rate (statistic value) 1203 , response time (statistic value) 1204 , and baseline use time/date 1205 . The contents of the service group performance abstract information table 306 a are time 1201 , work name 502 a, service group name 502 b, throughput statistic value ( 1202 ), error rate (statistic value) 1203 , response time (statistic value) 1204 , and baseline use time/date 1205 .
[0076] FIG. 13 illustrates a system performance abstract information table 306 b of the baseline information 306 for storing a resultant work information-mounted system baseline information stream 409 b which is obtained by finding a statistic value of a performance value for a monitoring item of an agent of a host inside a system per predetermined time (one hour, for example) in the baseline setting processing 413 for the work information-mounted system performance information stream 408 b . The work information-mounted system baseline information stream 409 b is made of time 1301 , work name 502 a, system name 502 c, host information 702 , agent name 703 , monitoring item 704 , and performance value (statistic value) 1302 . The contents of the system performance abstract information table 306 b are time 1301 , work name 502 a, system name 502 c, host information 702 , agent name 703 , monitoring item 704 , and performance value (statistic value) 1302 .
[0077] The performance value (statistic value) in the system performance abstract information table 306 b in FIG. 13 is used in consideration of the baseline use time/date 1205 for the time 1201 and the work name 502 a in the service group performance abstract information table 306 a in FIG. 12 which match with the work name 502 a in the time zone to which the time 701 in the work information-mounted system monitoring information stream 706 in FIG. 7 belongs.
[0078] FIG. 14 illustrates a service catalog table 1401 and a system operating information table 1402 included in the system operating information 308 . The contents of the service catalog table 1401 are system type 1403 , server specification 1404 , OS type 1405 , middleware type 1406 , and quantity 1407 .
[0079] The contents of the system operating information table 1402 are system name 502 c, system type 1403 , UP (User Program) information 1408 , cumulative operating days 1409 , number of alerts 1410 , number of failures 1411 , average service performance information per predetermined time 1412 , and average system performance information per predetermined time 1413 .
[0080] A PaaS (Platform as a Service) provider registers a service to be provided in the service catalog table 1401 .
[0081] The system name 502 c, the system type 1403 selected from the service catalog table 1401 , and the UP information 1408 are registered in the system operating information table 1402 on construction or modification of the system. The cumulative operating days 1409 , the number of alerts 1410 , and the number of failures 1411 are periodically registered and updated from separately-managed incident management. Further, the average service performance information per predetermined time 1412 and the average system performance information per predetermined time 1413 are periodically subjected to a count processing by the performance information 305 to be registered and updated.
[0082] The system operating information table 1402 is required to search a system having the same system type 1403 as the target system or to select a system having longer or closer operating performance from among the similar systems.
[0083] FIG. 15 illustrates a flow of processings in the performance analysis processing unit 303 . The performance analysis processing unit 303 performs the processings in the order of the work identification processing 410 , the abnormality determination processing 411 , the similar event detection processing 412 , and then the baseline setting processing 413 .
[0084] The work identification processing 410 is made of a processing 1501 of receiving a monitoring information stream and a processing 1502 of adding work information to the monitoring information stream. The reception processing 1501 is to receive new information on the monitoring information stream.
[0085] The processing 1502 of adding work information to the monitoring information stream is such that the configuration information 304 is referred to, and in the case of the service monitoring information stream, works related to service groups having a common URI are acquired, and service information having common URI and query is acquired thereby to create a work type-mounted service monitoring information stream.
[0086] In the case of the system monitoring information stream, a work related to a system including hosts is acquired thereby to create a work information-mounted system monitoring information stream.
[0087] In the case of the event monitoring information stream, a work related to a service group is acquired from among the service information stored in the object information thereby to create work type-mounted event monitoring information when the object type is service. When the object type is host, a work related to a system including hosts is acquired thereby to create work type-mounted event monitoring information. The work type-mounted event monitoring information is stored in the event information 307 .
[0088] The abnormality determination processing 411 is made of a processing 1503 of finding statistic values (average, maximum, minimum and dispersion) of the performance values and creating a work type-mounted service performance information stream for the work type-mounted service monitoring information stream incoming within a predetermined time, and a processing 1504 of determining whether the statistic value of the work type-mounted service performance information exceeds a baseline thereby to register the work type-mounted service performance information stream in the performance information 305 , or determining whether the performance value exceeds a baseline for the monitoring item of the agent in the host of the work type-mounted system monitoring information thereby to register the work type-mounted system performance information stream in the performance information 305 .
[0089] As a result of a determination unit 1505 as to whether the baseline permitted range is exceeded, when the baseline is exceeded, the similar event detection processing 412 is performed. The similar event detection processing 412 is made of an event information comparison processing 1506 of comparing event information between during normal time and during abnormal time and detecting a differential event, and a similar event search processing 1507 of searching whether a similar event to the differential event was present in past.
[0090] In the baseline setting processing 413 , at first, a processing 1508 of creating performance abstract information within a predetermined time is to calculate a statistic value within a predetermined time (one hour, for example) of the service performance (such as response time or throughput) per unit time (one minute, for example) per service group for each work, thereby creating service performance abstract information. The processing 1508 is to calculate a statistic value within a predetermined time (one hour, for example) of the performance value of the monitoring item per agent of each host in the system, thereby creating system performance abstract information. The processing 1508 is to accumulate the statistic values (maximum value, minimum value and average value) of the performance information every unit time (one minute, for example).
[0091] Then, a processing 1509 of detecting a past statistic value close to the throughput statistic value within the predetermined time thereby to determine a baseline in a next time zone is to find a date of a closest throughput statistic value among the throughput statistic values in the same time zone in past for the service group of the same work when the performance abstract information for the predetermined time (one hour, for example) is accumulated, to assume it as a baseline use date in a next time zone and to store it in the baseline information 306 .
[0092] FIG. 16 illustrates a flow of processing in the similar event detection processing 412 . The similar event detection processing 412 is made of the event information comparison processing 1506 and the similar event search processing 1507 .
[0093] The event information comparison processing 1506 is made of a processing 1601 of acquiring event information within a most recent predetermined time including an over-baseline time per work, a processing 1602 of acquiring event information in the baseline use time zone (during normal time), and a processing 1603 of comparing event IDs of the event in the over-baseline time zone (during abnormal time) and the event in the baseline use time zone (during normal time), detecting a differential event not appearing during normal time but appearing during abnormal time, and storing the differential event in the event information 307 .
[0094] The similar event search processing 1507 is made of a processing 1604 of searching an event whose event ID matches with a differential event (combination) from the past events of the same work, a matched differential event determination unit 1605 , a processing 1606 of, when a matched event is found, storing the similar event (combination) in the event information 307 , a processing 1607 of searching other system having the same system configuration as the system related to the work with reference to the system operating information 308 , a system similarity determination unit 1608 , and a processing 1609 of searching an event whose event ID matches with the differential event (combination) from the past events of the similar system-related work.
[0095] FIG. 17 and FIG. 18 illustrate the monitor screens executed by the screen display processing unit 301 in the service monitoring manager 114 installed in the service monitoring server 113 and displayed on the Web browser 118 in the terminal 117 .
[0096] FIG. 17 illustrates a monitor screen 1700 when an exceeded baseline is detected and a differential event not appearing during normal time is detected as a result of baseline monitoring of the service and related system performance per work. The monitor screen 1700 is configured of a work list display unit 1701 , a display period designation unit 1702 , a topology display unit 1703 , a differential event list display unit 1704 , and a graph display unit 1705 .
[0097] The way the monitor screen is used is that when an abnormality is sensed in an in-work service or host on the integrated event monitoring tool, a work to be confirmed is first selected by the work list display unit 1701 in the monitor screen 1700 . Then, a period is designated by the display period designation unit 1702 and the operating situation of the service and host in the system configuring the work is confirmed by the topology display unit 1703 . At this time, an event appearing only during abnormal time is displayed in the differential event list display unit 1704 . Then, an abnormal portion's performance trend selected in the topology display unit 1703 and an event occurrence situation selected in the differential event list in the period designated in the display period designation unit 1702 are confirmed in the graph display unit 1705 . The performance value on a date in the same time zone to which the number of most recent accesses is the closest is employed as a baseline in the graph display unit 1705 , and thus the baseline of the response time of date 1706 when event 2 occurs is assumed as a baseline of the response time of date 1707 to which the number of accesses is the closest.
[0098] FIG. 18 illustrates a monitor screen 1800 as a result of detection of a similar event from among the past events of the same work and other works having the same system configuration for the differential event detected in FIG. 17 . The monitor screen 1800 is configured of a work list display unit 1801 , a display period designation unit 1802 , a differential event list display unit 1803 , a similar event list display unit 1804 , and a graph display unit 1805 .
[0099] The way the monitor screen is used is to designate a period in the display period designation unit 1802 and to confirm the number of differential event occurrences for the differential events during abnormal time detected in FIG. 17 in the differential event list display unit 1803 . Herein, the differential events frequently occur, and a determination is made as to whether an event is ignorable or rarely occurs but is to be paid attention.
[0100] Subsequently, when an event rarely occurs but is to be paid attention, a similar event is searched from the past events on the same work or works in a similar system, and the search result is displayed in the similar event list 1804 .
[0101] In the graph display unit 1805 , the similar event occurrence situation and the performance trend are compared between current time and past time, an occurrence of failure is predicted, and possible information is presented before the failure occurs.
[0102] The above description is on the first embodiment.
Second Embodiment
[0103] A second embodiment will be described below with reference to the drawings.
[0104] FIG. 19 is a diagram illustrating a structure of the second embodiment, which is different from the first embodiment in that an incident management server 119 is added. An incident management 120 program is stored in a storage resource and is executed in the incident management server 119 .
[0105] FIG. 20 illustrates a structure and a processing flow when similar incident information is added to the structure and the processing flow of the service monitoring manager 114 in the service monitoring server 113 in FIG. 4 in association with the incident management 120 in the incident management server 119 . In the performance analysis processing unit 303 in the stream data processing system 302 , with the similar event detection processing 412 , when a service performance or system operating performance exceeds a baseline permitted range, an event in an abnormal time zone and an event in a normal time zone used for the baseline are extracted from the event information 307 and are compared with each other for the work, and a differential event appearing only during abnormal time is detected. Then, with an incident search processing 2001 of the incident management 120 in the incident management server 119 , a search is made as to whether similar incident information is present in incident information 2002 previously registered based on the past events for the work. As a result of the searching, when a similar incident is found, a work information-mounted incident information stream 2003 is generated to be stored in similar incident information 2004 .
[0106] FIG. 21 illustrates input information 2101 and output information 2103 for the incident search processing 2001 of FIG. 20 as well as an incident information table 2101 inside the incident information 2002 and a similar incident information table 2104 inside the similar incident information 2004 .
[0107] The input information 2101 for incident search is made of start time/date 2105 and end time/date 2106 indicating a search period, work name to be searched 502 a, service group name 502 b, system name 502 c, and incident-related event ID 2107 .
[0108] The incident information table 2102 is made of title 2108 , severity 2109 , incident ID 2110 , URL to incident ID 2111 , work name 502 a, service group name 502 b, system name 502 c , occurrence time/date 2112 , and incident-related event ID 2113 .
[0109] The output information 2103 for incident search result corresponds to the items in the incident information table 2102 .
[0110] The similar incident information table 2104 is made of items corresponding to the incident information for storing the incident search results in 2103 .
[0111] FIG. 22 illustrates a processing flow in which a similar failure search processing 2201 is added to the processing flow of the similar event detection processing 412 of FIG. 16 . In the similar event detection processing 412 , a differential event is detected by the event information comparison processing 1506 to be stored in the event information 307 .
[0112] Then, in the similar failure search processing 2201 , a search is made as to whether an incident based on a related event similar to the differential event (combination) is present. The similar failure search processing 2201 is made of a processing 2202 of creating a data set made of search period, work information, and differential event (combination), a processing 2203 of generating a search command with a similar incident as a return value by use of the created data set as an input parameter, and a processing 2204 of transmitting the generated search command to the incident management and receiving a list of similar incident information.
[0113] A determination processing 2205 is performed as to whether a similar incident is found as a result of the similar failure search processing 2201 , and when a similar incident is found, a processing 2206 of storing the list of similar incident information in the similar incident information table is performed to store it in the similar incident information 2004 . When a similar incident is not found, the similar event search processing 1507 is performed.
[0114] FIG. 23 illustrates a flow of processings of the incident search processing 2001 in the incident management 120 in the incident management server 119 . The incident search processing 2001 is made of a processing 2301 of extracting an incident of the same work within a period between the search start time/date and end time/date, a processing 2302 of extracting an incident including a related event from among the extracted incidents, a processing 2303 of creating a data set made of “title”, “severity”, “incident ID”, “URL to incident ID”, “work name”, “occurrence time/date”, and “related event ID” from the extracted incident information, and a processing 2304 of transmitting the created data set.
[0115] FIG. 24 illustrates a monitor screen executed by the screen display processing unit 301 in the service monitoring manager 114 installed in the service monitoring server 113 and displayed on the Web browser 118 in the terminal 117 . FIG. 24 illustrates the monitor screen 2400 as a result of detection of a similar incident unlike the monitor screen 1800 as a result of detection of a similar event for a differential event in FIG. 18 .
[0116] When search period 2402 is designated in differential event list 2401 in the monitor screen 2400 , the number of event occurrences is displayed.
[0117] Then, a result obtained by searching an incident for events (combination) whose similarity to be searched is assigned with check 2403 is displayed in a similar incident list 2404 .
[0118] Further, when incident ID 2405 is clicked, an incident screen 2406 at detailed incident URL is displayed. Incident information 2407 is displayed in the incident screen 2406 , where a determination can be made as to whether a currently-occurring event may lead to a failure. Further, the incident screen 2406 displays thereon the contents such as workaround and solution made and input by a manager of the service execution infrastructure, and thus the manager of the service execution infrastructure can address a failure with reference to the displayed information before it occurs.
[0119] As described above, with the monitoring system according to the first and second embodiments, it is difficult to find a baseline as past performance information of a similar use situation in both indeterminately-changing service use and an in-system processing such as batch job for periodical standard processing, but a date close to a current throughput is found from among the throughputs of the past service in the same time zone, and thus the baselines for system and service added with the periodically-executed inside processing can be found with good accuracy in a short time.
[0120] With the monitoring system according to the first and second embodiments, when a baseline permitted range is exceeded, handling may be required since a failure can be caused and handling may not be required since a failure can be recovered over time, but information for correct determination can be presented in a prediction stage.
[0121] With the monitoring system according to the first and second embodiments, the system operating performance in the same time zone with a similar service use situation is assumed as a baseline, thereby sensing an in-system processing abnormality not due to an external access variation (disturbance). Thus, an external factor due to external access and an internal factor due to internal processing abnormality can be discriminated, and thus a time required for cause investigation can be reduced and a proper handling method can be employed.
[0122] As illustrated in FIG. 16 , event information acquired in step 1602 is event information in a time zone of an employed baseline, and thus consequently-acquired event information, which is suitable for a service monitoring value, is selected. This is suitable when a different event occurs between on many service requests and on less service requests, for example. However, when the similar event detection processing of FIG. 16 applies a baseline even if not managing it in association with a service monitoring value, an event can be rapidly analyzed after an abnormality is detected in the service execution infrastructure. This is applicable also in FIG. 22 .
[0123] Pseudo baselines may be combined (two baselines are averaged, for example) from among a plurality of baselines instead of selecting one baseline close to a service monitoring value for the baseline used for component abnormality detection. The combination is suitable when a component monitoring value does not rapidly change while service loads of the service execution infrastructure slightly increase. On the other hand, for selecting one baseline, when a baseline is displayed as illustrated in FIG. 17 , the displayed baseline is actually generated, and thus the user of the monitoring system can make fact-based analyses more deeply. Corresponding event information can be more easily selected when one baseline is selected.
[0124] An event streamed from the event monitoring server 115 may be detected by the event monitoring server 115 when the event monitoring server 115 receives a message indicating the contents of the event from the Web system 101 . Other event detecting methods may employ a method for transmitting a status acquisition request from the event monitoring server 115 to the service execution infrastructure and detecting an event based on the received status. However, the event detection may be accomplished by other methods.
REFERENCE SIGNS LIST
[0000]
101 Web system
102 Terminal
111 Traffic monitoring server
113 Service monitoring server | A monitoring system for monitoring a service execution infrastructure for providing a service to client computers via a network manages baselines of monitoring values of components per load of the service provided by the infrastructure, and uses the baselines depending on a current service load. When detecting an abnormality of a service monitoring value or component monitoring value by use of the baselines, the monitoring system compares events up to predetermined minutes ago from now with events in the baseline time zone thereby to specify a differential event (or non-normal recent event). | 7 |
This application is a National Stage Application of PCT/US01/45519 which claims priority from U.S. Provisional Application Ser. No.: 60/249,765 filed 17 Nov. 2000.
BACKGROUND OF THE INVENTION
The present invention relates to valves and, in particular, to a valve with a special handle that tracks the usage of the valve to enable logging and billing. The valve handle may thus be used not only to dispense a gas but, in combination with the disclosed procedure, to provide a method for conveniently providing tracking of the use of the gas and subsequent billing for medical treatments using the gas.
Some medical treatments involve the use of gases that are inhaled by the patient. In the past, medical gas suppliers have charged for the gas in the cylinder at the time of delivering the filled cylinder to the user. This method has been used both for industrial and medical uses. Pharmaceutical gases, dispensed by prescription, have great variability of use from patient to patient due to treatment regimen and dispensing methods. A method of charging for treatment time would be a desirable way for allocating the true value of the product. However, in the past, there has not been a way to automatically track the duration of treatments by cylinder or to tie the treatments to the patients who receive the treatments in order to make it easy to bill for use of the gas. Such a method is provided in accordance with the present invention.
SUMMARY OF THE INVENTION
The present invention provides a valve with a smart handle for the gas bottle (or cylinder). This valve records all the treatment information and makes the information readily accessible for use in tracking and invoicing. It permits the vendor to invoice the user for total treatment time and to provide users, such as hospitals or clinics, the information to bill individual patients. It also provides both the vendor and the user with data which is useful for trend analysis and inventory control.
The valve handle includes sensors for sensing the opening and closing of the valve, a timer for timing the duration over which the valve is opened, and an electronic memory device which records the pertinent information. The information recorded by the memory device may include the cylinder fill date, the lot batch number, cylinder number, the patient's name, the number of times the valve is opened, and the date, time, and duration of each opening of the valve, as well as additional information, if desired.
The data then can be readily transferred from the memory device to a device that generates reports or invoices.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded, perspective view of an example of a valve with a smart handle made in accordance with the present invention;
FIG. 1A is the same view as FIG. 1 but from a different perspective and with the lock mechanism further exploded from the view;
FIG. 2 is the same view as FIG. 1 but from a different perspective;
FIG. 2A is the same view as FIG. 1 but with the lock mechanism further exploded from the view,
FIG. 2B is a schematic diagram showing the processor mounted on the handle of FIG. 1 and the input/output devices associated with it;
FIG. 3 is a side view of the valve of FIG. 1 mounted on a gas cylinder;
FIG. 4 is an enlarged plan view of the valve and cylinder of FIG. 3 ;
FIG. 5 is an exploded, perspective view of the handle part of the valve of FIG. 1 ;
FIG. 6 is an enlarged bottom view of the assembled handle of FIG. 5 ;
FIG. 7 is an enlarged side view of the assembled handle of FIG. 5 ;
FIG. 8 is a section view taken along the line 8 — 8 of FIG. 7 ;
FIG. 9 is a schematic operational logic diagram for the valve handle of FIG. 1 ;
FIG. 10 is a perspective view of the handle of the valve of FIG. 1 ;
FIG. 11 is a perspective view of a hand-held recorder used to export data from the valve of FIG. 1 ;
FIG. 12 is a perspective view of a button-type storage device used with the recorder of FIG. 11 ;
FIG. 13 is a hand-held portable computer which may be used to initialize the memory device on the valve of FIG. 1 , and which may be used to export data from the memory device;
FIG. 14 is a wand reader used to transfer data to and from the valve handle of FIG. 1 and to and from a computer;
FIG. 15 is a perspective view of a BlueDot receptor that may be used for transferring data from a button-type memory module (as shown in FIG. 12 ) to a computer; and
FIG. 16 is an adapter which can be used to download data from the valve of FIG. 1 to a button-type memory module.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1–16 show a first preferred embodiment of the present invention. A valve 10 is provided, which may be attached onto a gas cylinder 12 . The cylinder may contain pharmaceutical gas or other gases.
Referring to FIGS. 1 , 2 , and 3 , the valve 10 includes a valve body 14 , a stem 15 projecting upwardly from the valve body 14 , and a handle 16 mounted on top of the valve stem 15 for manually opening and closing the valve 10 . FIGS. 1 and 2 show that the valve body 14 includes a threaded inlet port 18 which screws onto the outlet port of the cylinder 12 . The valve body 14 also includes an outlet port 20 . The valve body 14 , the outlet port 20 , and the inlet port 18 may be modified for specific uses, cylinder sizes, or gases.
The handle 16 mounts on the valve stem 15 . An operator grasps the handle 16 and rotates it in order to open and close the flow of gas from the cylinder 12 to a ventilator or other gas dispensing device (not shown). The handle 16 has a substantially circular cross-section and includes ribs around its outer edge to facilitate grasping the handle.
As shown in FIG. 2B , several electronic devices are mounted in the handle, including a processor 23 , a timer 21 , a reset button 27 , an open/closed sensor 28 , a battery 25 , a display 26 , and an electronic memory device 22 . In this embodiment, the memory device 22 communicates with a one-wire port 22 ′ that projects to the exterior of the handle 16 . The one-wire port 22 ′ in this embodiment is a metal can, which has the same shape as the portable memory buttons 22 A, shown in FIG. 12 , that can be used to transfer data from the handle's memory 22 to other devices. This enables the same communication devices to be used with the port 22 ′ and with the memory buttons 22 A.
Most of the components of FIG. 2B are housed inside a compartment formed by the handle 16 and the cover 24 in this preferred embodiment. The processor 23 is located inside the handle cover 24 and communicates with the electronic memory device 22 . Also inside the handle cover 24 are two (2) small batteries 25 . While FIG. 2B shows a single timer 21 , there preferably are at least two timers 21 , one of which is a calendar, and the other of which is an event timer. The reset button 27 , located inside the handle 16 , may be depressed to reset the event timer 21 . At least a portion of the top surface of the handle cover 24 is clear, in order to permit the user to view the LCD display 26 mounted inside the handle 16 . On the underside of the handle 16 is mounted the sensor 28 , as seen in FIGS. 1A , 2 and 8 . The sensor 28 that is used in this preferred embodiment is a proximity switch model MK20-BV50:170 manufactured by Meder Inc. A collar 30 is mounted onto the valve body 14 , just below the handle 16 . This collar 30 holds a stationary magnet 32 (See FIG. 1 ). In the embodiment shown here, the collar 30 has a twenty-four-sided interior cross section 34 which fits directly onto the nut 36 on the valve body 14 , so the collar 30 remains stationary relative to the valve body as the handle 16 is rotated to rotate the valve stem 15 , in order to open and close the valve. The angular position of the collar 30 may be changed by lifting it up and rotating it, then fitting it back down over the nut 36 . However, this can be done only when the handle 16 is removed from the valve 10 .
The handle 16 is protected from undesired removal by a special stud 38 (such as a “Torx” stud) and its corresponding security nut 39 (See FIG. 5 ), making it difficult for anyone to tamper with the position of the collar 30 and magnet 32 , as will be explained in detail later. The proximity sensor 28 is mounted on the handle 16 , and the collar 30 is positioned so that, when the handle 16 is rotated to the closed position, the sensor 28 is adjacent to the magnet 32 that is fixed to the collar 30 . When the proximity sensor 28 is adjacent to the magnet 32 , it sends no signal to the processor 23 , thereby indicating that the valve is in the “closed” position. When the handle 16 is rotated to open the valve, the proximity sensor 28 senses that it has been moved away from the magnet and sends a signal to the processor 23 , indicating an “open” position. The processor 23 instructs the memory 22 to record the event of opening the valve and to record the time and date of the event as indicated by the calendar timer 21 . The processor 23 instructs the memory device 22 to continue checking the position of the valve as long as the valve 10 is open. When the valve is closed, the processor uses the logged open and close times to calculate the amount of time the valve was open and instructs the memory device 22 to record that duration as well a recording an accumulated open time duration. Thus, every time the valve 10 is opened, the time and date of the event is recorded, the closing time and date is recorded, the duration of time during which the valve 10 is open is calculated and logged, and the accumulated open time is calculated and logged. FIG. 9 shows the operational logic for the timing and logging operation.
While the simple proximity sensor 28 and magnet 32 are used in this preferred embodiment, many other arrangements are known in the art for sensing and signaling when the valve 10 is open and when it is closed, and it would be obvious to those skilled in the art to use other known sensing arrangements.
The display 26 may be arranged to display in a variety of ways. However, in this embodiment, it alternates flashing of two different numbers—first the accumulated open time, and then the open time for the current event preceded by a “plus sign”. If the valve is closed, then the current event open time flashes as a “minus sign” with no digits adjacent to the “minus sign”.
The threaded security stud 38 is fixed at its top end to the handle cover 24 and projects downwardly. It is received by the special security nut 39 , which is rotatable relative to the handle 16 but is trapped onto the underside of the handle 16 . The nut 39 must be unthreaded from the stud 38 in order to remove the handle cover 24 to allow access to the interior of the handle 16 . This arrangement helps make the handle 16 tamper-proof. Once the handle cover 24 has been removed, there is access to the batteries 25 , reset button 27 , and so forth, and there is access to the screw 37 which secures the handle 16 to the valve stem 15 .
An optional locking device 54 (See FIGS. 1A and 2A ) prevents inadvertent rotation of the handle 16 during transport and can only be installed when the valve handle 16 is in the closed position. This serves to provide additional visual cues of the valve handle 16 position to the user. The locking device 54 preferably is made of plastic and includes a curved wall 56 , which conforms closely to the shape of the outside wall of the valve handle 16 . An arm 58 extends inwardly from the lower end of the wall 56 , and a finger 60 projects upwardly from the free end of the arm 56 . The finger 60 is designed to mate with the hole of the security nut 39 , while the arm 58 fits snugly within the notch 40 of the fixed collar 30 . A tab 62 at the top end of the locking device 56 projects both outwardly and inwardly, so that, when installed, the inward portion of the tab 62 snaps over the top of the handle 16 to retain the locking device 56 in place on the handle 16 , with the finger 60 mated to the security nut 39 and the arm 58 in the notch 40 of the collar 30 .
Since the collar 30 is fixed on the valve 14 , and the arm 58 of the locking device 54 is caught in the notch 40 of the collar 30 , the locking device 54 is fixed and does not rotate relative to the valve body 14 . Furthermore, since the finger 60 is attached to the arm 58 (which is part of the locking device 54 ), and is mated to the security nut 39 (which is part of the handle 16 ), then the handle : 16 is also unable to rotate relative to the valve body 14 . In order to open the valve 10 , the locking device 54 is removed by pushing downwardly on the outwardly-projecting portion of the tab 62 to release the inwardly-projecting portion of the tab 62 from the top of the handle 16 , and then the locking device 54 is slid downwardly to remove the finger 60 from the nut 39 and to remove the arm 58 from the notch 40 . Then, the handle 16 can be rotated to open the valve 10 . As long as the locking device 54 is properly attached to the valve 10 , accidental opening of the valve 10 (such as due to vibration during transport) is unlikely.
Installation of the Valve and Handle:
The following steps may be taken to install the valve and handle on the gas cylinder. First, the valve body 14 (without the valve handle 16 ) is installed onto the cylinder 12 by threading the inlet port 18 of the valve body onto the cylinder 12 . At this point, the valve stem 15 is in the full clockwise (closed) position. The cover 24 is removed from the handle 16 , and the handle 16 is temporarily placed onto the valve stem 15 by placing the square hole 15 A of the handle 16 over the valve stem 15 . The handle 16 should be in a position in which there will be easy access to the memory module 22 . The location of the security nut 39 should be noted, and then the handle 16 should be removed from the valve stem 15 .
As shown in FIGS. 2 and 6 , the collar 30 has a notch 40 , which should only line up with the security nut 39 when the valve handle 16 is in the closed position, so the only time there will be access to the security nut 39 will be when the valve is closed. This will ensure that the handle 16 may only be removed when the valve 10 is closed. The target collar 30 should be installed over the nut 36 with the notch 40 in the proper position to provide access to the security nut 39 when the valve is closed. The position of the notch 40 may be adjusted by lifting the collar 30 off of the nut 36 , rotating the collar 30 , and then reinstalling the collar 30 on the nut 36 until the notch 40 on the collar 30 matches up with the intended location of the security nut 39 . The 24-point cross-section 34 of the collar 30 allows for precise positioning of the collar 30 on the hexagonal nut 36 .
Once the collar 30 and its notch 40 and magnet 32 are properly positioned onto the valve body 14 , the handle 16 can then be placed back onto the valve stem 15 , with the square opening 15 A of the handle 16 fitting onto the valve stem 15 , making sure to align the security nut 39 with the notch 40 on the collar 30 . The handle 16 is then secured to the stem 15 by using a Fender washer 35 and threading a button-head cap screw 37 from the top side of the handle 16 into the threaded top of the stem 15 , as is well known in the art. (See FIG. 1 ).
The reset button 27 on the inside of the handle 16 is then depressed to reset the timers 21 . The handle cover 24 is then installed onto the handle 16 by lining up the security stud 38 with the security nut 39 and tightening the security nut 39 from below, extending a tool upwardly through the notch 40 . This draws the handle cover 24 onto the handle 16 . The LCD display 26 should read −00.0 The minus sign indicates that the valve handle is not currently logging time and ensures that the magnet 32 on the target collar 30 and the sensor 28 on the handle 16 are properly aligned. When the valve handle 16 is in the closed position, the LCD display 26 toggles between a “ - - - ” display indicating that the valve 10 is closed, to a “-XXX” display where XXX represents the total accumulated time the cylinder has been open. When the valve handle 16 is in the open position, the LCD display 26 toggles between the treatment time display and the total accumulated time display.
Configuring the Valve with Smart Handle
Once the valve handle 16 is reset and is mounted on the cylinder 12 , the valve handle should now be configured to input the initial parameters such as:
Born on date (date when cylinder was filled) Cylinder serial number Gas lot number Set the timers (which may include a calendar timer and an event timer) Clear the log registers Additional area may be available for recording specific notes or information relative to a specific treatment or lot.
This initial configuration would typically be done by the distributor who is filling and supplying the filled cylinders to the user. The distributor uses a computer in which the required software has been previously installed and the initialization parameters have been previously inputted. The distributor inputs the initialization parameters from its computer to the smart handle 16 by some known data transfer mechanism. In this preferred embodiment, the distributor uses the transfer device 44 shown in FIG. 14 . This transfer device plugs into the distributor's computer at one end, and the other end fits onto the one-wire port 22 ′ on the handle 16 to transfer the initialization parameter data from the distributor's computer to the memory 22 in the valve handle 16 .
Similarly, the user (such as the hospital) may add more data into the memory device 22 of the valve 10 . This information may include a patient identification number, a treatment number, and so forth, which the hospital may use for its record keeping and for billing its patients or other end users. One way to add that data is by using a hand held computer 50 or laptop (not shown), inputting the information into the computer 50 and transferring that information to the memory device 22 through an adapter 48 (shown in FIG. 16 ) and through the transfer device 44 .
The hospital or other user, as well as the distributor, may later download the data from the memory device 22 to be used for record keeping and billing.
Valve Operation
Typically, the outlet port 20 of the valve 10 is connected to a delivery device, such as a ventilator (not shown), which is used to adjust the concentration and flow rate or to mix gases administered to the patient. When the valve handle 16 is turned to open or close the valve, the proximity sensor 28 triggers the processor 23 to instruct the memory device 22 to log the event, including date, time, and whether the event was an opening or a closing of the valve. This information is stored in a non-volatile, read-only-memory (NVROM) in the memory device 22 . As was explained above, FIG. 9 shows a schematic operational logic diagram for the timer of the valve 10 . Thus, as the handle 16 is rotated to open the valve 10 in order to provide gas treatments to patients, the memory device 22 in the handle 16 records the number and duration of the treatments.
All this information may be read or downloaded by the user and/or by the supplier, using a number of data transfer methods. Three methods are described here, but others may also be used.
1—Using a PIR-2 reader (See FIG. 11 ), the information may be downloaded into portable DS-1996 iButtons 22 A (See FIG. 12 ). Each portable iButton 22 A has enough memory to store the data for 12 valves, with each valve having up to 72 logs.
The data on the portable iButtons 22 A may then be transferred to a computer via a DS-1402 BlueDot receptor 52 (See FIG. 15 ). The data may be imported into a suitable software program, such as a spread sheet program, to generate usage reports or billing reports.
2—The data may be downloaded directly onto a hand-held or lap-top computer 50 using a wand reader 44 , as shown in FIG. 14 , which communicates through the one-wire port 22 ′, and then it may be downloaded from the portable computer 50 to a main computer. Depending upon the types of ports on the computer, an adapter 48 , as shown in FIG. 16 may be used. Again, the data may be imported into a suitable software program to generate usage reports or billing reports.
3—The data may be sent directly from the port 22 ′ on the handle 16 to a printer.
The user may use the generated reports to keep a record of the treatments on the patients, for record keeping, for billing the patients, and for checking the billing it receives from its supplier. The supplier may use the generated reports or print outs to bill the user for the treatments and for inventory control purposes.
For instance, a worker may walk around the user's facility (a hospital or clinic, for example) at certain intervals with a reading device and download the data from the ports 22 ′ on the handles 16 of the cylinders 12 to a portable iButton 22 A or to some other portable recording device. It would also be possible for the handle 16 to include a transmitter to transmit the data to a remote recording device at intervals or on command, as desired. The HA7MB reader of FIG. 16 (produced by Point Six, Inc. of 391 Codell Dr., Lexington, Ky. 40509, USA) may be used to transfer data from the memory device 22 to portable iButtons 22 A using a handheld computer 50 . The collected data on the iButtons 22 A is then downloaded into a main computer. The software in the computer then uses the data that has been collected to generate reports, to track treatments, do billings, and to control inventory. While this method of moving data from the valve handle 16 to the computer station is preferred, it is understood that many other methods for transmitting the data from the valve 10 to the main computer could be used.
In the first preferred embodiment shown in FIGS. 1–16 , a Dallas Semiconductor 1-wire protocol establishes a method for storing and retrieving information from the handle.
Some advantages of this Smart Valve handle system include:
The system provides a convenient way to track and charge for therapy, as the gas is being used, instead of just charging for a bottle of gas. This may be much more desirable for the parties. Actual treatment time can be ascertained directly at the gas cylinder, and the smart valve 10 is relatively tamper proof, so there is little opportunity for error or fraud. Little or no paperwork is required, as all the data is stored in electronic format. The data may be stored as a comma delimited file, making it easy to import the data into spreadsheet or database software (such as Access™ or Excel™) for data servicing and manipulation. Data logs are also maintained in the Smart Handle device allowing for a back-up of the downloaded material. The record of the Born On Date (date the cylinder is filled) and Batch number reside at the bottle in the memory device 22 . It is not necessary to search this data in files from a serial number or bar code. The system allows for expansion and software development which will provide hospitals and researchers the ability to track trends in patient use of various treatments, develop therapy protocols, assign patient ID to cylinders, identify and control cylinders for blinded clinical trials, and other uses currently handled by means of complicated and labor-intensive administrative methods. Various password protections may be used to ensure that only the appropriate users can make certain inputs of data. For example, only the enterprise filling the cylinders should be able to input the Born On Date.
The embodiment described above is only intended to be one example of a device made in accordance with the present invention. It will be obvious to those skilled in the art that modifications may be made to the preferred embodiment described above without departing from the scope of the present invention. | A valve with a smart handle including a memory module to log relevant data. A sensor on the handle determines when the valve is open, and this triggers the start of timers and recording of the “open” event in a log in the memory module. When the valve is closed, the sensor triggers stopping of the timers and recording of the “closed” event in the log. The timer information is used to calculate the duration of the time “open” event, and this, together with the actual date and time of the opening and closing of the valve are recorded in the log. Other relevant information, such as cylinder fill date, cylinder I.D. number, batch number, and patient name or account number may also be logged in the memory module. The log of the events and the corresponding dates and times may be used to prepare invoices for billing gas treatments, for inventory control, and for other record-keeping and control functions. | 8 |
FIELD OF THE INVENTION
This invention relates to flat solid media for the storage of samples of biological materials and methods of analysing biomolecules contained within the samples following storage. In particular, the invention relates to the storage, recovery and further processing of biomolecules such as proteins, enzymes and nucleic acids.
BACKGROUND OF THE INVENTION
The use of solid media or supports such as filter paper for the collection and analysis of biological materials such as human blood dates back to the early 1960s, when Dr. Robert Guthrie used dried blood spot (DBS) specimens to measure the biomolecule phenylalanine in newborns for the detection of phenylketonuria (Mei, J., et al., 2001; Journal of Nutrition, 131:1631S-1636S). This novel application for collecting blood led to the population screening of newborns for the detection of treatable, inherited metabolic diseases. DBS have now been used for over 40 years to screen for a large range of neonatal metabolic disorders including enzymes, proteins and for inherited disease using nucleic acid analysis.
The gathering of biological materials such as DBS specimens is carried out by spotting whole blood, for example, onto a solid support, such as a membrane, glass fiber or paper, either from venous blood or directly from a finger or heel prick, making this method particularly suitable for the shipment of specimens from peripheral clinics to central laboratories. Furthermore, DBS packed in zip-lock plastic bags with desiccant can be stored and shipped at ambient temperature, thus avoiding the need for i) cold chain storage and ii) fast specialized transportation. DBS collected by applying a drop of blood onto an absorbent material such as Whatman 903 Neonatal STD paper are not subject to the IATA Dangerous Goods Regulations (Addendum II, March 2005).
Commonly, analysis of DBS is carried out for the presence of infectious agents such as for the presence of human immunodeficiency virus (HIV) or other pathogens. Typically serological or nucleic acid tests are carried out for this application.
The combination of DBS and the detection of endogenous protein biomolecules has been described in the scientific literature; for example, the biomarker for cystic fibrosis (CF) is immunoreactive trypsin (IT). The first reported use of endogenous IT from DBS for CF screening was published by Ryley et al., in 1981 ( J. Clin. Pathol. 34, 906-910). Since then, it has been routinely used as an indicator of CF using DBS from neonates. A number of commercial organisations supply FDA approved immunoassay kits for this application. Many simply use a “paper-in” approach, in which a paper punch containing the DBS is applied directly in to the immunoassay and the analyte of interest is extracted in situ. Recently (Lindau-Shepard & Pass, 2010, Clinical Chem. 56, 445-450) demonstrated that IT exists in two different isoforms. These authors reported the development of a suspension (or paper-in) array-based immunoassay for the diagnosis of CF using the two different isoforms of IT. All these protein-based studies were carried out on uncoated Guthrie cards (Whatman 903 paper).
Since the inception of anonymous human immuno-deficiency (HIV) screening, over 1.2 million DBS tests have been carried out for the serological detection of endogenous anti-HIV antibodies in the blood from expectant mothers. These studies have proved that i) concerns about long-term storage of blood and any associated proteins of interest have proved unfounded and ii) the presence of haem in the DBS does not interfere with assay performance.
Additional solid paper supports that are used for collecting, transportation and storing DBS and other bodily fluids for newborn and neonatal screening purposes include
1. Ahlstrom 226 2. Munktell TFN (CE marked) 3. Toyo Roshi grade 545 Advantec Toyo, Tokyo (see Elvers L et al 2007; J. Inherit Medtab Dis 30, 4, 609).
Slow desiccation or even a small degree of rehydration under conditions of high relative humidity will allow the growth of biomolecule-destroying microflora. Even in the presence of bacteriostatic agents of the type that do not denature proteins, there will be conditions that permit enzymatic-autolytic breakdown of the biomolecule and some non-enzymatic breakdown of the biomolecule (in enzymatic-autolytic breakdown, dying or damaged tissues, either human cells or parasite cells, activate enzymes that degrade their own components). With nucleic acids, there is also considerable difficulty desorbing very high molecular weight DNA from paper matrices. Surface adsorption effects can cause losses of DNA and this will cause the preferential loss of the least degraded, i.e. the most desired class of DNA molecules. Thus the long-term archiving of biomolecules is a desirable feature of a storage medium.
Molecular and Nucleic Acid Analyses
The polymerase chain reaction (PCR) is a common tool used in molecular biology for amplifying nucleic acids. U.S. Pat. No. 4,683,202 (Mullis, Cetus Corporation) describes a process for amplifying any desired specific nucleic acid sequence contained in a nucleic acid or mixture thereof.
Furthermore, U.S. Pat. No. 5,593,824 and U.S. Pat. No. 5,763,157 (Treml) describe biological reagent spheres useful for the PCR reaction. Additionally, this invention describes a convenient approach by means of excipient mixes comprising suitable carbohydrates useful for storage of reagents used in downstream genetic analysis such as PCR. Carbohydrates are preferably Ficoll and melezitose. This technology has been commercialised in a ready to go (RTG) PCR format (GE Healthcare).
Long-term storage, transport and archiving of nucleic acids on filter paper or chemically modified matrices is a well-known technique for preserving genetic material before the DNA or RNA is extracted and isolated in a form for use in genetic analysis such as PCR. Thus, EP 1563091 (Smith et al., Whatman) relates to methods for storing nucleic acids from a sample such as cells or cell lysates. The nucleic acid is isolated and stored for extended periods of time at room temperature and humidity, on a wide variety of filters and other types of solid phase media. The document describes methods for storing nucleic acid-containing samples on a wide range of solid phase matrices in tubes, columns, or multiwell plates.
Cellulose derived solid supports are described by reference to the following prior art.
WO 90/003959 (Burgoyne) describes a solid medium for the storage of DNA, including blood DNA, comprising a solid matrix having a compound or composition which protects against degradation of DNA incorporated into or absorbed on the matrix. The document also discloses methods for storage of DNA using this solid medium, and for recovery of DNA or in situ use of DNA or RNA.
Forensic and Human Identification Applications
DNA profiling (also called DNA testing, DNA typing, or genetic fingerprinting) is a technique employed by forensic scientists to assist in the identification of individuals by their respective DNA profiles. DNA profiles are encrypted sets of numbers that reflect a person's DNA makeup, which can also be used as the person's identifier. DNA profiling should not be confused with full genome sequencing. It is used in, for example, parental testing and criminal investigations.
The method of DNA profiling is based on PCR using short tandem repeats of nucleotide sequences. This method uses highly polymorphic regions that have short repeated sequences of DNA (the most common is 4 bases repeated, but there are other lengths in use, including 3 and 5 bases). Because unrelated people almost certainly have different numbers of repeat units, short tandem repeats (STRs) can be used to discriminate between unrelated individuals. These STR loci (locations on a chromosome) are targeted with sequence-specific primers and amplified using PCR. The DNA fragments that result are then separated and detected using electrophoresis. There are two common methods of separation and detection, capillary electrophoresis (CE) and gel electrophoresis.
Clinical Applications
A number of DNA databases created from babies' blood samples also exists. Blood samples taken in heel-prick tests to screen for serious conditions are being held for years by some hospitals and can be subsequently accessed by the police to identify people involved in crimes. The samples can also be used by coroners and medical researchers for a variety of purposes. Blood spot screening is carried out on babies aged between five and eight days old in order to test for a variety of serious conditions such as cancer, tumour marking and archiving, sickle cell, PKU and cystic fibrosis. Government guidelines advise hospitals to store the samples for at least five years before destroying them.
In Denmark, for example, Danish Newborn Screening Biobank at Statens Serum Institut retains a blood sample from all neonates born after 1981. The purpose is to test for PKU and other diseases. This database is also used for DNA tests to identify deceased and suspected criminals.
With all the applications outlined above, however, there is a great need for new advances for improved inert matrices that are convenient, safe and confer stability to the biomolecules which is to be analysed. For example, while Burgoyne (U.S. Pat. No. 5,756,126) describes a medium for analysis of genetic material, no reference is made to other biomolecules such as proteins, polypeptides and metabolites.
Pathogens and Infectious Agents
Infectious diseases, also known as contagious diseases or transmissible diseases, and including communicable diseases, comprise clinically evident illness (i.e., characteristic medical signs and/or symptoms of disease) resulting from the infection, presence and growth of pathogenic biological agents in an individual host organism. In certain cases, infectious diseases may be asymptomatic for much or their entire course. Infectious pathogens include viruses, bacteria, bacterial spores, fungi, protozoa, and, multicellular parasites. These pathogens are the cause of disease epidemics, in the sense that without the pathogen, no infectious epidemic occurs. Common examples of infectious agents include Staphylococcus aureus, Pseudomonas aeruginosa, Escherichia coli, Salmonella choleraesuis and Candida albicans and those that cause sexually transmitted disease or septicaemia. Common microorganisms that are routinely isolated from wounds, using clinical swabs, have included Staphylococcus aureus, Corynebacterium sp, Candida albicans and Pseudomonas aeruginosa.
Transmission of pathogen can occur in various ways including physical contact, contaminated food, body fluids, objects, airborne inhalation, or through vector organisms, so safe capture of infectious agent would be of significant value during any diagnostic workflow. Infectious diseases that are especially infective are sometimes called contagious and can be easily transmitted by contact with an ill person or their secretions. Infectious diseases with more specialized routes of infection, such as vector transmission or sexual transmission, are usually regarded as contagious. Thus inactivation of the target pathogen may be useful prior to diagnostic testing. Sample types may include: pathological specimens from human or samples from veterinary medicine e.g. blood, urine, semen, vaginal secretions, faecal samples, CSF, tissue, lung lavage, sputum, nasopharyngeal samples, cell cultures, soil, water supplies, stream or river samples, aerial.
Once dry, samples could be transported and stored in a dark and dry environment. These simple conditions will ensure that the integrity of the biological sample on the solid medium/card is maintained. No specific temperature control is required for either storage or transport, as both are carried out at room temperature.
Alginate
Alginate, a salt of alginic acid, is extracted from marine kelp (seaweed). The calcium, sodium, and ammonium alginates have been used in foam, cloth, and gauze for absorbent surgical dressings. Soluble alginates, such as those of sodium, potassium, or magnesium, form a viscous sol that can be changed into a gel by a chemical reaction with compounds such as calcium sulphate. Salts of alginic acid with monovalent cations (Na-salt, K-salt, NH4-salt) as well as Alginate Ester are all soluble to cold and hot water, and generate viscous aqueous solution with long-flow properties. Alginic acid and calcium alginate are water-insoluble.
Alginic acid is substantially insoluble in water. It forms water-soluble salts with alkali metals, such as sodium, potassium, and, lithium; magnesium; ammonium; and the substituted ammonium cations derived from lower amines, such as methyl amine, ethanol amine, diethanol amine, and triethanol amine.
Alginate absorbs water quickly, which makes it useful as an additive in dehydrated products, and is well known as an additive in the manufacture of paper and textiles to facilitate printing with ink and/or dye products. Accordingly, paper producers are familiar with usage of alginate components, such as sodium alginate, during manufacturing and processing. Sodium alginate can make paper glossy and smooth and it raises the paper's absorption to printing ink and increases its pliability and toughness.
Alginate dressings are natural wound dressings derived from different types of algae and seaweeds. These types of dressings are best used on wounds that have a large amount of exudate and may also be applied onto dry wounds after normal saline is first applied to the site of application.
U.S. Pat. No. 5,820,998 (Schweitzer Maudit Int Inc.) describes a process of making a coated paper for wrapping papers used in smoking articles comprising the steps: 1) providing a paper layer composed of a blend of pulp fibers and particulate material containing polyvalent metal cations, 2) applying a acidified alginate solution of a material selected from salts and derivatives of alginic acid to cover at least a portion of the paper, 3) reacting the salts and/or derivatives of alginic acid with polyvalent metal cations in the paper to form a polymer coating, and 4) drying the paper and polymer coating. The permeability of the coated paper is generally at least about 75 percent less than the permeability of an identical uncoated portion of the paper.
Bonino et al. (2011 Carbohydate Polymers 85 111-119) describes the electrospinning of alginate-based nano-fibres.
U.S. Pat. No. 5,482,932 (Courtaulds Fibres (Holdings) Ltd) describes alginate gels which have the form of a fibrous paste and which particularly have an alginate content (expressed as alginic acid) in the range 2 to 11 percent by weight. The gels may be prepared by treating a water-insoluble or water-swellable alginate fibre, for example calcium alginate fibre, with an aqueous solution of a solubilizing salt, for example sodium chloride. The new gels are easier to handle than known alginate gels and are useful in wound dressing applications.
Calcium alginate is a water-insoluble, gelatinous, cream coloured substance that can be created through the addition of aqueous calcium chloride to aqueous sodium alginate. Calcium alginate can be used for entrapment of enzymes and forming artificial seeds in plant tissue culture. It is also incorporated into wound dressings as a homeostatic agent.
Sodium alginate is a gum, extracted from the cell walls of brown algae. As a flavourless gum, it is used by the foods industry to increase viscosity and as an emulsifier. It is also used in indigestion tablets and the preparation of dental impressions. Other applications include use in reactive dye printing, as a thickener for reactive dyestuffs, in textile screen-printing and in carpet jet-printing.
Potassium alginate is the potassium salt of alginic acid. It is an extract of seaweed and is widely used in foods as a stabilizer, thickener, and emulsifier. Its use as a pharmaceutical excipient is currently limited to experimental hydrogel systems. The viscosity, adhesiveness, elasticity, stiffness, and cohesiveness of potassium alginate hydrogels have been determined and compared with values from a range of other hydrogel-forming materials.
Silver alginate is known to have antimicrobial activity. For example, some alginate wound dressings contain a silver alginate, which provides antimicrobial protection and may be considered for an infected wound.
U.S. Pat. No. 6,696,077 (Scherr) relates to the preparation of cellulosic foam products prepared from silver alginate and derivatives thereof and process for preparing them.
U.S. Pat. No. 7,344,726 (Chitoproducts Ltd) discloses a process for the preparation of an article having a contact biocidal property comprising a polymer solution which contains atomic/metallic silver in suspension or complexed with the polymer.
Percival et al (2011 Int. Wound J. 8 (3) 237-243) describes the antimicrobial efficacy of a silver alginate dressing against a broad spectrum of clinically relevant wound isolates.
Cloud et al. (2002 J Clin Microbiol. 40(10): 3838-3840) compared the performance of various swabs and transport media routinely used to collect specimens submitted for Bordetella culture and PCR. The authors reported that calcium-alginate swabs inhibited the PCR and recommended that calcium-alginate swabs should not be used for PCR detection of B. pertussis.
Eibak et al. (2012 Anal. Chem. 84, 8783-8789) demonstrated the storage and recovery of model substances (citalopram, loperamide, methadone and sertraline) from DBS spotted sodium alginate foams using electromembrane extraction and liquid chromatography-mass spectrometry analysis. The authors reported that lower recoveries were obtained with the commercial cards (i.e. Whatman FTA DMPK and Agilent Bond Elut DMS) for most of the model substances compared to the recoveries with the alginate foam.
The present invention addresses the problems associated with the room temperature, dry storage and subsequent analysis of biomolecules present in samples of biological materials and provides an alternative solution to those known or suggested by the prior art. Moreover, the invention further provides a means for inactivating microbial pathogens which may be present in the biological material.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention, there is provided a flat solid medium for storing at least one sample of a biological material containing a biomolecule, the solid medium comprising a solid matrix having sorbed thereto or incorporated therein a composition comprising an alginate.
It will be understood that the composition of alginate, present for example as fibres, may be woven throughout the solid matrix.
The invention is particularly useful in genotyping, diagnostics and, predominantly, forensics applications, with amplification of low copy number genes or low expression mRNA; short tandem repeats (STRs), alleles, loci, or other genetic materials, derived from crude biological samples.
In one aspect, the solid medium additionally comprises a protein denaturing reagent. The protein denaturing reagent can lyse cell membranes and thus provide antimicrobial activity and/or will release biomolecules and cellular components onto the solid medium, thereby preventing degradation of the biological material by enzymatic activity. The protein denaturing reagent may be an ionic or anionic detergent such as sodium dodecyl sulphate (SDS) or sodium lauryl sarcosinate.
In one preferred embodiment, the ionic detergent of the invention causes inactivation of a microorganism which has protein or lipid in its outer membranes or capsids, for example, fungi, bacteria or viruses. This includes microorganisms which may be pathogenic to humans or which may cause degradation of the biomolecule.
In another aspect, the solid medium additionally comprises a free radical trap. Examples of free radical traps include uric acid or a urate salt. Typically, free radicals are believed to be generated by spontaneous oxidation of the groups which are present, for example, in denatured serum protein of blood. Free radicals may also be generated by radiation such as UV light, x-rays and high-energy particles.
In a further aspect, the solid medium additionally comprises a chelating agent. As used herein, a chelating agent is any compound capable of complexing multivalent ions including Group II and Group III multivalent metal ions and transition metal ions (eg., Cu, Fe, Zn, Mn, etc). According to the invention, a preferred chelating agent is a strong chelating agent such as to ethylene diamine tetraacetic acid (EDTA). Chelating agents such as a citrate or oxalate are also suitable for the invention.
It is believed that one function of the chelating agent of the invention is to bind multivalent ions which if present with the stored biomolecule may partake in causing damage to the biomolecule, particularly nucleic acid. Ions which may be chelated by the chelating agent include multivalent active metal ions, for example, magnesium and calcium, and transition metal ions, for example, iron. Both calcium and magnesium are known to promote nucleic acid degradation by acting as co-factors for enzymes which may destroy nucleic acid (e.g., most known nucleases). In addition, transition metal ions, such as iron, may readily undergo oxidation and reduction and damage nucleic acids by the production of free radicals or by direct oxidation.
In one aspect, the solid medium additionally comprises a chaotrophic salt. Guanidine salt is an example of a chaotrophic salt.
In a further aspect, the alginate is selected from the group consisting of calcium alginate, sodium alginate, potassium alginate, ammonium alginate, magnesium alginate, lithium alginate and silver alginate.
In one aspect, the alginate has antimicrobial activity.
In a preferred aspect, the alginate is silver alginate.
Candidates for co-coating purposes which facilitate pathogen inactivation or biomolecules storage include mild detergents (e.g. Triton, SDS), chelating agents (e.g. EDTA) and uric acid or a urate salt in order to facilitate stability and to act as a free radical trap.
Paper or inert matrix could be modified directly (or simply coated) with chemical groups that will support the elution (if needed) of a specific biomolecule. This selective elution could be based upon for example; ion exchange mechanisms (alginate as a bio-carrier will mainly rely on charged chemical moieties).
Enzymes that hydrolyse alginates are known, which will prove useful to liberate nucleic acid, protein or other biomolecules captured on the coated support. Alginase enzyme production from cultured Bacillus circulans is described in Hansen et al. (1984) ( Appl Environ Microbiol. 47(4): 704-709).
Paper or other suitable matrices could be co-coated with alginate and/or modified with a number of different chemicals, all of which will alter the surface properties so that it becomes resistant to irreversible biomolecule absorption, thereby facilitating that elution of the biomolecule of interest.
Additional candidates for co-coating include—
a) Self-assembled monolayer of alkanethiols. b) Polyethylene glycol which has been used as a coating for biomedical devices. c) Other surface-grafted polymers that resist the adsorption of protein include polyvinyl alcohol (PVA), polyethyloxazoline (PEOX), poly(vinylpyrrolidone), (PVP) and poly(ethyleimine) (PEI). d) An alternative is the preparation of papers that possess a hydrophobic surface. e) A further refinement include co-coating one of the surface-grafted polymers described above with a protein (e.g. horse IgG, albumin) to further enhance biomolecule elution.
In another aspect, the solid matrix is selected from the group consisting of a cellulose matrix, a nitrocellulose matrix, a carboxymethylcellulose matrix, a polyester matrix, a polyamide matrix, a polytetrafluoroethylene matrix, a fibreglass matrix and a porous ceramic matrix. Other solid matrices suitable for this purpose include, but are not limited to, hydrophilic polymers including synthetic hydrophilic polymers such as polyester and carbohydrate polymers).
In a preferred aspect, the solid matrix is a cellulose matrix.
In a particularly preferred aspect, the solid matrix is a cellulose matrix and the alginate is silver alginate.
In one aspect, the sample of biological material is selected from the group consisting of eukarytic cell, prokaryotic cell and prion cell. In particular, the sample of biological material is selected from the group consisting of blood, plasma, saliva, urine and buccal cells.
In another aspect, the sample of biological material contains a biomolecule selected from the group consisting of nucleic acid, protein, biopharmaceutical and polysaccharide.
In a further aspect, the solid medium additionally comprises a sample of a biological material stored thereon.
In one aspect, the solid medium additionally comprises a sample of an analytical process. For example, the sample is a liquid chromatography analysis, or an HPLC analysis.
According to a second aspect of the present invention, there is provided a method for storing a sample of a biological material containing a biomolecule on a flat solid medium comprising the steps of
a. applying a sample of a biological material containing a biomolecule to a flat solid medium comprising alginate or comprising a solid matrix having sorbed thereto or incorporated therein a composition comprising an alginate; and b. storing said sample of biological material on said flat solid medium.
It will be understood that the flat solid medium of the second aspect may consist totally of alginate or be composed of alginate fibres. In another embodiment, the composition of alginate, present for example as fibres, may be woven throughout the solid matrix.
In one aspect, the sample is stored on the dry solid medium without refrigeration. In another aspect, the sample is stored on the dry solid medium at a temperature in the range of 4° C. to 50° C. Typically aqueous biological samples are stored at low temperatures in freezers or fridges to prevent cellular degradation and microbial growth. The method of the invention avoids the problems associated with low temperature storage and transport, in terms of the cost of buying and running fridges and freezers, together with the space requirements of such equipment. Transport of the samples is also facilitated since the dry solid media can be sent through the post without the need for any cooling.
In one aspect, the sample is stored on the solid medium for a period of at least 1 day. Indeed the sample can be stored on the dry solid medium for a period selected from the group consisting of at least 1 week, at least 1 month, at least 6 months, at least 9 months, at least 1 year, at least 2 years, at least 5 years, at least 10 years, at least 15 years and at least 20 years.
According to a third aspect of the present invention, there is provided a method of analysing a sample of a biological material containing a biomolecule stored on a flat solid medium, the flat solid medium comprising alginate or comprising a solid matrix having sorbed thereto or incorporated therein a composition comprising an alginate, comprising the step of analysing the biological material for the presence and/or level of a biomolecule.
It will be understood that the flat solid medium of the third aspect may consist totally of alginate or be composed of alginate fibres. In another embodiment, the composition of alginate, present for example as fibres, may be woven throughout the solid matrix.
Methods for analysing the biomolecule present in the biological material include for example, but are not limited to, nucleic acid amplification by the polymerase chain reaction (PCR), short tandem repeat for human identification purposes and DNA profiling, isothermal amplification, additionally serological testing using antibodies, lateral flow, antibody based tests such as enzyme-linked immunosorbent assay (ELISA), Western blotting, fluorescence energy resonance transfer, mass spectrometry, GC/MS and tandem mass spectrometry.
The biomolecule is selected from the group consisting of nucleic acid, protein, biopharmaceutical and polysaccharide.
In one aspect, the step of analysing the biological material for the presence and/or level of a biomolecule is carried out directly on the solid medium or a portion thereof. For example, the portion may be a disc which can be cut or punched from the sold support into a test tube or well of a multi-well plate and then assayed for the presence and/or level of a biomolecule. This process may be carried out manually or automatically using standard robotic laboratory equipment.
In another aspect, the method additionally comprises the step of eluting the biological material from the solid medium prior to analysing the biological material for the presence and/or level of the biomolecule. It will be understood that this process may be carried out manually or automatically using standard robotic laboratory equipment.
In a further aspect, the solid medium additionally comprises a protein denaturing reagent. The protein denaturing reagent can be, for example, a detergent such as a sodium dodecyl sulphate.
In yet another aspect, the solid medium additionally comprises a free radical trap. For example, the dry solid medium may comprise uric acid or a urate salt.
In one aspect, the solid medium additionally comprises a chelating agent. EDTA is an example of a suitable chelating agent.
In another aspect, the solid medium additionally comprises a chaotrophic salt. An example of a suitable chaotrophic salt is a guanidine salt.
In a further aspect, the alginate is selected from the group consisting of calcium alginate, sodium alginate, potassium alginate, ammonium alginate, magnesium alginate, lithium alginate and silver alginate.
In one aspect, the alginate has antimicrobial activity.
In a preferred aspect, the alginate is silver alginate.
In a further aspect, the solid matrix is selected from the group consisting of a cellulose matrix, a nitrocellulose matrix, a carboxymethylcellulose matrix, a polyester matrix, a polyamide matrix, a polytetrafluoroethylene matrix, a fibreglass matrix and a porous ceramic matrix.
In one aspect, the solid matrix is a cellulose matrix.
In a preferred aspect, the solid matrix is a cellulose matrix and the alginate is silver alginate.
In another aspect, the sample of biological material is selected from the group consisting of the group consisting of eukarytic cell, prokaryotic cell and prion cell. In particular, the biological material is selected from the group consisting of blood, saliva, plasma, urine and buccal cells.
In a further aspect, the sample of biological material contains a biomolecule selected from the group consisting of nucleic acid, protein, biopharmaceutical, polysaccharide and cellular component.
According to a fourth aspect of the present invention, there is provided a kit of parts, comprising a flat solid medium as hereinbefore described and instructions for use.
According to a fifth aspect of the present invention, there is provided a use of a flat solid medium as hereinbefore described for collecting or storing or analysing a sample of a biological material.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows the results of a bacterial growth inhibition test. Alginate and FTA discs exhibited zones of inhibition whereas 903 (uncoated paper) did not. Control dishes exhibited typical bacterial lawns.
FIG. 2 shows the results of an inhibition of pathogen replication test. Alginate exhibited inhibition of bacterial ( Staphylococcus aureus ) replication while untreated (903 paper) solid media did not.
FIGS. 3A, 3B and 3C show the data from the STR/DNA profiling experiments. FIG. 3A shows the profile obtained from the alginate coated matrix; FIG. 3B shows the profile from the FTA paper; and FIG. 3C shows the profile from the 903 paper.
FIGS. 4A, 4B and 4C show the results from experiments to detect protein and enzyme Detection using DNase and RNase as Target Molecules. FIG. 4A shows the detection of DNase (0.125-0.5 U) which had been added to alginate, 903 and FTA Matrices. FIG. 4B shows the detection of DNase activity following the addition of native DNase (0.5 U) to matrices having Human Embryonic Stem (10 6 ) Cells Applied to the alginate, 903 and FTA matrices. FIG. 4C shows the detection of RNase activity following the addition of native RNase (10 μU) to matrices having Human Embryonic Stem Cells (10 6 ) Cells applied to the alginate, 903 and FTA matrices.
FIG. 5 shows the results from RT PCR of β-Globin Gene Fragment from human embryonic stem cells. The results are shown as agarose gel (2%) electrophoresis of the RT-amplified product in which:
Lane 1: No Template control.
Lane 2: RNA template isolated from the alginate matrix using RNA spin; amplified β-globin gene fragment.
Lane 3: Negative control-un-extracted whole blood sample.
Lane 4: Negative control-un-extracted whole blood sample.
Lane 5: Negative control-un-extracted whole blood sample.
Lane 6. Internal Control Sample.
Lane 7: No Template Control.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
To more clearly and concisely describe and point out the subject matter of the claimed invention, the following definitions are provided for specific terms, which are used in the following description and the appended claims. Throughout the specification, exemplification of specific terms should be considered as non-limiting examples. The term “flat” as used herein will mean a generally smooth, even sheet- or card-like structure which is horizontally level.
As used herein, the term “biological material” shall include any material or sample originating from, derived from or obtained from a biological source. Examples will include samples of human or animal origin, such as saliva, blood, plasma, urine and buccal cells. Other examples include samples from cell cultures of animal, plant, bacterial, fungal or viral origin. Yet other examples include samples containing pathogens, such as saliva, blood, plasma, urine and buccal cells. Further examples include cellular components, e.g. organelles.
The term “biomolecule” as used herein shall mean any “biomolecule” or “synthetically-derived biomolecule” as defined below:
i) A biomolecule is any organic molecule that is produced by a living organism, including large polymeric molecules such as proteins, polysaccharides, and nucleic acids as well as small low molecular weight molecules such as primary metabolites, secondary metabolites, and natural products. ii) A synthetically-derived biomolecule is a “biomolecule” as defined in i) above that is generated using recombinant DNA technologies or chemically synthesised by other non-living in-vitro methods. iii) The term “nucleic acid” is used herein synonymously with the term “nucleotides” and includes DNA, such as plasmid DNA and genomic DNA; RNA, such as mRNA, tRNA, sRNA and RNAi; and protein nucleic acid, PNA. iv) A “biopharmaceutical” is a biomolecule as defined by any of i) to iii) above which is designed or produced as a drug or drug candidate.
As used herein, the term “sorb” means that the composition of the invention is absorbed, adsorbed, coated or otherwise incorporated into or onto a solid matrix in such a way as not to be readily removed from the matrix unless subjected to conditions which are intentionally or inadvertently performed to remove the sorbed composition from the solid matrix.
“Alginate” as used herein is the term usually used for the salts of alginic acid, but it can also refer to all the derivatives of alginic acid and alginic acid itself.
Herein, the term “room temperature” shall mean a temperature between 4 and 50 degrees Celcius.
Materials
The Alginate Matrix (Urgosorb, silver alginate wound dressing, Lot 36943, was obtained from Urgo Medical (Urgo Limited, Sullington Road, Shepshed, Loughborough, UK, LE12 9JG), 903 (W101, lot 6891711) and Indicating FTA cards (WB650060, Lot FTA6903311) were obtained from GE Healthcare (GE Healthcare Life Sciences, Amersham Place, Little Chalfont, Buckinghamshire, HP7 9NA UK).
Alternative Methods for Preparing Alginate Matrices
Other methods, which are well known in the art, can be used to prepare solid supports according to the present invention.
For example, to 10 ml of ethyl alcohol is added with stirring, 2 g of sodium alginate and 1 g of sodium hypochlorite. 10 ml of deionised water is added and the resultant mixture incubated at room temperature for 24 hours. A solid support is immersed into the liquid containing sodium alginate and quickly immersed in a solution of aqueous 5% (w/v) calcium chloride which is used to convert the sodium alginate to calcium alginate. The solid support is removed, excess liquid squeezed off and the solid support washed with distilled water. After washing, the solid support is dried by passing over heated rollers. The dried coated material is mechanically softened (micrexed) to produce a plaint material. The calcium alginate forms a hydrogel. The amount of alginate added to the solid support can vary from between 2-100% (w/v).
Alternatively solution sodium alginate/calcium alginate may be added to the solid support directly in the presence of glycerine as a wetting agent and ethyl alcohol to prevent a gel formation. The coated material is dried as above.
To prepare a matrix comprising silver alginate, calcium alginate is prepared using a mixture containing for example silver nitrate, silver proteinate, silver sulfadiazine, or silver acetate, and this mixture is added to the solid support as describe above.
Zone of Inhibition Testing
Disk diffusion antibiotic sensitivity testing is a test which uses antimicrobial-impregnated discs to test whether particular bacteria are susceptible to a specific agent. Known quantities of bacteria are grown on agar plates in the presence of discs containing relevant antimicrobial agent. If the bacteria are susceptible to a particular antimicrobial, an area of clearing surrounds the disc where bacteria are not capable of growing (called a zone of inhibition). This along with the rate of diffusion of the antimicrobial agent is used to estimate the bacteria's sensitivity to the particular antimicrobial agent. In general, larger zones correlate with smaller minimum inhibitory concentration (MIC) of that bacterium.
Staphylococcus aureus (ATCC 25923, lot 57941605) were cultured in tryptone soy agar in sterile petri dishes overnight at 37° C. 6 mm discs of alginate coated inert matrix (FTA GE Healthcare) and 903 (GE Healthcare) were applied to the agar surface of the cultures and the cultures again incubated overnight at 35° C. Each bacterial lawn was examined for growth inhibition (zone of inhibition) around each disc. Control cultures consisted of bacterial lawn without the addition of 6 mm disc.
The results from the Zone of Inhibition experiments are shown in FIG. 1 . Alginate and FTA discs exhibited zones of inhibition, 903 (uncoated paper) did show any inhibition of bacterial growth. Control dishes exhibited typical bacterial lawns.
This experiment shows the inhibitory nature of the alginate coated matrix to bacterial growth.
Inhibition of Pathogen Replication
Antimicrobial testing was also carried out using the following procedure. Staphylococcus aureus (ATCC 25923, lot 57941605) was cultured in Tryptone Soy Broth overnight at 35° C. without shaking. The following day, 100 μl of the neat culture was added to Butterfields Buffer containing 6 mm punches of alginate coated matrix, or 903 paper. The neat cultures were mixed to disrupt the matrices. A dilution series of organism was constructed from 10 −4 -40 −7 cfu in Butterfields Buffer and each sample was allowed to incubate at ambient temperature for 10 minutes. 0.5 ml volumes of each sample were then plated on to Tryptone Soy Agar and the plates were allowed to dry for 10 minutes at ambient temperature. The plates were inverted and cultured overnight at 35° C. Colony counts were carried out the following day and results from alginate matrix were compared with control plates (uncoated 903 paper).
The results from the pathogen Inactivation experiments are shown in FIG. 2 . Alginate exhibited inhibition of pathogen growth, 903 (uncoated paper) did not show any inhibition of bacterial replication. Control dishes exhibited typical bacterial lawns. This experiment shows the inhibitory nature of the alginate coated matrix to bacterial growth.
Short Tandem Repeat (STR) Profiling of Amplified DNA Sequences
This experiment was carried out to amplify DNA directly for the alginate matrix and to compare results with established matrices such as FTA and 903 (Controls). DNA profiling is described here and is based on PCR which uses short tandem repeats (STR), which are short repeating sequences of base pairs of DNA. This method uses highly polymorphic regions that have short repeated sequences of DNA (the most common is 4 bases repeated. Because unrelated people almost certainly have different numbers of repeat units, STRs can be used to discriminate between unrelated individuals. These STR loci (locations on a chromosome) are targeted with sequence-specific primers and amplified using PCR. The DNA fragments that result are then separated and detected using capillary electrophoresis. Thus, STR loci consist of short, repetitive sequence elements 3-7 base pairs in length. These repeats are well distributed throughout the human genome and are a rich source of highly polymorphic markers, which may be detected using PCR. Alleles of STR loci are differentiated by the number of copies of the repeat sequence contained within the amplified region and are distinguished from one another using fluorescence detection following electrophoretic separation.
Direct amplification of DNA from storage card punches was followed. Direct STR profiling was carried out on duplicate punches using a PowerPlex 21 System (Product code DC8902, Promega, Southampton, UK) over 28 amplification cycles. The PowerPlex 21 System allowed co-amplification and four-colour fluorescent detection of 21 loci (20 STR loci and Amelogenin), including D1S1656, D2S1338, D3S1358, D5S818, D6S1043, D7S820, D8S1179, D12S391, D13S317, D16S539, D18S51, D19S433, D21S11, Amelogenin, CSF1PO, FGA, Penta D, Penta E, TH01, TPDX and vWA. The PowerPlex 21 System provide all materials necessary to amplify STR regions of human genomic DNA, including a hot-start thermostable DNA polymerase, master mix and primers and this kit was used to amplify DNA directly from 1.2 mm punches from 10 6 human embryonic stem cells (GE Healthcare; cell line ref: WCB307 GEHC 28) applied to alginate coated matrix, FTA and 903 papers. The procedure was followed exactly as outlined in the instruction booklet (PowerPlex 21 System, Promega, Southampton, UK).
Thermal Cycling conditions over 28 cycles were as follows:
96° C. for 1 minute, then: 94° C. for 10 seconds 59° C. for 1 minute 72° C. for 30 seconds for 28 cycles, then: 60° C. for 20 minutes 4° C. hold
The resulting PCR products were analysed on an ABI™ 3130x1 Genetic Analyzer capillary electrophoresis system with GENEMAPPER™ v3.2 software (Life Technologies, Paisley, UK). The STR profiles generated from punches were taken and sample results were compared.
The results of DNA amplification and DNA profiling from the alginate coated matrix, FTA and 903 papers are shown in FIG. 3 . Full DNA profiles were obtained from the alginate coated matrix ( FIG. 3A ), FTA paper ( FIG. 3B ) and 903 paper ( FIG. 3C ). The results from the alginate coated matrix ( FIG. 3A ) indicated that DNA may be stored and amplified from this matrix.
Protein and Enzyme Detection
Protein and enzyme testing was carried out with fully configured DNase and RNase Contamination Kits (DNase & RNase Alert QC Systems, catalogue codes AM1970 & AM1966, Life Technologies) according to the manufacturer's instructions.
In a first series of experiments, 0.125-0.5 U of DNase was applied to alginate coated matrix FTA and 903 paper in 10 μl volumes. DNAse and RNase activity was measured as outlined below.
In a second series of experiments, 1.2 mm punches were taken from 10 6 human embryonic stem cells (GE Healthcare; cell line ref: WCB307 GEHC 28) which had been applied to alginate coated matrix, FTA and 903 papers in 10 μl volumes as above. DNAse and RNase activity was measured as outlined below.
In a third series of experiments, 1.2 mm punches were taken from 10 6 human embryonic stem cells (GE Healthcare; cell line ref: WCB307 GEHC 28) containing either 0.5 U of DNase or 10 μU of RNase added to these cells which had been applied to alginate coated matrix, FTA and 903 papers in 10 μl volumes.
Detection of DNase activity was carried out as follows using a cleavable fluorescent-labelled DNase substrate. Each punch was ejected into separate wells of 96-well plates. Lyophilized DNase Alert Substrate was dissolved in TE buffer (1 ml) and dispensed (10 μl) into the test wells of the 96-well plate. 10× DNase Alert Buffer (10 μl) and nuclease-free water (80 μl) was added and the test solution (100 μl) incubated for 60 minutes at 37° C. The DNase Alert QC System Substrate is a modified DNA oligonucleotide that emits a pink fluorescence when cleaved by DNase. For this assay, fluorescence was measured on a Tecan Ultra (excitation/emission 535/595 nm using medium gain). Solutions containing DNase activity produced a pink fluorescence, whereas solutions without DNase activity did not fluoresce. Thus, higher levels of DNase corresponded to an increase in the amount of light output. Negative controls consisted of nuclease-free water (80 μl) in place of sample. FIG. 4A shows that DNAase activity can be detected and quantified in a rate dependent manner using the alginate, 903 or FTA papers.
Detection of RNase was carried out as follows using a cleavable fluorescent-labelled RNase substrate. Each punch was ejected into separate wells of 96-well plates. Lyophilized RNase Alert Substrate was dissolved in TE buffer (1 ml) and dispensed (10 μl) into the test wells of the 96-well plate. 10× RNase Alert Buffer (10 μl) and nuclease-free water (80 μl) was added and the test solution (100 μl) incubated for 60 minutes at 37° C. The RNase Alert QC System Substrate is a modified RNA oligonucleotide that emits a green fluorescence when cleaved by RNase. For this assay, fluorescence was measured on a Tecan Ultra (excitation/emission 485/535 nm using medium gain). Solutions containing RNase produced a green fluorescence, whereas solutions without RNase activity did not fluoresce. Thus, higher levels of RNase corresponded to an increase in the amount of light output. Negative controls consisted of nuclease-free water (80 μl) in place of sample. FIG. 4B shows that RNAase activity can be detected and quantifie in a rate dependent manner using the alginate, 903 or FTA papers.
Reverse Transcription (RT) PCR of Total RNA
Reverse transcriptase (RT) is an enzyme used to generate complementary DNA (cDNA) from an RNA template, a process termed reverse transcription. Reverse transcriptase creates single-stranded DNA from an RNA template. Reverse transcription polymerase chain reaction (RT-PCR) is one of many variants of PCR. This technique is commonly used in molecular biology to detect RNA expression levels. RT-PCR is used to qualitatively detect gene expression through creation of complementary DNA (cDNA) transcripts from RNA. RT-PCR is used to qualitatively detect gene expression through creation of cDNA transcripts from RNA. The technique using of end-point RT-PCR requiring the detection of gene expression levels by the use of a fluorescent dye incorporated into an agarose gel is reported here.
10 7 human embryonic stem cells (GE Healthcare; cell line ref: WCB307 GEHC 28) were applied to alginate coated matrix. Total RNA was extracted from this matrix using an illustra RNAspin mini RNA isolation kit (GE Healthcare, Product Code 25-0500-70). Total RNA was prepared exactly as described in the instruction booklet. Yield was 312 ng/μl. Purity at 260/280 nm as measured on a NanVue spectrophotometer was 1.95.
Direct RT PCR was carried out in 96-well cluster plates using illustra Ready to Go-RT PCR beads 2.0 units of Taq polymerase, M-MuLV reverse transcriptase, 1.5 mM MgCl 2 , 60 mM KCl, 10 mM Tris-HCL, stabilisers and 40 ng template RNA, prepared above with RT-PCR carried out in 50 μl volumes following the two-step method outlined in the instruction booklet.
Following addition of 200 μM dNTPs, reactions were Incubated at 42° C., 30 mins, and then followed by the addition of β-globin primer sequences. β-globin primer sequences (Sigma Genosys) were as follows:
β-globin-exon I: Sequence (5′ . . . 3′)
(SEQ ID NO. 1)
GGT GAA CGT GGA TGA AGT TG
β-globin-exon III: Sequence (5′ . . . 3′)
(SEQ ID NO. 2)
AGC ACA CAG ACC AGC ACG T
Thermocycling conditions were as follows:
94° C., 3 min 94° C. 30 secs 55° C., 1 min 72° C. 30 secs 72° C. 5 mins 42 cycles 4° C., for ever
RN'ase free agarose gel electrophoresis (2% w/v) with 1 μl of 6× loading buffer, was carried out to analyse the products. Results are shown in FIG. 5 . Lane 2 shows amplified β-globin gene fragment obtained from extracted RNA from the alginate coated matrix. These data shows that it is possible to extract and amplify RNA from the alginate coated matrix.
While preferred illustrative embodiments of the present invention are described, one skilled in the art will appreciate that the present invention can be practised by other than the described embodiments, which are presented for the purposes of illustration only and not by way of limitation. The present invention is limited only by the claims that follow. | This invention relates to flat solid media for the storage of samples of biological materials and methods of analyzing biomolecules contained within the samples following storage. In particular, the invention relates to the storage and further analysis of biomolecules present in the biological materials, such as proteins, enzymes and nucleic acids. The invention finds particular utility in the dry, room temperature storage of biological materials. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to tire soaper apparatus used to soap the beads of a tire preceding its being mounted to a wheel. More particularly, the present invention relates to a tire soaper which provides minimal soap waste yet provides thorough soaping of tire beads.
2. Description of the Prior Art
Pneumatic tubeless tires must be sealingly mounted to the respective wheels. In this regard, the seal between the beads of the tires and the rims of the wheels is critical. In order to achieve an air tight seal between the rims and the beads, the beads are coated by soap prior to mounting the tire onto its wheel. The soap provides reduced friction as the beads are slipped over the rims and further provides a film for aiding the seal between the rims and the beads.
When one, two or an otherwise low volume of tires are to be mounted to wheels, a rag, brush or sponge can be dipped in soap and then run around the beads to provide a soap film thereto prior to wheel mounting. However, in industrial facilities associated with automotive production, high volume mounting of tires to wheels is routinely involved. In order to provide the necessary high volume soaping operation, automated tire soaping apparatus are used for this purpose. Apparatus of this type are generally described for example in U.S. Pat. Nos. 4,723,563, 4,563,975, and 3,658,152. Tire soaping apparatus are generally not soap efficient, especially those employing soap spray systems. Soap waste is not merely a cost consideration, as waste soap can get into the tire prior to mounting and then be trapped therein potentially causing wheel balance problems. U.S. Pat. No. 3,658,152 addresses minimization of soap waste, but the requirement that the tire be vertically supported on a rotating roller which is itself immersed partly in soap, renders it generally complex as compared to spray soapers.
What remains needed in the art is a tire soaper apparatus which is truly simple in structure and operation, provides for minimization of soap waste, and yet provides well soaped tire beads in a high volume, automated environment.
SUMMARY OF THE INVENTION
The present invention is a tire soaper apparatus which is truly simple in structure and operation, provides for minimization of soap waste, and yet provides well soaped tire beads in a high volume, automated environment.
The tire soaper apparatus according to the present invention includes a soaper station and a conveyor for selectively advancing tires to the soaping station. The soaping station is characterized by a translationally mounted rotator for being moved into engagement with a tire to thereby rotate it, a pivotally mounted soap applicator located above the conveyor for selectively contacting the beads of the tire, and a soap dispensing circuit for selectively providing soap at the soap applicator for applying soap to the beads of the tire.
The soap applicator is pivoted into the central opening of the tire and engages, via bead receptacles, each of the beads thereof. The tire is rotated by the rotator rotating against the tread of thereof, wherein the rotator moves translationally toward the soap applicator so that the tire is squeezed therebetween with the beads seated in the bead receptacles and soap transferred to the beads as the tire rotates in relation to the soap applicator. A kicker is provided for laterally moving the tire out of the way to a secondary conveyance for delivering the tire to a tire mounting apparatus.
Preferably, operation of the tire soaper apparatus is processor controlled to thereby optimize operation. Preferably further, rotation and translation of the rotator, soap applicator pivot mechanism, and soap dispensing are all pneumaticaly actuated and controlled by the processor.
Accordingly, it is an object of the present invention to provide a tire soaper apparatus which provides thorough soaping of the beads of a tire yet minimizes waste of the soap.
It is an additional object of the present invention to provide a tire soaper apparatus which seats the beads of the tire in respective bead receptacles for providing thorough soaping of the beads.
It is another object of the present invention to provide a tire soaper apparatus which seats the beads of the tire in respective bead receptacles for providing thorough soaping of the beads, wherein the tire is laying on its side thereduring.
It is a further object of the present invention to provide a tire soaper apparatus which seats the beads of the tire in respective bead receptacles for providing high speed soaping of the beads.
It is yet a further object of the present invention to provide a tire soaper apparatus which seats the beads of the tire in respective bead receptacles for providing thorough soaping of the beads, where a processor controlled measure of soap is delivered under pressure to the tire soaper for transfer to the tire.
It is still a further object of the present invention to provide a tire soaper apparatus which seats the beads of the tire in respective bead receptacles for providing thorough soaping of the beads, where a processor controlled measure of soap is delivered under pressure to the tire soaper for transfer to the tire, and wherein the tire soaper is soap purged during each cycle of operation.
It is still another object of the present invention to provide a tire soaper apparatus which seats the beads of the tire in respective bead receptacles for providing thorough soaping of the beads, wherein a wide range of tire sizes is accommodated.
These, and additional objects, advantages, features and benefits of the present invention will become apparent from the following specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partly sectional top view of the tire soaper apparatus according to the present invention, shown in operation with respect to a plurality of tires.
FIG. 2 is a side view, along line 2--2 of FIG. 1, of the tire soaper apparatus according to the present invention, shown in operation with respect to a plurality of tires.
FIG. 3 is a detail side view of the tire soaper apparatus according to the present invention, showing the tire soaping station thereof awaiting delivery of a tire thereto.
FIG. 4 is a detail side view of the tire soaper apparatus as in FIG. 3, showing the tire soaping station thereof initially engaged with respect to a tire.
FIG. 5 is a detail side view of the tire soaper apparatus as in FIG. 3, showing the tire soaping station thereof fully engaged with respect to a tire whereby soap is being transferred to the beads thereof.
FIG. 6 is a side view of the soap applicator of the tire soaper apparatus according to the present invention.
FIG. 7 is a partly sectional top view of the soap applicator, seen along line 7--7 in FIG. 6.
FIG. 8 is a detail side view of the soap applicator and tire rotator components of the tire soaper apparatus, shown engaged with respect to tires of various size.
FIG. 9 is a sectional side view of an alternative soap applicator of the tire soaper apparatus according to the present invention.
FIGS. 10A, 10B, 10C, and 10D depict schematically selective advancement of tires along the conveyor of the tire soaper apparatus according to the present invention.
FIG. 11 is a schematic depiction of the pneumatic and soap circuits of the tire soaper apparatus according to the present invention.
FIG. 12 is a schematic depiction of the electronic processor control of the tire soaper apparatus according to the present invention.
FIG. 13 is a schematic flow chart of an algorithm for carrying-out the electronic processor control of FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the Drawing, an overview of the present invention can be discerned from FIGS. 1 and 2, wherein depicted is the tire soaping apparatus 20 in operation with respect to a plurality of tires 22. The tire soaper apparatus 20 has a base frame 24 and a soaping station 25 located at a head portion 24a of the base frame. More particularly, the tire soaper apparatus 20 includes a conveyor 26 composed of a plurality of driven rollers 28, a plurality of free rollers 30 at the soaping station 25, and first and second stop pins P a , P b for regulating tire advancement. The tire soaper apparatus 20, at the soaping station 25, also includes a spinner 32 composed of a cylindrically shaped rotator 34 structured for engaging the tread 36 of a tire 22 to thereby cause the tire to spin as the rotator spins, a rotary drive 38 for the rotator and a translational drive 40 for the rotator. The tire soaper apparatus 20 further includes, at the soaping station 25, a soaper 42 composed of a soap applicator 44 and a pivot mechanism 46 situated above the conveyor 26 for pivoting the soap applicator into position with respect to a tire to thereby provide soap to the beads 48a, 48b of a tire 22 situated at the soaping station, the soap applicator pivoting into and out of the central opening 40 of the tire.
Operation of the tire soaper apparatus 20 is electronic processor controlled to perform as follows. A tire 22 is advanced by the conveyor 26 to the soaping station 25, whereupon the soap applicator 44 pivots downwardly to its deployed position into the central opening 50 of the tire, wherein bead receptacles 52a, 52b formed in the body 45 of the soap applicator 44 align with respective beads 48a, 48b. The rotator 34 commences rotation and advances translationally toward the soap applicator to thereby squeeze the tire therebetween. The tire commences spinning and soap is delivered through a soap circuit to openings in the soap applicator whereby the beads of the tire become soap coated. Thereupon, soap delivery ceases, the soap circuit at the soap applicator is purged of soap, and the rotator retreats translationally away from the soap applicator, whereupon the tire is no longer rotatably driven. The soap applicator thereupon pivots upwardly to its retracted position out of the way of tire advancement, and a kicker 54 is then actuated to laterally eject the tire to another conveyance for being mounted to a tire at a tire mounting apparatus (not shown). The conveyor then advances a second tire to the soaping station and another soaping cycle commences.
Referring now additionally to the remaining figures, the structure and function of the tire soaper apparatus 20 will be described with greater specificity.
Referring in particular to FIGS. 3 through 8, the soaping station 25 located at the head portion 24a of the base frame 24 will be described firstly.
The spinner 32 includes the aforementioned cylindrically shaped rotator 34, wherein flutes 56 are provided on the periphery thereof at an orientation parallel with the axis of rotation of the rotator (defined along the shaft 66 of the rotator) to thereby enhance tractional engagement with the tread 36 of a tire 22a. Preferably, the rotator 34 is bifurcated into upper and lower rotator components 34a, 34b for optimally engaging tires of varying size.
The translational drive 40 is mounted to the head portion 24a of the base frame 24. An actuator 58, preferably a pneumatic piston-cylinder, is connected at one end to the base frame 24 and at the other end to a carriage 60. Of course, other actuators could be employed, such as an electric motor and ball screw combination. The carriage 60 is slidably mounted to the base frame 24 via a pair of slide rail and bushing sets 62 located on either side of the actuator 58. A rotary drive mounting bracket 64 is connected with the carriage 60.
The rotary drive 38 is preferably a pneumatically driven motor 38a, such as for example a Gast model 4AM-NRV-70C, which is coupled to one end of the shaft 66 of the rotator 34 via a gear reducer 38b, such as for example an Electra-Gear model 177RHSC53OR. Of course, other drive devices could be utilized, such as an electric motor. The rotary drive 38 is mounted to the rotary drive mounting bracket 64, so as to be movable with the carriage 60 in response to actuation of the actuator 58. The shaft 66 is mounted at its other end to a bushing connected with the carriage 60.
The soaper 42 includes the aforementioned soap applicator 44, wherein upper and lower bead receptacles 52a, 52b are provided for respectively receiving therein the beads 48a, 48b of a tire. In this regard, since the soap applicator 44 is pivoted downwardly into its deployed position whereat it is situated in the central opening 50 of the tire, the upper and lower bead receptacles 52a, 52b, as well as the front face 44a, are concavely shaped to generally match the contour of the beads 48a, 48b.
As depicted by FIG. 8, the upper bead receptacle 52a is longitudinally elongated, whereas the lower bead receptacle 52b is longitudinally localized. Because of this structural feature, various sizes of tires 22, as shown in phantom, are accommodated by the soap applicator 44. In this regard, one bead 48b (the bead closest the conveyor rollers) of the various sized tires is commonly receivable into the lower bead receptacle 52b. However, in order for the other bead 48a (the bead farthest from the conveyor rollers) to be received into the upper bead receptacle 52a, an elongation thereof is necessary to accommodate the range of tire widths. In order to facilitate engagement with the beads, the upper and lower bead receptacles 52a, 52b are ramped or otherwise beveled at the respective ends thereof (see FIG. 6). However, for applications where one size of tire is routinely soaped, an alternative embodiment of the soap applicator 44' exemparily shown in FIG. 9 may be used, wherein each of the upper and lower bead receptacles 52a', 52b' are both longitudinally localized.
The pivot mechanism 46 is mounted to a pivot mechanism bracket 68, via a mounting bracket 68a, wherein the pivot mechanism bracket is connected to the head portion 24a of the base frame 24. The pivot mechanism is preferably in the form of an actuator and crank set 70, preferably wherein the actuator 70a thereof is a pneumatic piston-cylinder, such as for example an ISI clamp cylinder, model FU106-A-3A-P2-S3-C1-2 1/2-FM3-2CPC1. The crank arm 70b of the actuator and crank set 70 is pivotally connected to the mounting bracket 68a and extends outwardly therefrom and terminates in a soap applicator bracket 72. The soap applicator 44 is connected to the soap applicator bracket by threaded fasteners 74 (see FIG. 6).
A preferred internal soap circuit 76 for the soap applicator 44 is depicted in FIGS. 6 and 7. An entry passage 76a in the body 45 of the soap applicator 44 passes from the rear of the soap applicator toward the front face 44a thereof. The soap applicator bracket 72 is provided with an interface passage 76b which communicates with the entry passage 76a. A suitable hose connector 78 is provided at an opening in the interface passage 76b for connecting thereto a flexible hose 80. A longitudinally oriented distribution passage 76c in the body 45 communicates with the entry passage 76a. A lower bead receptacle passage 76d in the body 45 communicates with the distribution passage 76c, wherein the lower bead receptacle passage terminates in a lower orifice 82 located at the apex A p of the convex shape of the lower bead receptacle 52b at an orientation normal thereto. A connector passage 76e in the body 45 communicates with the distribution passage 76c and further communicates with an upper bead receptacle passage 76f in the body 45, wherein the upper bead receptacle passage terminates in an upper orifice 84 parallel to the longitudinal length of the upper bead receptacle 52a. In this regard, an upper bead receptacle soap distribution groove 86 is formed in the body 45 along the longitudinal length of the the upper bead receptacle 52a at the apex A p ' of the convex shape thereof. The upper bead receptacle soap distribution groove 86 is aligned with the upper orifice 84 and receives soap therefrom. The bead receptacle soap distribution groove 86 ensures that soap is delivered to the entire longitudinal length of the upper bead receptacle 52a whereby a tire 22 of any given size will operatively receive transfer of soap to a bead thereof which is located therein.
Now, with reference to FIGS. 10A through 10D, the selective advancement of tires 22 will be described.
As indicated hereinabove, tires are advanced into soaping position at the soaping station 25 via the urging of the driven rollers 30. In this regard, the driven rollers may be driven by in any suitable mechanism, such as for example a chain and sprocket drive 88 (see FIG. 1) driven by an electric motor (not shown).
In order that the tires advance discretely with each soaping cycle, stop pins P a , P b are provided which selectively abuttingly engage the tires 22 (individually distinguished by letters A through D) to regulate advancement thereof. A first stop pin P a is intended to restrain a line of tires so that when the second stop pin P b is retracted only one tire is advanced to the soaping station 25. The sequence is as follows. The first and second stop pins P a , P b move oppositely into respective raised and lowered positions, with initially the first stop pin P a at the lowered position and the second stop pin P b at the raised position, as shown in FIG. 10A. As shown at FIG. 10B, the first stop pin P a is raised and the second stop pin P b is lowered to 1) allow tires B, C and D to advance toward location L a by the central opening of Tire B abutting the first stop pin P a , and 2) allow only tire A to advance to location L b (ie., into soaping position) at the soaper station 25. Subsequently, the first stop pin P a is lowered and the second stop pin P b is raised to allow tire B to advance to location L a , as shown in FIG. 10C. After tire A has been soaped at location L b (the soaper station 25) and ejected therefrom, the second stop pin P b is lowered and the first stop pin P a is raised to 1) allow only tire B to advance to location L b , and 2) allow tires C and D to advance toward location L a by tire C abutting (in its central opening) the first stop pin P a , as shown at FIG. 10D. Tire B is soaped and then ejected, whereupon the stop pins continue cycling as above recounted to thereby provide orderly advance of the tires in a discrete manner.
Now turning to FIG. 11, the soap and pneumatic circuits will be discussed.
The pneumatic circuit 90 is connected to a source of compressed air 92 having conventional compressor, filter, pressure regulator and indicator components. Pneumatic hose 94 supplies the compressed air to the various constituents of the pneumatic circuit 90. A four-way pneumatic valve V a operated by solenoid S a and solenoid S b controls lowering and raising of the first and second stop pins P a , P b via pneumatic piston-cylinder actuators 96, 98 connected respectively thereto and which are connected at preselected locations to the base frame 24. A four-way pneumatic valve V b operated by solenoid S c and solenoid S d controls actuation of the pivot mechanism 46. A four-way pneumatic valve V c operated by solenoid S e and solenoid S f controls actuation of the kicker 54 via a pneumatic cylinder-piston actuator 100 connected to the base frame 24, wherein the kicker is pivotally mounted to the base frame and pivotally moved by the actuator 100. A four-way pneumatic valve V d operated by solenoid S g and solenoid S h controls actuation of the translational drive 40. A four-way pneumatic valve V a operated by spring loaded solenoid S i controls operation of the rotary drive 38.
The soap circuit 106 includes a soap supply tank 102 (which may take the form, for example, of a 55 gallon drum) for providing a reservoir of liquid soap 104, soap hoses 80, a pneumatic pump 108 for pumping the soap 104 from the soap supply tank, a pneumatic flow valve 110, and the aforementioned soap applicator 44. A four-way pneumatic valve V f operated by spring loaded solenoid S j controls actuation of the flow valve 110 to thereby regulate delivery of soap 104 to the soap applicator. Finally, a four-way pneumatic valve V g operated by spring loaded solenoid S k controls purging of soap 104 from the soap applicator 44 after the flow valve 110 is closed.
Referring now to FIG. 12, a schematic electrical circuit is depicted, wherein control of operation of the tire soaper apparatus 20 is provided by an electronic processor, such as a microprocessor used in microcomputers and controller devices.
The microprocessor 112 is provided with suitable interface electronics and is further provided with appropriate read only memory (ROM) and/or is provided with software programmable read only memory (RAM) such as from a floppy disk or other data storage media such as a hard drive or semiconductor chip.
While not required, it is optionally possible to include a keyboard 114 and a display 116 to thereby allow programming adjustment and display of programming information.
The microprocessor 112 is interfaced with a plurality of sensors which indicate the status of particular operations of the tire soaper apparatus 20. For example, a sensor 118 senses if a tire is located at location L a , a sensor 120 senses if a tire is located at location L b , a sensor 122 senses the pivotal position of the soap applicator 44, a sensor 124 senses the translational position of the rotator 34, and a sensor 130 senses the pivotal location of the kicker 54. While not respected, it is optionally possible to include other sensors, such as for example sensors 126 for sensing soap delivery at the orifices 82, 84 and a sensor 128 for sensing the fill level of the soap supply tank 102. Yet other sensors can be included, such as for example a pressure sensor to sense squeeze pressure on the tire between the soap applicator and the rotator and thereby, via generation of an appropriate signal to the translational drive 40 by the microprocessor, serve to define the translational movement of the rotator. The sensors are of conventional nature, being appropriate to the quantity intended to be sensed. For example, the sensors may be photoelectrically, electrically or mechanically based.
The sensed data is interpreted by the microprocessor 112 using the aforementioned software. The result is output to the various components of the tire soaper apparatus 20. For example, the microprocessor 112 will output a start conveyor signal 132 to the electric motor thereof, output a raise/lower stop pins signal 134 to solenoids S a , S b , output a pivot up/down soap actuator signal to solenoids S c , S d , output a translational advance/retract signal 138 to solenoids S g , S h , output soap dispense/purge signals 140 to solenoids S j , S k , output a rotate rotator signal 142 to solenoid S i , and output an eject tire signal 144 to solenoid S e . Other output signals can be provided.
Referring now to FIG. 13 a schematic flow chart of an exemplar algorithm for carrying out the electronic circuit of FIG. 12 will be described.
At block 146 sense information from the sensors is provided to the microprocessor 112. The microprocessor interprets the sensed data based upon a software instructional program at decision block 148, and inquires whether the tire soaping apparatus 20 is ready for operation. If not it waits, otherwise, the microprocessor, at execution block 150, Sets the initial position of the stop pins P a , P b , starts the conveyor 26 by actuating the electric motor thereof, initiates the supply of compressed air 90 and starts the pump 108 to thereby prime the soap circuit 106. Next, at decision block 160, the microprocessor inquires whether a tire is located at location L a . If not, the microprocessor at execution block 162 sends a signal to raise stop pin P b and lower stop pin P a and then re-inquires at decision block 160 whether a tire has advanced to location L a ; if a tire is detected at location L a the microprocessor at execution block 164 sends a signal to raise stop pin P a and lower stop pin P b . The microprocessor next inquires at decision block 166 whether a tire is located at location L b . If not, the microprocessor at execution block 168 sends a signal to raise stop pin P a and lower stop pin P b and then re-inquires at decision block 166 whether a tire has advanced to location L b ; if a tire is detected at location L b the microprocessor at execution block 170 sends a signal to lower stop pin P a and raise stop pin P b . The microprocessor then inquires at decision block 172 whether a tire is present at each of locations L a and L b . If not, the microprocessor returns to decision block 160 whereupon the tire advance sequence is revisited. If no tire advances, after a preset time the microprocessor sends a standby signal to Block 150 to thereby place the tire soaping apparatus in a wait state.
With a tire at the soaper station, the microprocessor generates and sends appropriate signals as follows. At execution block 174 the microprocessor sends a signal to pivot the soap applicator 44 to its deployed position; at execution block 176 the microprocessor sends a signal to start rotation of the rotator 34; at execution block 178 the microprocessor sends a signal to translationally advance the rotator toward the soap applicator; at execution block 180 the microprocessor sends signals to dispense soap to the soap applicator via the pump 108 and flow valve 110; at execution block 182 the microprocessor sends a signal to stop soap delivery via the flow valve and introduce compressed air into the internal soap circuit passages of the soap applicator to thereby purge them of soap; at execution block 184 the microprocessor sends signals to translationally retract the rotator and stop rotation of the rotator; at execution block 186 the microprocessor sends a signal to pivot the soap applicator 44 to its retracted position; and finally, at execution block 188 the microprocessor sends a signal to pivot the kicker 54 to eject the tire from the soaping station 25, whereupon the microprocessor returns to decision block 160.
In operation, the conveyor discretely advances tires to the soaping station as needed. When a tire reaches the soaping station, the soap applicator is pivoted to its deployed position whereat it is positioned into the central opening of the tire, the upper and lower bead receptacles being in alignment with respective beads of the tire. The rotator commences rotation and then translationally advances toward the soap applicator until the tire is squeezed therebetween with the rotator against the tread and the beads seated in the respective upper and lower bead receptacles (alternatively the rotator may commence rotation after the tire is squeezed). With the tire rotating on the free rollers of the conveyor in response to rotation of the rotator, liquid soap is delivered to the soap applicator, whereupon the beads of the tire become coated with soap. Because this is a coating process, there is little wasted soap. After perhaps 5 to 20 tire rotations, the soap flow is stopped and soap is purged therefrom. Then, the rotator is translationally retracted away from the soap applicator and rotation thereof ceases. The soap applicator is then pivoted back to its retracted position. Next, the kicker ejects the soaped tire to a conveyance for the tire mounting station, such as preferably for example that described in U.S. Pat. Nos. 5,094,284, 5,141,040 and 5,170,828. Now, the next tire is advanced to the soaping station and the cycle repeats, in rapid, predictable and efficient fashion.
It is to be understood that the term "tread" as used with reference herein means the road bearing surface of a tire and includes tires with or without an actual tread design (ie., slicks). Further, the term soap herein is used to mean any tire mounting liquid applied to the beads of a tire to facilitate mounting thereof to a wheel.
To those skilled in the art to which this invention appertains, the above described preferred embodiment may be subject to change or modification. Such change or modification can be carried out without departing from the scope of the invention, which is intended to be limited only by the scope of the appended claims. | A tire soaper apparatus including a soaper station and a conveyor for selectively advancing tires to the soaping station. The soaping station is characterized by a translationally mounted rotator for being moved into engagement with a tire to thereby rotate it, a pivotally mounted soap applicator located above the conveyor for selectively contacting the beads of the tire, and a soap dispensing circuit for selectively providing soap at the soap applicator for applying soap to the beads of the tire. The soap applicator is pivoted into the central opening of the tire and engages, via bead receptacles, each of the beads thereof. The tire is rotated by the rotator rotating against the tread of thereof, wherein the rotator moves translationally toward the soap applicator so that the tire is squeezed therebetween with the beads seated in the bead receptacles and soap transferred to the beads as the tire rotates in relation to the soap applicator. A kicker is provided for laterally moving the tire out of the way to a secondary conveyance for delivering the tire to a tire mounting apparatus. Preferably, operation of the tire soaper apparatus is processor controlled to thereby optimize operation. | 1 |
BACKGROUND OF THE INVENTION
This present invention is concerned with an improved process for converting the green liquor stream from a kraft paper plant to white liquor.
The kraft process is based on the pulping or digesting of wood chips in a strongly alkaline liquor. This liquor is called white liquor. It is a fluid consisting mainly of NaOH and Na 2 S. The pulping operation consumes the NaOH whereas the Na 2 S content remains substantially constant.
The spent liquor from the digesters plus the filtrate from the washing operation is commonly known as black liquor and contains substantially all the alkali originally added and other wood and wood derived residues from the pulping operation. The black liquor is sent to an alkali recovery plant where it is evaporated and the concentrate then burned. The residue from the combustion process includes Na 2 S and Na 2 CO 3 . This residue is dissolved with water to form green liquor. The green liquor will contain, in varying amounts, a high content of sodium carbonate and a minor amount of NaOH. Lime is added to boiling green liquor to form white liquor according to the following reactions:
Slaking reaction
CaO+H.sub.2 O⃡Ca(OH).sub.2
Causticizing reaction
Ca(OH).sub.2 +Na.sub.2 CO.sub.3 ⃡2NaOH+CaCO.sub.3 ↓
The process does not affect the absolute amount of Na 2 S in the green liquor because Na 2 S does not react in the slaking or causticizing process. The CaCO 3 byproduct mixture formed is known as lime mud or sludge and it is separated off and CaO (lime) is then regenerated in a lime kiln for reuse in the further conversion of green liquor to white liquor.
The concentration or amount of Na 2 CO 3 in the green liquor is the basis for determining how much lime is introduced into the causticizing plant. The heterogeneous nature of the regenerated lime particles and green liquor makes it difficult to precisely control the lime flow so that there will not be variations in causticizing efficiency. These variations also affect the lime mud settling rate in the white liquor clarifier where the white liquor is clarified by separating out the lime mud present.
The settled out mud is removed from the white liquor clarifier for further processing. An online density controller regulates the density (solids concentration) of the lime mud by adjusting the mud flow rate from the clarifier. If the lime mud density is high, the flow from the clarifier is increased to pump out the lime mud until the density of the lime mud is lowered. In the alternative, the density of the lime mud may be raised by decreasing the flow rate.
A torque measurement on the rake mechanism can override this control method. If the torque rises above the target level, the density controller is overridden and additional lime mud is pumped out to bring the torque to a level which will not cause equipment damage and process interruption.
The variation in the lime settling rate and the torque control mechanism used to compensate for such variation can result in widely different flow rates. For example, in a commercial plant these rates have been known to vary from about 150 liters per minute to about 500 liters per minute within 3 to 4 hours.
This cycle may be repeated 6 or 7 times during a day. As a given amount of wash water is introduced counter currently to wash the mud, fluctuations in the mud flow rate would affect the mud washing efficiency, clarity of the wash and the efficiency of the lime kiln operation.
Accordingly, it is a primary object of the invention to provide an improved method for the regeneration of white liquor from green liquor of a kraft paper plant stream.
It is also an object of this invention to provide an improved method of controlling the variations in the operation of the clarifier in the lime mud separation step in the production of white liquor in a kraft paper plant stream by using a controlled rate of lime mud removal.
These and other objects of the invention will become apparent from the text of the specification and the appended claim.
SUMMARY OF THE INVENTION
The invention provides an improved method for causticizing the green liquor of a kraft paper plant by contacting the green liquor with lime to form white liquor, the improvement comprising removing the lime mud at a predetermined rate.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic of the various apparatus components and piping which may be utilized to convert green liquor to white liquor according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The process of the invention may be practiced in any suitable apparatus which is typically utilized in the conversion of green liquor from a kraft paper mill stream to white liquor. An example of an apparatus which may be employed is set forth in FIG. 1. As shown in FIG. 1, green liquor is fed to slaker 4 through line 8. A stoichiometric amount of lime is fed through line 5 to take-off line 6 at valve 7. Take-off line 6 is connected to slaker 4. The stoichiometric amount of lime is calculated after analysis of the amount of Na 2 CO 3 in the green liquor using conventional analytical techniques or automated sensor systems which are well known to those who are skilled in the art. The lime is allowed to react with the amount of Na 2 CO 3 present in the green liquor to produce calcium hydroxide. The mixture from slaker 4 is fed through line 12 to a series of discrete causticizers 14, 16 and 18 which are provided with interconnecting lines 20 and 22 and agitators 26, 28 and 30. A number of discrete causticizer vessels are normally used to reduce risk of lime particles migrating directly out of the system without undergoing reaction. The causticizers are provided with agitators, for instance mechanical stirrers in order to mix the reactants i.e., Na 2 CO 3 +Ca(OH) 2 and maintain them in a state of uniform solution. The residence time in the causticizers is, for sake of example, on the order of an hour and a half to two. The effluent from the last causticizer 18 is fed to a solids liquid separator e.g. clarifier 19 through line 27. In the clarifier the mixture is separated by gravity into a liquid phase consisting of clear white liquor which is strong in NaOH and which is used in the pulping process and a phase heavy in solids, mainly CaCO 3 which is later washed with water to reduce its white liquor content and then passed to a lime kiln where the solids are calcined to yield fresh CaO. The lime mud is withdrawn from the bottom of clarifier 19 through line 31 at a constant predetermined rate. The rate is determined by determination of the amount of calcium carbonate and the determination of the amount of calcium hydroxide in the lime feed. The control means for adjusting the rate at which the lime mud is withdrawn comprise a flow meter and a control valve. The flow meter controls the flow to a given set point arrived at by manipulating the control valve.
Clarifier 19 is provided with a rake mechanism 20 which is agitated by motor means (not shown) that is provided with conventional torque detecting means (not shown). The torque detecting means comprise a pressure transmitter which measures the pressure on the rotating arms of the rake mechanism.
The lime mud is withdrawn through line 31 and passed to the lime mud washer (not shown) through line 44 prior to being passed to the lime kiln.
The rate of lime mud withdrawal through line 31 is fixed according to green liquor flow with a clamp of ∓10% or preferably about ∓6% to provide for fluctuation in green liquor or lime quality. The quality of the green liquor is monitored by an automatic density controller and also by bi-hourly manual testing. The quality of the lime is also monitored by manual testing. A control system such as the Videospec system manufactured by Foxboro is used to integrate the data concerning the green liquor and the lime to provide the information necessary to enable the controller for the lime mud flow rate to adjust the lime mud flow within the predetermined limits. The torque controller on the rake in the clarifier is included to override the preset limit in lime mud flow to insure that the process stream will not be interrupted and to protect the motor driving the rake.
The following example will serve to illustrate the invention.
EXAMPLE
In an actual operating plant comprising a 750 TPD market pulp mill, the process of the invention is carried out using the conventional apparatus constituting a causticizing plant constructed in accordance with the invention.
The following operating conditions were used in the instant example:
______________________________________Green GreenLiquor Lime Lime Mud Liquor Lime MudAnalysis Analysis Density Flow Flow Rate Torque______________________________________110-115 92-93% 1.4-1.5 600 100-110 39-41%GPL as as Cao gpm gpmNa.sub.2 O______________________________________
COMPARATIVE EXAMPLE
The following operating conditions were followed in the apparatus of the type described in the drawing but utilizing the conventional unmodified apparatus and method.
______________________________________Green GreenLiquor Lime Lime Mud Liquor Lime MudAnalysis Analysis Density Flow Flow Rate Torque______________________________________110-115 92-93% 1.2-1.5 600 40-150 35-45%GPL as as Cao gpm gpmNa.sub.2 O______________________________________
The Example carried out in accordance with the invention shows that the mud flow rate, mud density and the torque are all maintained at uniform rates and almost no fluctuation is seen as compared with the results for the Comparative Example. | An improved method for causticizing the green liquor formed in a kraft paper plant by contacting the green liquor with lime to thereby form white liquor followed by clarifying the white liquor by removing the lime mud therefrom in a clarifier is disclosed wherein the improvement lies in removing the lime mud from the clarifier at a predetermined rate. | 8 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of copending International Application No. PCT/DE99/02565, filed Aug. 16, 1999, which designated the United States.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a printed circuit board for use in the testing of electrical components having distributed two-dimensional connection contacts, and also to a method for producing such a printed circuit board.
[0004] The testing of electrical components can be explained with reference to the testing of chip-size or chip-scale packages. In the case of these designs of integrated circuits, a check is made prior to packaging to determine whether the integrated circuits operate in a manner that is dynamically electrically proper. In a first step, the integrated circuits are tested statically directly after fabrication on a semiconductor wafer. After the processes of sawing from the wafer and contact-connection into a chip-size package, it is necessary to test these integrated circuits again, because they have been subjected to further process steps in which additional fault sources can occur. This is carried out since the packaging of fault-free components is a prerequisite in the case of the connecting methods currently used in which the contacts which are no longer visible and monitorable, and in particular in the case of multichip modules, in order to achieve an acceptable overall yield.
[0005] For this purpose, U.S. Pat. No. 5,510,721 discloses a test device for testing an integrated circuit. The test device uses conductive strips extending over trenches. The strips are aligned with connection contacts on the integrated circuit. When these bond contacts or connection contacts of the integrated circuit are brought into contact with the strips, the strips exert a counterforce in the opposite direction in order to ensure a good electrical contact during the testing of the integrated circuit.
[0006] Electrical testing using known test devices proves to be problematic precisely in the case of electrical components having a multiplicity of contacts. Such components often have ball-like connection bumps with which contact can be made only with difficulty using test needles of test adapters or the known metallic test strips. Moreover, when testing using test needles, it can happen that the test needles damage the integrated circuit being tested.
[0007] U.S. Pat. No. 5,065,506 discloses a method for producing a printed circuit board which provides an electrical line on one side of a substrate and carries out selective irradiation of the other side of the substrate with a laser beam, thereby sublimating a section of the substrate. An opening is made in the process and a line traverses the opening. This line is subsequently bonded on contact areas of an electrical component.
SUMMARY OF THE INVENTION
[0008] It is accordingly an object of the invention to provide a printed circuit board and a method for testing electrical components on the printed circuit board which overcomes the above-mentioned disadvantageous of the prior art apparatus and methods of this general type, and which in particular simplifies the testing of the electrical components.
[0009] With the foregoing and other objects in view there is provided, in accordance with the invention, a printed circuit board for use in testing an electrical component having distributed two dimensional electrical contacts. The printed circuit board includes an electrically insulating insulation layer provided with through openings. In a region of a respective through opening, an electrically conductive contact pad is provided on a surface of the insulation layer, with the result that a contact point of the electrical component comes into contact with a contact pad of the printed circuit board. Proceeding from a respective contact pad, a respective conductor track extends to an edge region of the insulation layer. Elastic spring elements are provided at least in the region of the through openings below the contact pads and are arranged in such a way that the contact pads each make contact with a spring element.
[0010] The invention is based on the fundamental concept of providing a flexible test structure which provides an elastic press-on connection with contact points of electrical components. The electrical component can be pressed by its contact points onto the printed circuit board in such a way that a respective contact point of the electrical component comes into contact with a contact pad of the printed circuit board. The contact pad, which is situated in particular above the through opening, can yield into the through opening or out of the through opening and thus compensate for tolerances in the formation of contact points of the electrical component. Furthermore, damage to contact points of the electrical component is avoided.
[0011] In accordance with an added feature of the invention, the elastic spring elements may be arranged in such a way that the contact pads each make contact with a spring element through the through openings. With these configurations, it is possible for the compliance of the contact pads to be accurately set independently of their position with regard to the through openings.
[0012] In accordance with an additional feature of the invention, the contact pads lie between the insulation layer and the elastic spring element. A contact element of an electrical component can then be connected to the contact pad through the through openings. The spring element compensats for tolerance differences between the contact pad and connection bump. As an alternative to this, the elastic spring element may also be arranged within the through opening, in which case the contact pad can be forced into the through opening by a contact point of an electrical component against the resistance of the spring element.
[0013] In accordance with another feature of the invention, the spring elements may be designed as contiguous regions of an elastic mating layer, which may have silicone rubber. This allows the printed circuit board to be produced in a particularly simple manner.
[0014] In accordance with a further feature of the invention, the contact pads may also be arranged at least partly in a self-supporting manner in the through openings, as a result of which simplified and reliable use of the printed circuit board according to the invention can be achieved.
[0015] With the foregoing and other objects in view there is provided, in accordance with the invention, a method for producing a printed circuit board for testing an electrical component having distributed two dimensional electrical contacts, the method includes steps of: providing an electrically insulating insulation layer having an edge region and a side coated with a conductive metal layer; producing through-holes at locations in the insulation layer that are intended to contact the electrical contacts of the electrical component, and producing contact pads adjacent the through-holes so that contact points can be formed between the electrical contacts of the electrical component and the contact pads; producing conductor tracks in the conductive metal layer which each extend from a location adjacent a respective one of the through-holes to the edge region of the insulation layer; providing elastic spring elements at least in locations that are adjacent the through-holes and that are also below the contact pads; and configuring the elastic spring elements so that each one of the contact pads contacts a respective one of the elastic spring elements.
[0016] In accordance with an added mode of the invention, it is possible to provide the electrically insulating insulation layer coated with a conductive metal layer. Such support materials can be obtained cost-effectively, so that the production of the printed circuit board according to the invention can be carried out economically.
[0017] In accordance with an additional mode of the invention, the through openings are made in the insulation layer preferably by laser ablation using a mask, while the production of conductor tracks in the metal layer can be carried out for example by means of a photolithographic and etching method.
[0018] The use of laser ablation allows the use of already coated support materials in the inventive method, since only the insulation layer can be removed by the laser ablation, while the copper coating remains in the region of the through opening.
[0019] The through opening may also be produced by chemical and/or physical etching or by stamping.
[0020] If the step of producing contact pads is provided, to be precise in each case as a section of a conductor track in a region of a through opening, then it is possible to produce a printed circuit board which functions particularly reliably in use. Such contact pads may be permanently protected against corrosion, for example by depositing a metal, in particular gold.
[0021] In the inventive methods and in the printed circuit board, the production of the flexible test structure is based on the use of process steps which are also employed during spider production for TAB mounting (Tape Automated Bonding). In this case, particularly fine conductor structures can be produced, in particular also in a self-supporting manner above openings in the support material.
[0022] In accordance with another mode of the invention, this method is used to produce self-supporting, gold-plated contact pads for connections of an electrical component which is to be tested. The electrical component is then pressed onto these contact pads, so that a spring element fitted behind and made of silicone rubber, for example, is used both to compensate for tolerances and to produce a good electrical test contact. From the contact pads, conductor tracks lead to connections in a coarser grid pattern, which can be connected to test bases and other elements in a customary way.
[0023] The openings in the support sheet into which the contact pads project can be produced in various ways. Thus, chemical or plasma etching can be employed in the same way as methods of laser removal. The possibility of using stamping depends on the grid-pattern fineness and the hole diameter of the through openings.
[0024] Unlike the usual case, a certain edge bevel of the hole cross-section of the through openings is desirable in the present case. This is because if, in the case of testing, the component is pressed onto the test structure from the opening side, then the hole edges bring about a centering effect, which correspondingly increases the required positioning accuracy.
[0025] However, in a variant, the component can also be pressed on from the other side. In this case, the resilient material must fill the openings, and this can be achieved by placing the sheet for example onto a liquid bed of silicon rubber with subsequent curing.
[0026] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0027] Although the invention is illustrated and described herein as embodied in a printed circuit board for use in the testing of electrical components and method for producing it, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0028] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] [0029]FIG. 1 shows a plan view of a printed circuit board;
[0030] [0030]FIG. 2 shows a cross-section through another printed circuit board in a region of a through opening;
[0031] [0031]FIG. 3 shows a cross-section through another printed circuit board in a region of another through opening;
[0032] [0032]FIG. 4 shows a cross-section through an electrical component to be tested and also through the printed circuit board shown in FIG. 3, in a region of two through openings;
[0033] [0033]FIG. 5 shows a cross-section through another electrical component and also through the printed circuit board shown in FIG. 2, in the region of further through openings; and
[0034] [0034]FIG. 6 shows a plan view of another printed circuit board.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 thereof, there is shown a plan view of a printed circuit board 1 . The printed circuit board 1 is subdivided into an electrically insulating insulation layer 2 having through openings 3 .
[0036] Electrically conductive contact pads 4 , which are gold-plated, are arranged in a freely suspended manner within the through openings 3 . Furthermore, conductor tracks 5 are provided on the underside of the insulation layer 2 , which conductor tracks extend across the through openings and are connected to the contact pads 4 .
[0037] In order to produce the printed circuit board 1 , the through openings 3 are produced in a copper-coated support material having a thickness of e.g. 50 μm, to be precise by laser ablation using a mask which is not shown in this view.
[0038] Afterward, the copper coating provided on the rear side of the insulation layer 2 in FIG. 1 is coated with photoresist and the structure of the conductor tracks 5 is exposed with register accuracy with respect to the opening pattern. After the photoresist (not shown in this view) has been developed, the copper coating is etched and stripped. Finally, the contact pads 4 , in particular, are coated with gold.
[0039] [0039]FIG. 2 shows a region of the printed circuit board 1 around a through opening 3 in cross section. As can be seen particularly well in this view, the contact pad 4 , proceeding from the conductor track 5 , extends into the through opening 3 . An edge bevel of the through opening 3 toward the contact pad 4 is desirable.
[0040] [0040]FIG. 3 shows a partial region of another printed circuit board 10 in cross section.
[0041] The printed circuit board 10 is subdivided into an insulation layer 11 , in which a through opening 12 is provided. A conductor track 13 is deposited above the insulation layer 11 , a circular contact pad 14 coated with gold has been produced in the conductor track.
[0042] The printed circuit board 10 is produced by a TAB method (=Tape Automated Bonding method).
[0043] [0043]FIG. 4 illustrates the printed circuit board 10 shown in FIG. 3 when used with an electrical component 20 to be tested, which, on its underside, has a first contact bump 21 having an essentially circular cross section and also a second contact bump 22 having an essentially circular cross section. Within the tolerance range, the diameter of the second contact bump 22 is significantly greater than the diameter of the first contact bump 21 .
[0044] As can be seen particularly clearly in FIG. 4, the through openings 12 are arranged in the insulation layer 11 in such a way that they lie exactly under the first contact bump 21 and under the second contact bump 22 . In this case, the first contact bump 21 just touches the contact pad 14 of the through opening shown on the left-hand side in FIG. 4, while the second contact bump 22 presses downward the contact pad 14 of the through opening shown on the right-hand side in FIG. 4.
[0045] In order to increase the flexural resistance of the contact pads 14 , a spring layer 23 made of silicone rubber is provided below the insulation layer 11 . The spring layer bears on a fixed support not shown in this view. A press-on force “F” on the electrical component 20 is counteracted by the spring layer 23 with an area load “q”.
[0046] By virtue of the design of the contact pads 14 in conjunction with the flexible conductor track 13 , size tolerances between first contact bump 21 and second contact bump 22 are compensated for, as can be seen particularly well in FIG. 4.
[0047] [0047]FIG. 5 illustrates the printed circuit board 1 shown in FIG. 2 in conjunction with the electrical component 20 from FIG. 4. A spring layer 30 is provided below the insulation layer 2 and the conductor tracks 5 . The spring layer counteracts deformation of the contact pads 4 downward under the action of the first contact bump 21 and of the second contact bump 22 . As is seen particularly well in this view, this configuration ensures tolerance compensation on account of the different sizes of first contact bump 21 and second contact bump 22 .
[0048] [0048]FIG. 6 shows another printed circuit board 40 according to the invention in plan view. The printed circuit board 40 has an insulation layer 41 , on which a copper coating is applied. A series of conductor tracks have been formed in the copper coating, which conductor tracks are designed for the purpose of test contact-connection of a component. In this case, each contact bump present on the underside of an electrical component (not shown in this view) is assigned a through opening with contact pad, as is shown in more detail in FIGS. 3 and 4. A contact pad 42 is singled out here by way of example, this contact pad is connected via a conductor track 43 to a coarse connection 44 at the edge of the insulation layer 41 . Likewise, all of the other contact pads in a contact region 45 of the printed circuit board 40 are also connected to coarse connections on the periphery of the printed circuit board 40 .
[0049] In order to check an electrical component whose contact bumps are arranged in the same way as the contact pads in the component region of the contact region 45 , the component is pressed onto the contact region 45 . All of the contact bumps of the electrical component can thereupon be scanned via the coarse connections on the periphery of the printed circuit board 40 . | A printed circuit board for use in testing electrical components having distributed two-dimensional connection contacts. The printed circuit board has an electrically insulating insulation layer provided with through-holes. In the region of a respective through-hole, an electrically conductive contact pad is provided on a side surface of the insulation layer. Proceeding from a respective contact pad, a respective conductor track extends to an edge region of the insulation layer. | 6 |
FIELD OF THE INVENTION
This invention relates to a rotor for use in a fluid flow machine and particularly for use in a gas turbine engine.
BACKGROUND OF THE INVENTION
In fluid flow machines bladed rotors comprising a rotor disc bearing aerofoil blades around its rim are commonly used. Such rotors are vulnerable to damage to the rotor disc rim causing blades to break off of the disc or the disc itself to break up. Such damage can be caused by erosion by the fluid flow itself or impact damage by solid foreign objects carried in the fluid flow.
These problems are particularly pronounced in the turbine and compressor rotors in gas turbine engines because of the very high rates of rotation involved. As a result centrifugal loads are very large and failure of the rotor disc or blade loss can be catastrophic because of the high kinetic energy of the released blade or disc fragments.
In addition these high rates of rotation and the generally high gas flow velocities within the engine make the chances of erosion or foreign object damage more likely than in rotors subjected to less extreme conditions, this is particularly true of turbine rotors which operate at high temperatures in a very high temperature gas flow.
The very high temperature of the gas flow can also indirectly cause damage to the disc due to the stresses produced by differential thermal expansion, because the disc rim will be heated by the gas flow to a much higher temperature than the main bulk of the disc.
One known method of protecting the rotor rim from these problems is to coat it with a layer of material less susceptible to damage than the basic rotor material and having a low thermal conductivity. The choice of rotor material generally cannot be made based on damage resistance and capacity to endure temperature differentials alone but must be a trade off between these and other properties such as strength and density, but the use of a coating to protect the disc from impact and insulate it to reduce temperature differences allows the disc material to be selected based only on these other properties.
The use of such a coating has two main drawbacks, firstly the problem of ensuring that the coating does not separate from the disc under centrifugal and differential thermal expansion loads and secondly, if a blade is damaged it will be more difficult to remove and replace it because this will generally require that at least part of the coating also be removed and replaced, a demanding operation.
This invention was intended to provide a rotor at least partially overcoming these problems.
SUMMARY OF THE INVENTION
This invention provides a rotor for use in a fluid flow machine, the rotor comprising a disc bearing a plurality of blades at its outermost rim and having a plurality of plates each extending between adjacent blades, the numbers of plates and blades being equal and the plates forming a substantially continuous barrier around the disc.
The plates form a protective barrier preventing erosion or foreign object damage to the disc, as a result the disc material can be selected purely on strength and other criteria ignoring erosion and damage resistance. The plates can easily be secured so as to accommodate thermal expansion and being separate from the blades and disc can easily be removed and replaced to allow blade replacement.
The plates also form a barrier preventing exposure of the disc to the fluid flow, where the fluid is at a high temperature the plates act as a thermal barrier and so reduce the temperature differentials within the disc.
BRIEF DESCRIPTION OF THE DRAWINGS
A rotor employing the invention will now be described by way of example only with reference to the accompanying diagrammatic figures in which:
FIG. 1 shows an axial view of a portion of a rotor;
FIG. 2 shows a cut away perspective view of the rotor of FIG. 1; and
FIG. 3 shows a cut away view along the line A--A in FIG. 1, identical parts having the same reference numerals throughout.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to the figures a gas turbine rotor for use in a gas turbine engine is formed by a disc 1 having an axis of rotation 2 and bearing a plurality of blades 3 at its rim. The blades 3 are conventional being aerofoils in cross section and having upstream and downstream edges and suction and pressure surfaces and are evenly spaced around the circumference of the disc 1. The blades 3 are formed separately from the disc 1 and then attached by linear friction bonding to provide an integral bladed turbine disc or blisk.
Each blade 3 has a first and a second ridge 5A on its pressure and suction surfaces respectively, each extending from the upstream edge to the downstream edge of the blade 3. All of the ridges 5A are at the same distance along the blades 3 from the disc 1, so they are all at the same radius relative to the axis 2.
Each blade 3 also has a pair of ridges 5B and 5C on its pressure surface and on its suction surface, the ridge 5B being towards the leading edge of the blade 3 and the ridge 5C being towards its trailing edge. The ridges 5B and 5C are parallel to and spaced apart from the ridges 5A. All of the ridges 5B and 5C are at the same distance along the blades 3 from the disc 1 and they are all at the same radius relative to the axis 2.
The ridges 5A are at a greater radius relative to the axis 2 than the ridges 5B and 5C.
A plurality of plates 4 are held between the blades 3. Each plate 4 extends between two adjacent blades 3 and the edges of the plates 4 lie between the ridges 5A and the ridges 5B and 5C on each of the adjacent blades 3. the ridges 5A, 5B and 5C hold the plates 4 in place between them, preventing them from moving radially inward or outward. The plates 4 can however be moved axially, sliding between the ridges 5A, 5B and 5C, this allows removal and replacement of the plates 4. The plates 4 form an annular substantially continuous protective barrier surrounding and spaced apart from the disc 1. The barrier formed by the plates is broken by the blades 3 where they pass between the plates 4, however the barrier is still substantially continuous because the blades 3 are effectively a part of the barrier at these points.
The plates 4 are able to move slightly circumferentially because they are slightly smaller than the distance between the blades 3, the ridges 5A, 5B and 5C project far enough from the faces of the blades 3 to ensure that the plates 4 cannot come out radially. This slight movement allows any movement due to differential thermal expansions to be taken up without producing damaging strains in the rotor.
In use the main radial loads on the plates 4 will be centrifugal loads acting radially outwards, the only load acting radially inward will be gravity and this will be completely outweighed by the centrifugal loads except then the turbine is not operating and for a very short period on starting and shutting down the engine. The radially outward loads will be much larger than the radially inward loads, so although continuous ridges 5A are needed to support the radially outward loads only partial ridges 5B and 5C are needed to support the radially inward loads.
The gas flow to the turbine is delivered through an annular gas duct coaxial with the disc 1 and with an inner boundary at the radial position of the plates 4, this causes the gas flow to pass outside of the plates 4.
The plates 4 prevent the gas flow coming into contact with the rim of the disc 1 and thus protect the disc 1 from erosion or foreign object damage and reduce heat flow from the gas flow to the disc 1. As a result only the portion of the blades 3 lying radially outside of the plates 4 interact aerodynamically with the gas flow.
Each blade 3 contains a first set of six cooling air channels 6 which inject cooling air between the plate 4 and the rim of the disc 1. This cools the plate 4 and produces a layer of cool air between the plate 4 and the disc 1, reducing heat transfer between them.
Each blade 3 also contains a second set of three cooling air channels 7 arranged so that cooling air passes in turn through all three of the cooling air channels 7 and then exhausts through a number of cooling air passages 8 at the training edge of the blade 3 into the gas flow through the turbine. Internal cooling air systems of this kind are well known in turbine blades and need not be described further here.
Both sets of cooling air channels 6 and 7 are fed with cooling air through passages 9 within the disc 1. The passages 9 open out on the faces of the disc 1 within the disc live rim. The disc live rim is the largest radius where the disc 1 forms a continuous circle and is denoted by the dotted line 10.
Cooling air can be contained adjacent the faces of the disc 1 by sealing structures between the disc 1 and the non-rotating parts of the turbine (not shown), such seals are commonly used in the art and need not be described herein, this cooling air can then be directed into the cooling air passages 9.
Since the cooling air passages 9 open out within the disc live rim it is not necessary to provide a seal between non-rotating turbine parts and the disc 1 outside the disc live rim, which simplifies seal construction.
The plates 4 are prevented from moving axially by a pair of annular lockplates 10, shown in FIG. 3 only. Each lockplate 10 is an annulus coaxial with the disc 1 and cooperates with projections on a face of the disc 1 to form a bayonet joint securing the lockplate 10 to the disc 1. Bayonet joints are well known and need not be described in detail herein. The outer rim of each lockplate 10 bears against the ends of the plates 4 and the edges of the blades 3 and so prevents the plates 4 from moving axially. The lockplates 10 slow the escape of cooling air from the spaces defined between the disc 1, blades 3 and plates 4, but no seal is formed between the plates 4 and the lockplate 10. This allows cooling air injected between the plates 4 and the disc 1 by the cooling air channels 6 to escape, thus allowing circulation of this cooling air.
The lockplates 10 can be removed simply by rotating them relative to the disc 1 to undo the bayonet joint, the plates 4 can then be slid out axially from between the blades 3. Thus damaged plates 4 can be easily replaced, and plates 4 can be easily removed and replaced to allow replacement of damaged blades 3.
The invention can be applied to a compressor rotor as well as to the turbine rotor described.
It is not essential to the invention that the blades or the spaces between the plates and disc rim be cooled, even if no cooling is provided the plates will still protect the disc from damage.
If the blades and plates are cooled other cooling air routes than those described could be used. For example cooling air could be introduced into the space between the plate and the disc by passing it between the lockplate and the disc face, the air could then enter the blades via the cooling air channels 6. The number of cooling air channels can of course be varied depending on cooling air requirements.
The lockplates could be replaced by other axial fixing structures, such as projections integral with the blades or disc or the use of pins.
It is not essential for the ridges 5A to be continuous, partial ridges could be used provided they were able to support the loads on the plates, similarly the ridges 5B and 5C could be replaced by a continuous ridge or three or more partial ridges. The ridges 5A shown are at a constant radius from the axis 2, such that they all lie on the surface of a cylinder, instead this radius could vary along the length of each ridge 5A so that they lie on the surface of a cone. Similarly the ridges 5B and 5C could also lie on the surface of a cone, the ridges 5B and 5C being parallel to the ridges 5A to allow removal and replacement of the plates.
Also the plates could be secured by their edges fitting into grooves in the surfaces of the blades, but the use of ridges is preferred because grooves would weaken the blades.
The described example is a blisk formed by attaching blades to the disc using linear friction bonding, the invention is equally applicable to blisks formed in other ways such as welding, diffusion bonding or machining the disc and blades from a single metal block or to rotors employing discrete blades and discs. | A rotor having a bladed disc and for use in a fluid flow machine has plates extending between and supported by the blades to protect the disc rim from erosion and foreign object damage and also, when the rotor is a gas turbine, to protect the disc rim from the heating effects of high temperature gasses. The plates are held between ridges on the blade faces. | 5 |
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