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STATEMENT OF RELATED APPLICATIONS
This application claims priority on pending U.S. Provisional Patent Application Ser. No. 60/072,662, filed on Jan. 27, 1998.
BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates generally to the field of rigid-rod polymer analogs and specifically to the field of multidimensionally crosslinkable benzobisazole polymers and processes for making such polymers.
2. Prior Art
The rigid-rod aromatic heterocyclic polymers are well known for their outstanding mechanical and thermal properties. These polymers can be processed into fibers or films with high tensile strengths and moduli, but they have relatively low fiber axial compressive properties compared to carbon fiber and inorganic fibers. The characteristically low compressive properties limit their potential applications in certain structural composites.
Molecular crosslinking has been attempted to enhance the compressive properties of rigid-rod polymer fibers. Several crosslinkable rigid-rod polymer systems, such as methyl pendent rigid-rod polymers (Tsai et al, U.S. Pat. No. 5,001,217), halogenated rigid-rod polymers (Sweeny, U.S. Pat. No. 5,100,434) and benzocyclobutene rigid-rod polymers (see Dang et al, ACS Polymer Preprints, Vol. 36, No. 1, pp. 445-456, 1995), have been accordingly designed to enhance the fiber compressive properties. Improvements in fiber compressive properties are apparent in certain systems as the degree of crosslinking increases.
BRIEF DESCRIPTION OF THE INVENTION
Multidimensionally crosslinkable benzobisazole polymers, a rigid-rod analog, are prepared by polycondensation of amino hydrochloride monomers with methyl ortho-substituted biphenyl dicarboxylic acid or its derivatives and terephthalic acid or terephthaloyl chloride in polyphosphoric acid. High molecular weights of the polymers can be produced. Concentrated polymer solutions in polyphosphoric acid can be processed into fibers, which can be heat treated to induce a crosslinking reaction resulting in a crosslinked polymer fiber or film with improved compressive strength due to multidimensional crosslinking. The fibers or films produced from the polymer have high performance characteristics with extremely high tensile strength and modulus. The heat treated fibers can be used as reinforcement materials in structural composites.
In accordance with the present invention, there are provided rigid-rod aromatic heterocyclic polymers having repeating units of the following formula: ##STR3## wherein X is selected from the group consisting of --O--, --S--, and --NH--; m and n are positive real numbers, each representing the fraction that the respective different recurring units are present in said repeating unit; m is 0.05 to 1.0; n is 1.0-m; Ph is 1,4-phenylene; and Ar is ##STR4## wherein R 1 ═R 2 ═R 3 ═R 4 ═C 1-3 alkyl; or R 1 and R 2 can be the same or different and are selected from the group consisting of C 1-3 alkyls and H; and R 3 and R 4 can be the same or different and are selected from the group consisting of C 1-3 alkyls. The C 1-3 alkyl is preferably CH 3 ; and m is preferably 0.1 to 0.3, and most preferably about 0.25.
This invention also provides methods for processing the aforementioned polymers into fibers and for preparing crosslinked polymeric fibers of improved compressive strength, as described hereinafter.
It is an object of the present invention to provide novel multidimensionally crosslinkable rigid-rod aromatic heterocyclic polymers and fibers which exhibit improved compressive properties after heat treatment.
It is another object of the present invention to provide methods for preparing these multidimensionally crosslinkable rigid-rod aromatic heterocyclic polymers and fibers.
Other objects, aspects, and advantages of the present invention will be apparent to those skilled in the art from a reading of the following detailed disclosure of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The polymers of this invention are prepared by the polycondensation of 4,6-diaminoresorcinol dihydrochloride, 2,5-diaminohydroquinone dihydrochloride, 4,6-diamino-1,3-benzenedithiol dihydrochloride, 2,5-diamino-1,4-benzenedithiuol dihydrochloride or 1,2,4,5-tetraaminobenzene tetrahydrochloride; an ortho-substituted biphenyl-4,4'-dicarboxylic acid or acid halide derivative of the formula ROC--Ar--COR, wherein R is OH or Cl, and Ar is as described previously; and a terephthalate. The polymers may be prepared by:
a. mixing an amino hydrochloride monomer with a polyphosphoric acid (PPA) having a phosphorous pentoxide concentration of about 77 to 85% and preferably below 80% at room temperature for about 24 hours.
b. heating the resulting mixture to about 60-80° C. for about 24 hours in an inert gas atmosphere such as nitrogen and argon. Reduced pressure is optionally used to facilitate removal of the hydrogen chloride in the final several hours.
c. adding the substituted biphenyl dicarboxylic acid or acid chloride monomer to the mixture resulting from step b to provide a mixture of amino monomer and acid monomer in the preliminary solvent.
d. increasing the phosphorous pentoxide content of the mixture resulting from step c to provide a reaction medium in which the percentage of phosphorous pentoxide should be about 82 to 85% and preferably about 83% by weight at the end of the polymerization.
e. placing the reaction medium resulting from step d at a temperature of about 110 to 200° C. for about 24 to 48 hours. Preferably, the reaction temperature is increased gradually during the polymerization period, e.g., 130° C. for 5 hours, then 160° C. for 18 hours, and finally 190° C. for 24 hours.
Alternatively, steps a, b, and c may be combined by adding the amino hydrochloride and substituted biphenyl diacid or acid chloride monomers to a PPA with 85% P 2 O 5 , then removing hydrogen chloride. After dehydrochlorination of the amino hydrochloride monomer the polymerization is carried out.
Step c may be modified by adding a solution of the substituted biphenyl dicarboxylic acid or acid chloride monomers in aromatic hydrocarbons such as benzene and toluene to the mixture resulting from step b, and then heating the mixture to a temperature of about 50-80° C. for several hours. The reduced pressure is used to remove the aromatic hydrocarbon. The initial polymerization is therefore carried out on the interfaces between polyphosphoric acid and the aromatic hydrocarbon. The application of interfacial reaction at the beginning may lead to a highly homogenous polymer solution at the end of the polymerization suitable for subsequent fiber spinning.
At the end of the reaction period, the polymer solution is in a very viscous or semisolid state. The polymer may be precipitated from the solution by pouring the reaction mixture into water. The precipitated polymer is initiated treated with ammonium hydroxide, then washed with water until all PPA is removed. The polymer is dried under reduced pressure.
The polymers of this invention are soluble in strong acids, such as methanesulfonic acid (MSA) and chlorosulfonic acid (CSA). The molecular weight of these polymers is commonly indicated by intrinsic viscosity of the polymer. The intrinsic viscosity is determined in MSA or CSA at 30° C.
The polymers produced in accordance with the invention may be used to produce fibers and films. In order to process these polymers into fibers or films, solutions are prepared containing about 5 to about 15, preferably about 8 to 12, weight percent of the copolymer in PPA. Such solutions may be spun or extruded into a coagulation bath of water.
The fibers of this invention can be crosslinked by exposure to an elevated temperature or by exposure to suitable radiation. Crosslinking by exposure to heat may be accomplished by exposing the fibers to a temperature of about 450-550° C. for about 0.5 to 30 minutes under an inert atmosphere of nitrogen or argon. The crosslinked fibers are insoluble in all strong acid solvents. Evidence of crosslinking is established by 13 C solid state nuclear magnetic resonance spectroscopy. 13 C NMR spectra of heat-treated fibers indicate that the intensity of pendent groups (for example methyl groups) at about 20 ppm decreases at the temperatures of 500-550° C., and in the meantime a new peak at 38 ppm emerges and its intensity increases with the temperature of heat-treatment. The crosslinked fibers in accordance with the present invention exhibit improved compressive strength.
The following examples illustrate the invention:
EXAMPLE I
Into the bottom of a 250-ml three-neck flask equipped with a mechanical stirrer, nitrogen inlet and outlet, was placed 0.996 g (4.061 mmol) of 2,5-diamino-1,4-benzenedithiol dihydrochloride and 22.45 g of PPA (83% P 2 O 5 ). The mixture was stirred at room temperature under a stream of nitrogen for 24 hours and then at 80° C. for another 24 hours (including 1 hour under reduced pressure). To the resulting clear solution was added 1.221 g (4.061 mmol) of 2,2'6,6'-tetramethylbiphenyl-4,4'-dicarboxylic acid and 2.5 g P 2 O 5 . The temperature was maintained at 80° C. for 5 hours and then raised to 110° C. for 1 hour, to 130° C. for 5 hours, 160° C. for 18 hours, 190° C. for 24 hours, and 200° C. for 6 hours. As the temperature increased, stir opalescence began to occur at about 160° C. The viscous solution was poured into water. The precipitated polymer was collected by filtration, washed thoroughly with dilute ammonium hydroxide aqueous solution, hot water, and finally dried in vacuum at 85° C. for 20 h. The yield was 1.54 (95%). The polymer was a bright brown color and was soluble in chlorosulfonic acid. The intrinsic viscosity was 9.17 dl/g in chlorosulfonic acid at 30° C. Analysis: Calculated for C 24 H 18 N 2 S 2 : C, 72.35; H, 4.56; N, 7.04; S, 16.06. Found: C, 71.50; H, 4.50; N, 6.84; S, 15.44.
EXAMPLE II
Into the bottom of a 250-ml three-neck flask equipped with a mechanical stirrer, nitrogen inlet and outlet, was placed 0.8000 g (3.2628 mmol) of 2,5-diamino-1,4-benzenedithiol dihydrochloride and 10 g of PPA with 85% of P 2 O 5 . The mixture was stirred at room temperature under a nitrogen stream for 24 hours and then at 80° C. for another 24 hours (including 1 hour under reduced pressure), which resulted in a clear solution. To such a yellow solution was added 1.0938 g (3.2628 mmol) of 2,2',6,6'-tetramethylbiphenyl-4,4'-dicarbonyl chloride under a nitrogen stream, and the mixture was maintained at 80° C. for 0.5 hour and heated to 120° C. for 1 hour, 140° C. for 3 hours, 160° C. for 12 hours, and 180° C. for 24 hours. As the temperature increased, stir opalescence began to occur at about 140° C. The solution was poured into water, washed with ammonium hydroxide, and dried under reduced pressure at 100° C. The yield was 1.26 g (97%). The intrinsic viscosity in MSA was 19.5 dl/g. Analysis: Calculated for C 24 H 18 N 2 S 2 : C, 72.35; H, 4.56; N, 7.04; S, 16.06. Found: C, 72.07; H, 4.69; N, 7.03; S, 15.92.
EXAMPLE III
Into the bottom of a resin flask equipped with a mechanical stirrer and nitrogen inlet and outlet, was placed 1.000 g (4.08 mmol) of 2,5-diamino-1,4-benzenedithiol dihydrochloride and 18.0 g of PPA (85% P 2 O 5 ). The mixture was slowly heated to 80° C., and the temperature was maintained at 80° C. for 24 hours. To the resulting yellow solution, 0.339 g (2.04 mmol) of terephthalic acid and 0.608 g (2.04 mmol) of 2,2',6,6'-tetramethylbiphenyl-4,4'-dicarboxylic acid were added. The mixture was heated under a nitrogen atmosphere at 80° C. for 3 hours, 110° C. for 1 hour, 130° C. for 5 hours, 160° C. for 18 hours, and 190° C. for 24 hours. The copolymer was precipitated in water, collected by suction filtration, washed thoroughly with dilute ammonium hydroxide and water for removal of PPA, and dried under reduced pressure at 100° C. overnight. Intrinsic viscosity in CSA at 30° C. was 8.3 dl/g.
EXAMPLE IV
Into the bottom of a resin flask equipped with a mechanical stirrer, nitrogen inlet and outlet, was placed 1.000 g (4.08 mmol) of 2,5-diamino-1,4-benzenedithiol dihydrochloride, 0.414 g (2.04 mmol) of terephthaloyl chloride, 0.684 g (2.04 mmol) of 2,2'6,6'-tetramethylbiphenyl-4,4'-dicarbonyl chloride and 6.0 g of PPA (77% P 2 O 5 ). The reaction mixture was heated under a nitrogen atmosphere to 65° C. for 24 hours. To the resulting mixture, 2.1 g P 2 O 5 was added to bring the polymer concentration to 15 percent. The mixture was heated under a nitrogen atmosphere to 110° C. for 2 hours, 140° C. for 5 hours, 160° C. for 24 hours, and 180° C. for 5 hours. Stir opalescence began to occur at 140° C. The copolymer was precipitated in water, collected by suction filtration, washed thoroughly with dilute ammonium hydroxide and water, and dried under vacuum at 85° C. for 30 hours. The product (1.35 g) was obtained in 99.5% yield. Intrinsic viscosity in methanesulfonic acid at 30° C. was 16.3 dl/g. Analysis calculated for C 19 H 12 N 2 S 2 ; C, 68.65; H, 3.64; N, 8.43; S, 19.29. Found: C, 68.21; H, 3.92; N, 8.44; S, 19.26.
EXAMPLE V
Into the bottom of a resin flask equipped with a mechanical stirrer, nitrogen inlet and outlet, was placed 5.031 g (20.52 mmol) of 2,5-diamino-1,4-benzenedithiol dihydrochloride, 1.041 g (5.13 mmol) of terephthaloyl chloride, 5.160 g (15.39 mmol) of 2,2'6,6'-tetramethylbiphenyl-4,4-dicarbonyl chloride and 31.4 g of PPA (77% P 2 O 5 ). The mixture was heated under a nitrogen atmosphere to 65° C., and maintained at 65° C. for 48 hours. P 2 O 5 (7.7 g) P 2 O 5 was added to bring the PPA concentration to 83%. The reaction mixture was heated to 80° C. for 1 hour, 110° C. for 5 hours, 140° C. for 20 hours, and 165° C. for 9 hours. The copolymer was precipitated in water, collected by suction filtration, washed thoroughly with dilute ammonium hydroxide and water, and dried under vacuum at 85° C. for 24 hours. Intrinsic viscosity in methanesulfonic acid at 30° C. was 12.7 dl/g. Analysis calculated for [C 14 H 6 N 2 S 2 ] 0 .25 [C 24 H 18 N 2 S 2 ] 0 .75 : C, 70.65; H, 4.14; N, 7.67; S, 17.54. Found: C, 68.98; H, 4.29; N, 7.44; S, 17.24.
EXAMPLE VI
The same procedure was used as described in Example II except for the addition of the designated amount of terephthaloyl chloride and tetramethylbiphenyl dicarbonyl chloride. The yellow solution of dehydrochlorinated 2,5-diamino-1,4-benzenedithiol dihydrochloride (4.0945 g, 16.70 mmol) in 40 of PPA with 8.3% of P 2 O 5 was allowed to cool to 50° C. To the solution was added 1.3996 g (4.170 mmol) of 2,2'6,6'tetramethylbiphenyl-4,4'-dicarbonyl chloride in 10 g benzene, and the mixture was maintained at 50° C. for 3 hours under stirring. The benzene was removed cautiously under reduced pressure. The temperature was raised to 80° C., and 2.5428 g (12.53 mmol) of terephthaloyl chloride was added to the flask. After 3 hours at this temperature, the mixture was heated to 110° C. for 12 hours, 140° C. for 24 hours and 165° C. for 10 hours. A small portion of the reaction solution was added to water, washed and dried in vacuo overnight at 100° C. for use in measurement of the intrinsic viscosity ([η]=14.0 dL/g in methanesulfonic acid at 30° C.) The remaining solution was bottled for use in fiber spinning. Analysis calculated for [C 14 H 6 N 2 S.sub. ] 0 .75 [C 24 H 18 N 2 S 2 ] 0 .25 : C, 66.19; H, 3.03; N, 9.36; S, 21.42. Found: C, 65.73; H, 3.13; N, 8.96; S, 20.22.
Fibers from the above examples were spun at 110° C., using a 500-mm diameter spinneret, into water passing through a 15-cm long air gap. The single filaments were wound on 15-cm diameter plastic spools at 100 cm/minute using a 4-12 spin-draw ratio. The fiber was washed by immersing it in running water for several days to remove residual PPA and then air dried. In a free annealing heat treatment, 5-cm long fibers were put in a small quartz tube, and heat-treated in a preheated tube furnace from 450-550° C. in a nitrogen stream for 10 minutes. The tension annealing of fibers was done in a 100-cm long ceramic tubular furnace. The fiber was put in the furnace at room temperature and heated up to 450-550° C. An 11.1 grams load (about 25 MPa tension) was used by hanging a weight at one end of the fiber. The heat treatment under tension was carried out in batches of about 100-cm lengths. Only the 30-cm middle sections of the heat-treated fibers were selected for study. The results for a heat-treated poly[tetramethylbiphenyl benzobisthiazole/co-(phenylene benzobisthiazole) copolymer fiber are shown in Table 1.
TABLE 1______________________________________Tensile Properties of Tetramethylbiphenyl PBZT/PBZT (25/75) Polymer Fiber Tensile Str. Modulus Elong. to RCS.sup.a Fiber (GPa) (GPa) break (%) (GPa) RCS/Tensile Str.______________________________________As-spun 1.22 ± 0.02 19.7 ± 0.6 5.9 ± 0.2 0.57 0.47 500f.sup.b 1.35 ± 0.12 54.7 ± 1.9 3.2 ± 0.1 0.45 0.33 500f 0.64 ± 0.01 20.5 ± 0.3 3.3 ± 0.1 >0.64 >1 520f 0.73 ± 0.03 23.7 ± 0.4 3.3 ± 0.1 ˜0.73 ˜1 550f 0.65 ± 0.02 25.9 ± 0.4 3.3 ± 0.1 <0.63 ˜______________________________________ .sup.a : RCS is recoil compressive strength. .sup.b : Number indicates heat treatment temperature in ° C. f and t means free and tension annealing, respectively.
Various modifications may be made to the invention as described without departing from the spirit of the invention or the scope of the appended claims.
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Rod-like aromatic heterocyclic polymers having repeating units of the formula --(--Q--Ar--) m --(--Q--Ph--) n )-- where Q is ##STR1## X is --O--, --S--, or --NH--; m is 0.05 to 1.0; n is 1.0-m; Ph is 1,4-phenylene; Ar is ##STR2## R 1 and R 2 are the same and are either H or CH 3 ; and R 3 and R 4 are CH 3 .
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 USC §119 to U.S. Provisional Patent Application Ser. No. 61/630,469, filed on Dec. 13, 2011, and titled “Non-Mechanical Method for Orchard Spray Recapture,” the entire contents of which are hereby incorporated by reference.
TECHNICAL FIELD
The present disclosure relates generally to a spray recapture system and method. More particularly, the disclosure relates to a system and method for spraying, containing, recirculating, and recapturing a spray discharge.
BACKGROUND
Spray recapture systems have been used in the past to prevent overspray of paint, agricultural chemicals including fertilizers, fungicides, herbicides, and pesticides, and other types of spray discharge intended for one or more target objects. Such sprays may be harmful to environs surrounding the target objects. Thus, it may be desirable to mitigate dispersal of such chemicals. In some cases, spray containment shells are used to contain overspray. However, very large target objects, such as a fully mature tree or an airplane, may be too large to fit within a practically-sized spray containment shell.
What is needed, therefore, is a method and system for mitigating overspray while enhancing spray coverage on a target object and increasing spray recapture.
SUMMARY
In one embodiment, a method of spraying a target object is disclosed. The method includes creating a first flow of air around a target space, creating a second flow of air within the target space, wherein the second flow of air flows counter to the first flow of air, locating a target object within the target space, and emitting a spray within the target space.
In another embodiment, an apparatus for spraying a target object is disclosed. The apparatus includes a primary blower adapted to direct a first flow of air through multiple radially-distributed air vents, a secondary blower, and a spray nozzle. The radially-distributed air vents are adapted to direct the first flow of air in a first direction. The secondary blower is adapted to direct a second flow of air in a second direction. The second direction is approximately opposed to the first direction. The spray nozzle is adapted to emit a spray into the second flow of air.
The present disclosure will now be described more fully with reference to the accompanying drawings, which are intended to be read in conjunction with both this summary, the detailed description, and any preferred or particular embodiments specifically discussed or otherwise disclosed. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only so that this disclosure will be thorough, and fully convey the full scope of the disclosure to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
This disclosure may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements, and in which:
FIG. 1 is a perspective view of a recapture sprayer according to an embodiment of the present disclosure;
FIG. 2 is a side view of a recapture sprayer according to an embodiment;
FIG. 3 is a front view of a recapture sprayer according to an embodiment;
FIG. 4 is an isometric top view of a recapture sprayer according to an embodiment; and
FIG. 5 is a perspective view of a recapture sprayer in use.
DETAILED DESCRIPTION
In the following description, reference is made to the accompanying drawings that form a part thereof, and in which is shown by way of illustration specific exemplary embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the concepts disclosed, and it is to be understood that modifications to the various disclosed embodiments may be made, and other embodiments may be utilized, without departing from the spirit and scope of the present disclosure. The following detailed description is, therefore, not to be taken in a limiting sense.
An objective of embodiments of the present disclosure is to apply a spray to a target object within a field of circulating air and recapture some of the spray while minimizing overspray, spill, and loss. Embodiments of the present disclosure comprise a powered or unpowered vehicle having spray nozzles, air pressure nozzles, and air inlet ports.
With reference to FIG. 1 , an embodiment of the present disclosure comprises vehicle 100 . In an embodiment, vehicle 100 comprises a non-self-propelled vehicle adapted for towing behind a tractor or similar self-propelled vehicle. In alternative embodiments, vehicle 100 comprises a self-propelled vehicle. Vehicle 100 may be adapted for use in orchards, fields, on-road, or other various environments.
Embodiments of the present disclosure comprise nose member 110 . Nose member 110 comprises multiple radially-distributed air vents 115 . Generally, air vents 115 comprise pass-through holes in nose member 110 in communication with an inner volume of nose member 110 , which comprises a plenum. Air vents 115 are targeted at multiple radially-distributed directions roughly perpendicular to a direction of travel of vehicle 100 . In alternative embodiments, air vents 115 are directed at points behind nose member 110 , such that an emitted flow of air may be directed at various outward and rearward angles relative to vehicle 100 . The embodiment depicted in FIG. 1 comprises approximately forty air vents 115 distributed roughly evenly around nose member 110 . Alternative embodiments may comprise other numbers of air vents 115 while still falling under the scope of the present disclosure. Plenum of nose member 110 is in fluid communication with an output port of primary blower 125 via primary blower outlet duct 130 . Primary blower inlet duct 135 is attached at an inlet port of primary blower 125 and comprises primary air intake vent 140 located at the rear of vehicle 100 . Primary air intake vent 140 comprises vent filter 145 . In embodiments of the present disclosure, a dust recapture system (not depicted) may be located within primary air intake vent 140 or primary blower inlet duct 135 .
The embodiment depicted in FIG. 1 further comprises side support beams 150 . Side support beams 150 comprise trestle members 155 . Near the rear of vehicle 100 , stanchions 160 support side support beams 150 and anchor side support beams 150 to vehicle 100 . Side support beams 150 support secondary air pipes 165 , which extend laterally beyond each side of vehicle 100 . In alternative embodiments, side support beams 150 are integrated with secondary air pipes 165 . For example, in an embodiment, side support beams 150 comprise a steel tube through which a flow of air may be carried. Secondary air pipes 165 comprise downturn pipes 170 at their lateral extremities, upon which secondary side vents 175 are attached. In the embodiment depicted in FIG. 1 , spray nozzles 180 are also attached on downturn pipes 170 and are connected to spray hose 185 , which provides fluid communication to a storage tank (not depicted). In an embodiment, the storage tank comprises an atomizer or other apparatus to convert liquid within the tank to an aerosol prior to transmitting the aerosol in a fluid stream through spray hose 185 . The storage tank may be installed on vehicle 100 or on a tow vehicle.
Secondary air pipes 165 are in fluid communication with an output port of secondary blower 190 via secondary blower outlet duct 195 . Secondary central vent 200 is also in communication with secondary blower outlet duct 195 . Secondary central vent 200 comprises a large nozzle having internal vanes adapted to create cyclonic air movement on a flow of air passing therethrough. Secondary blower inlet duct 205 is attached at an inlet port of secondary blower 190 and comprises fluid communication to secondary air intake vent 210 located behind nose member 110 near the front of vehicle 100 . In embodiments of the present disclosure, a filtration system (not depicted) may be located within secondary air intake vent 210 or secondary blower inlet duct 205 .
Alternative embodiments comprise additional spray nozzles 180 located at or near secondary air intake vent 210 and/or secondary central vent 200 . In alternative embodiments, functions served by primary blower 125 and/or secondary blower 190 may be fulfilled instead by one or more air compressors and/or air generators.
As depicted in FIGS. 1, 2, and 3 , vehicle 100 comprises two wheels 215 on an axle. In alternative embodiments, vehicle 100 additionally comprises one or two steerable or non-steerable front wheels. Vehicle 100 may be motivated by towing via tow hitch 220 . Alternatively, vehicle 100 comprises driven wheels and may thus be self-powered.
In operation, vehicle 100 is moved next to target objects 310 or one or two rows of target objects 310 where a spray application is intended. Referring now to FIG. 4 , Primary blower 125 may be activated to create a primary air system 300 . As a result, a first flow of air is ejected from air vents 115 and surrounds the vehicle 100 , forming a field that may be shielded from ambient air. The primary air system 300 may prevent ingress of bulk ambient air as vehicle 100 moves forward or ambient winds blow around or at vehicle 100 . Likewise, a substantially isolated field of circulating air may be maintained within the primary air system 300 , so as to minimize or reduce the potential for air that is circulating within the target space to drift out of the field. The first flow of air of the primary air system 300 passes around the outside of the vehicle 100 and is drawn into primary air intake vent 140 , before the first flow of air passes through primary blower 125 and is recirculated through air vents 115 . Primary air system 300 may comprise laminar air flow around the field of recirculating air.
Secondary blower 190 may be activated to create a secondary air system 305 . The secondary air system 305 comprises air circulating in the field encompassed within the primary air system 300 . A chemical spray, an aerosol, particular matter, and/or other like substance may be entrained within the secondary air system 305 . A secondary flow of air is ejected from secondary side vents 175 and secondary central vent 200 and circulated within the vicinity of vehicle 100 in the field surrounded by primary air system 300 . Air ejected from secondary central vent 200 may experience cyclonic mixing and circulation as caused by vanes within secondary central vent 200 . Air in the secondary air system 305 may be pulled into secondary intake vent 210 and pass through secondary blower inlet duct 205 to secondary blower 190 and be recirculated through secondary side vents 175 and secondary central vent 200 . Secondary air system 305 may comprise turbulent air flow within the field and around target objects 310 .
Spray nozzles 180 may emit a spray in liquid form, in aerosol form, as particulates entrained in a flow of air, or the like. Spray nozzles 180 may be adapted to emit an electrostatic spray. A pump may be activated to transmit the spray from a storage tank to spray nozzles 180 through spray hose 185 . In one embodiment, liquid stored in tank is converted to aerosol by an atomizer installed at or near the tank or at spray nozzles 180 . An aerosol may selectively be applied as spray if doing so might result in increased coverage on target objects 310 in comparison to liquid spray.
Spray may enter the secondary air system 305 and remain entrained therein as the air recirculates through the system. Alternate embodiments may not include spray nozzles 180 located at the secondary side vents 175 , but rather emit spray elsewhere into the secondary air system 305 . To apply a spray to a larger target object, volumetric air flows and air pressures may be increased to thereby increase the size of the field of recirculating air. Additionally, the size, direction, and number of air nose vents 115 may be altered to change the shape of the field of recirculating air.
Referring now to FIG. 5 , vehicle 100 may pass between rows of target objects 310 as primary blower 125 and secondary blower 190 create the primary air system 300 and secondary air system 305 (depicted in FIG. 4 ) and to thereby encompass the target objects 310 within the field of secondary air system 305 . Sprays may include pesticides, nutrients, fungicides, herbicides, defoliants, and the like, as desired. Due to the recirculation of the secondary air system 305 and the turbulent nature thereof, the spray entrained therein may contact target objects 310 at multiple angles and therefore may cover multiple surfaces, so that, for example, coverage may occur on both the top and the bottom of leaves. The speed of the vehicle 100 , whether towed by a tractor, other tow vehicle, or under self-power, may be typical of existing spray methods, which may typically be four to five miles per hour.
Alternative embodiments of the present disclosure may be utilized for spraying paint in automotive, aerospace, or like applications. Embodiments may be used for spraying de-icing spray in aerospace or like applications, spraying paint on road surfaces, or other applications wherein a spray may be applied to a target object.
In alternative embodiments of the present embodiment, vehicle 100 comprises curved skin surfaces at front and/or rear sections to improve laminar flow of primary air system 300 and to keep the primary air system 300 and secondary air system 305 from mixing with each other.
Systems and methods of the present disclosure may present numerous advantages over traditional spray technology and methods. Spray may be applied more precisely on target objects 310 , so that fewer nozzles may be used. Spray may be ejected at lower pressure, using lower volumetric airflow, and with less chemicals emitted than traditional methods. The recaptured and recycled spray in the secondary air system 305 may result in less wasted chemicals, thereby resulting in less chemical released into the atmosphere and less overall cost.
Another advantage is that systems of the present disclosure may be employed in fields even with overhead obstacles such as power lines since there is no large spray recapture shell. Another advantage is that embodiments of the present disclosure may be used in environments experiencing relatively strong side winds because the primary air system 300 may isolate the field enclosed therein.
Although the present disclosure uses terms of certain embodiments, other embodiments will be apparent to those of ordinary skill in the art having the benefit of this disclosure, including embodiments that do not provide all of the benefits and features set forth herein, which are also within the scope of this disclosure. It is to be understood that other embodiments may be utilized, without departing from the spirit and scope of the present disclosure.
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The present disclosure relates to a system and method for spraying one or more target objects. A primary blower system is adapted to create a relatively isolated field of circulating air by creating a primary air stream around the field of circulating air. A secondary blower system is adapted to circulate air within the isolated field by flowing a secondary air stream in directions contrary to the primary air stream. A chemical spray comprising liquid, aerosol droplets, particulate matter, or the like may be emitted into the circulating air within the field and thereby deposited on target objects within the field. Embodiments of the present disclosure may be used for agricultural, automotive, aerospace, and other applications to emit, contain, and/or recapture a spray.
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RELATED APPLICATION
This application is based on a further development of the invention disclosed in prior appication Ser. No. 89,320, filed Oct. 30, 1979, by means of which a fail-safe feature is added. The fail-safe feature is not restricted to such use, but is of general utility.
THE DRAWINGS
FIG. 1 is a box diagram showing how the logic of the temperature control system operates.
FIG. 2 is a circuit diagram of the heater resistor energizing and deenergizing portion of the system.
FIG. 3 is a circuit diagram of the portion of the system which responds to temperature to control the heater energization and deenergization portion of the system. Included in FIG. 3 is the tracking, runaway and shut down circuitry which ensures fail-safe operation.
FIG. 4 is a circuit diagram of the digital read out circuitry which displays the value of the temperature.
FIG. 5 shows how the present invention is utilized in an inhalation heater control system.
SUMMARY
Electric heating temperature control systems utilize temperature sensing means to control the heating. Thermistors are often used as the temperature sensing means since they have a steep resistance versus temperature characteristics, which permits the use of control circuits having lesser amplification than would be required if, say, a thermocouple or a platinum resistance thermometer were used. Thermocouples are midway, in sensitivity, between thermistors and platinum resistance thermometers. However, thermistors, comprising a composition, are not as stable as thermocouples and thermocouples are not as stable as a platinum resistance thermometer. That is, the thermistor (or thermocouple) can drift, with the result that the control circuitry stabilizes and nulls the circuit when an improper temperature has been achieved.
Drift in an electric temperature control system is not always acceptable. For example, when an unconscious non-breathing patient is kept alive in an intensive care unit by having a warmed air-oxygen-moisture mixture periodically forced into his lungs through an intubation tube, lodged air-tight in his trachea by means of an inflated cuff, it is imperative that the ventilating mixture be at a predetermined temperature. A departure from that temperature could be life-threatening.
Accordingly, a fail-safe assurance means is added to an electric temperature control system whereby, when the controlled temperature drifts away from its predetermined value, an alarm is given and the electric heating system is deenergized.
The fail-safe assurance means utilizes a pair of temperature sensors, located adjacent each other in the heated zone, to sense the temperature of the same locus. If the temperature sensors are operating correctly, the resulting electric signals, indicative of temperature, should be either identical or within a tolerance range from each other. The difference, if greater than the tolerance, is used to raise an alarm and shut down the electric heating system.
DETAILED DESCRIPTION
The block-diagram of FIG. 1 sets forth the concept behind the invention. An electric heater 1 supplies heat to a heated region 2. The desired temperature is set in adjustor 3 to produce a selected voltage, indicative of the desired temperature, on conductor 4. A temperature sensing means 5 in the heated region produces a voltage on conductor 6 indicative of the actual temperature. The voltages on conductors 4 and 6 are subtracted in comparer 7 to produce an algebraic difference signal on conductor 8. The said signal is an algebraic one because the sign of the signal indicates whether the voltage on conductor 4 is more positive than that on conductor 6, or vice versa.
The algebraic difference signal is applied to the amplitude responsive circuit 9 to produce an output on conductor 10 which controls the operation of electric heater 1. An anti-hunt circuit 11 may be provided when the electric heater or the heated region has a high thermal inertia. The control of electric heater 1 over the feedback logs 7, 8, 9, 10 and 11, as thus described, is in accordance with well known practice and need not be further elaborated.
The electric heater 1, when everything is working properly, will be running at a higher temperature than desired for the heated region 2, since heat flows from the heater 1 to the heated region 5 only because of a temperature difference. However, if electric heater 1 gets very hot, something is wrong, as normally the electric heater is only moderately hotter than the heated region.
Accordingly, a temperature limiting system is provided to limit the maximum temperature of the heater itself. This comprises a temperature sensing means 12 which is built into the electric heater itself. An adjuster 14 produces a voltage indicative of the permissible temperature limit on conductor 15, and this voltage is subtracted from the voltage on conductor 17, the voltage of which is indicative of the temperature of the electric heater 1. The voltages on conductors 15 and 17 are compared in comparer 16. The resulting algebraic difference signal appears on conductor 18, and is applied to amplitude circuit 19, which produces an output on shut-down conductor 20. When an output appears on shut-down conductor 20, an alarm 21 is activated and the electric heater 1 is disconnected from its energy source by the input control at 22.
In order to give fail-safe assurance that the temperature of heated region 2 is at the desired temperature, the temperature sensing means 5, previously described, is duplicated at 23. Temperature sensing means 5 and 23 are closely adjacent and will therefore sense the same temperature. If all is well, the voltage, indicative of temperature, on conductor 6 will be identical to that on the corresponding conductor 24. If one of the temperature sensing means 5 or 24 has drifted from its original characteristic, then the voltages on conductors 6 and 24 will differ. The voltages on conductors 6 and 24 are applied to absolute difference circuit 25 to produce on conductor 26 a voltage which increases monotonically from zero with either a positive or negative departure from zero of the difference in the voltages on conductors 6 and 24.
Thus, if one of the temperature sensing means drifts and the other is stable, it does not matter whether it is 5 or 23 which drifts, and it does not matter whether the drift is positive or negative--in any of these instances, the voltage on conductor 26 is a measure of the drift. That voltage is applied to amplitude circuit 27, and, if too large, will produce an output which appears on shutdown conductor 20 to activate alarm 21 and cut off the electric heater 1 at 22.
An exemplary wiring diagram of one embodiment of the invention is seen in FIGS. 2, 3 and 4. These Figures must be read together, as each shows a portion of the circuit. The way the Figures are interconnected will be apparent, especially from the legends, to those skilled in the art.
In FIG. 2 the heater resistor 30 is encased in a heater block 31, which also includes thermal fuse 32 and thermistor 33. The heater resistor 30 is energized from electric power plug 34 through an obvious circuit, including on-off switch 35 and triac 36. The triac 36 is a four layer PNPN device which normally is non-conducting to the AC voltage, but can be triggered by its gate 37 to be conductive. When heat is called for by the control system, to be described, the gate is pulsed once during each cycle of the alternating current by optically coupled triac 38a, which is activated by its integral light emitting diode 38b of FIG. 3. Thus, when the LED 38b lights up, triac 38a becomes conductive, which puts the required voltage on gate 37 of triac 36 needed to render the triac 37 conductive. This energizes the heater resistor 30.
Should the heater resistor 30 run away through some malfunction, the excess temperature is sensed be thermistor 33, which reduces its resistance between terminal B and chassis ground, to activate a shut-down circuit in FIG. 3, to be described. Should the heater resistor continue to increase further in temperature, the thermal fuse 32 will blow, completely disconnecting the heater resistor from electric power. The remainder of the circuitry of FIG. 2 relates to the bias power supplies, which need not be further described, being conventional.
In FIG. 3 there are two thermistors, corresponding to the temperature sensing means 5 and 23 of FIG. 1. Thermistor 40 controls the intermittant energization of heater resistor 30 of FIG. 2 while thermistor 41 is a tracking thermistor to sense excessive drift in the characteristics of the thermistor.
Thermistor 40 receives a bias current through an obvious circuit from bias supply conductor 42. As the temperature rises, the resistance of thermistor 40 falls, so the positive voltage at the output voltage follower amplifier 43 is inversely related to temperature. This output is directly utilized to control the digital temperature read-out indicator of FIG. 4, to be described. This output is also applied to the non-inverting input of differential amplifier 44, wherein it is compared with the voltage supplied by the temperature setting potentiometer 45 and voltage follower 46.
The voltage output of differential amplifier 44 is applied to the inverting input of differential amplifier 47.
Differential amplifier 47 is not supplied with any feedback circuit, and its gain is very large. Therefore, the output of differential amplifier 47 will tend to go to the extreme voltages of the bias supply or chassis ground, since the output will either saturate or be cut off when the two inputs are not almost identically equal.
It will be seen that, as the temperature of thermistor 40 climbs, the output of differential amplifier 47 has a tendency to go positive.
The non-inverting input of differential amplifier 47 is supplied with a saw tooth wave by saw tooth oscillator 48. The output from differential amplifier 47 will therefore be a pulse-width modulated pulse wave whose positive excursions will be of greater duration when the thermistor 40 is warmer.
When the output of differential amplifier is high, the voltage of the output will buck the bias voltage supply conductor 42 and the light emitting diode 38b will go out. LED 38b controls triac 38a of FIG. 2 and ultimately the heating of heater resistor 30.
It will be seen that the pulse-width modulated output of differential amplifier 47 makes the feedback system described a proportional control type, in which the correction applied is proportional to the departure sensed. Such a system, especially when the thermal inertia of the heater block 31 is low, is much freer from unwanted cycling and hunting than would be a system not using proportional control, such as an all heat on or all heat off system.
A green light emitting diode 49 is energized whenever the heater resistor 30 is energized. LED 49 thus winks on and off, at the frequency of the saw tooth oscillator 48, whenever the system is operating in a stable state.
Tracking thermistor 41 receives a bias current through an obvious circuit from bias supply conductor 42, and controls the voltage applied to the inverting input of differential amplifier 61 through voltage follower 60. This voltage is compared in differential amplifier 61 with a voltage, derived from temperature setting potentiometer 45, which is applied to the noninverting input. The resulting output of differential amplifier 61 is a voltage which varies linearly with the departure of the temperature sensed by thermistor 41 from that set by the temperature setting potentiometer 45. The steepness of the output characteristic slope is determined, in part, by the value of the feedback resistors 62, which will in turn affect the sensitivity of the tracking alarm, to be described.
The output of differential amplifier 61 is applied to the midpoint of a signal drift detector comprising a voltage divider which includes identical Zenner diodes 63 and 64 and identical resistors 65 and 66. The Zenner diodes each have a breakdown voltage of slightly more than half of the voltage on bias supply conductor 42.
Accordingly, when the output voltage of differential amplifier 61 is midway between the bias voltage and ground, neither of the Zenner diodes 63 or 64 will conduct. If the output of differential amplifier 61 goes more positive, Zenner diode 64 conducts, causing conductor 67 to go positive; if the output goes more negative, Zenner diode 63 conducts, causing conductor 68 to go more negative.
Bearing in mind the phase inversion from base to collector of transistor 70, it is apparent that either the just mentioned negative going voltage excursion on conductor 68 or the just mentioned positive going voltage excursion on conductor 67 will cause transistor 71 to conduct, thereby causing the audio alarm 72 to sound and the red light emitting diode 73 to light up.
Thus, if the output voltage of differential amplifier 61 wanders significantly from a value half way between bias voltage and chassis voltage, the signal drift detector will cause the audio alarm 72 to sound.
When the audio alarm 72 sounds, the red LED 73 will signal "danger". Furthermore, the low voltage at the collector of transistor 71 will, through diode 74, pull down the voltage of shut down bus 75, thereby turning off the electric heat at the inverting input of differential amplifier 47 through the same optical control switch 38 as hereinbefore described.
In the event there is a heat runaway, the thermistor 33 of FIG. 2 will signal run-away circuit 76 of FIG. 3 to cause a low output on conductor 77. This also will pull down the potential of shut down bus 75, to turn off the electric heat.
At this point it is well to point out a difference between the concept of FIG. 1 and the embodiment of FIG. 3. In FIG. 1 the comparison is made directly between two measurements of temperature in the critical region. In FIG. 3 the comparison is made of the desired temperature and the actual temperature. However, the overall result is the same, since in either instance a redundant temperature sensing means is used to ensure the accuracy of a non-redundant one which is used to directly control an electric heater. This illustrates the alternate ways the invention may be carried out.
When the audio alarm 74 sounds, if someone comes to cure the problem it is often desirable to be able to temporarily disable the alarm for a period of time long enough to permit repairs or other appropriate action. This is done by pressing the push button of the audio alarm disable circuit 80. That circuit includes a blocking oscillator and counter which, for a measured length of time, pulls the voltage on conductor 81 down. The low voltage on conductor 81 will turn on the transistor 82 to light up the yellow light emitting diode 83. The yellow "caution" indication will warn that the alarm is disabled. The low voltage on conductor 81 will also, through isolating diode 84 and transistor 71 turn off the audio alarm 72 and red LED 73. Thus, the yellow "caution" indication has been substituted for the red "danger" signal.
However, it is important to note that, when the audio alarm 72 is disabled, the shut down bus 75 is unaffected because of isolation supplied by diode 74. Thus, the electric heater resistor 30 can potentially still be turned off by an appropriate voltage applied to the inverting input of differential amplifier 47.
FIG. 4 shows the circuitry of the digital temperature display. The analog voltage from the output of voltage follower 43 of FIG. 3 is applied to analog to digital converter 88, which controls decoder driver 89, which controls the display device 90. The remainder of the circuitry need not be further explained since it will be apparent to those skilled in the art. The Figure is exemplary, for in many applications a display of tenths of a degree would be required.
FIG. 5 illustrates an actual application of the invention. An unconscious patient 100 is being intubated with a tracheal tube 101, retained in place by cuff 102. The patient's lungs are ventilated by a respirator through inhalation hose 104, exhalation hose 105 and wye 106. Two thermistors, 107 and 108, in the inhalation passage, correspond to the thermistors 40 and 41 of FIG. 3. The thermistor 109 has a use, not relevant to the present invention, which is explained in the above-identified copending application.
Many other applications are evident.
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In a system in which temperature control of a heated region is critical, assurance means of fail-safe nature are provided to guard against improper temperature. An example wherein temperature is critical is: the artificial ventilation of an unconcious patient's lungs by periodically inspired heated gas under pressure. The assurance means includes dual thermometers which sense the actual temperature in the heated region. The actual temperature is compared with the desired temperature to control an electric heater, which, when energized, increase the temperature of the heated region. Furthermore, the temperatures, as sensed by the two thermometers, are compared with each other. If the difference exceeds a predetermined limit, an alarm is given and the heating system is shut down.
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CROSS-REFERENCE TO RELATED APPLICATIONS, IF ANY
This application claims the benefit under 35 U.S.C. §119(e) of now abandoned provisional application Ser. No. 60/106,896, filed Nov. 3, 1998. Application Ser. No. 60/106,896 is hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
REFERENCE TO A MICROFICHE APPENDIX, IF ANY
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for hanging an air handling duct, and more particularly, to a duct hanging bracket device that easily fastens to both the duct and support structure.
2. Background Information
Air handling ducts are commonly made from sheet metal and are used to transfer air to and from heating and cooling devices. The air handling ducts, commonly called heating, ventilation and air conditioning (HVAC) ducts, are generally positioned along the underside of floors or ceilings in residential and commercial structures. This position allows for enclosing the ducts for a more pleasing appearance. The ducts are hung from the overhead support structure, such as ceiling or floor joists, using some type of hanger device. Often the installer merely uses pieces of sheet metal to hang the duct from the joists. The fashioning of these hanging strips can be quite time consuming. Consequently, there is a need for a preformed duct hanging member that is easy to install and provides secure fastening of the duct work to the overhead support structure.
Some examples of inventions for hanging duct work have been granted patents. Hoffman, in U.S. Pat. No. 2,889,145, describes an adjustable hanger apparatus for supporting hot air ducts. Reuter, in U.S. Pat. No. 3,017,174, discloses an air duct jack used for installing duct work. Bogret, in U.S. Pat. No. 3,263,388, and Liberman in U.S. Pat. No. 3,734,436, disclose hangers for installing ceiling tile grid work. Herb, in U.S. Pat. No. 3,863,879, discloses a hanger device for mounting a ceiling air terminal A variety of hangers and supports for duct work and piping are shown in U.S. Pat. No. 3,960,350 by Tardoskegyi, in U.S. Pat. No. 4,077,592 by Forbes and in U.S. Pat. No. 5,350,141 by Perrault et al. In U.S. Pat. No. 4,787,592 Aoshika describes a device for hanging duct work or piping, including an anchor embedded in the ceiling of a building. None of these patents disclose or suggest the duct hanging bracket of the present invention.
SUMMARY OF THE INVENTION
The invention is a duct hanging bracket member for supporting a duct member. The bracket member comprises a generally planar elongated linear segment with first and second ends, having a first leg section positioned at the linear segment first end and disposed essentially perpendicular thereto, with an aperture centrally position there through. A second leg section is positioned at the linear segment second end and disposed essentially perpendicular thereto and in opposition to the first leg section. The second leg section has an aperture centrally positioned there through, as well. A stop means is secured to the linear segment first end and disposed essentially perpendicular thereto, and in opposition to the first leg section. The stop means is oriented parallel to the second leg section and in spaced apart relation therefrom. The stop means and the second leg section are spaced to accept a duct member there between. The bracket member is secured to a support surface with a fastener positioned in the first leg section aperture, and a duct member positioned adjacent the elongated linear section is supported and secured by the stop means and the second leg section with a fastener positioned in the second leg section aperture. Additional apertures in the elongated linear segment are provided for additional fasteners to secure the duct to the bracket member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of an HVAC duct hung from overhead joists by the invention duct hanging brackets.
FIG. 2 is an end view of an HVAC duct hung from overhead members.
FIG. 3 is a perspective view of the preferred embodiment of the duct hanging bracket invention.
FIG. 4 is a front elevation of the preferred embodiment of the invention.
FIG. 5 is a side plan view of the preferred embodiment of the invention.
FIG. 6 is a perspective view of an alternate embodiment of the duct hanging bracket invention.
FIG. 7 is a perspective view of a simplified alternate embodiment of the invention.
FIG. 8 is a perspective view of another alternate embodiment of the invention.
FIG. 9 is a perspective view of another alternate embodiment of the invention.
FIG. 10 is a perspective view of another alternate embodiment of the invention which may be molded from plastic, this embodiment being also shown in design Pat. No. Des. 405,348.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Nomenclature
2 HVAC Duct
4 Duct Hanging Bracket Member
6 Upper End of Bracket Member
8 Joist
9 Fastener
10 Elongated Linear Segment of Bracket Member
12 First End of Bracket Member
13 Second End of Bracket Member
14 First Leg Section of Bracket Member
15 Aperture in First Leg Section
16 First Segment of First Leg Section
17 Aperture in Second Leg Section
18 Stop Member
19 Aperture in Elongated Linear Segment
21 Aperture in Elongated Linear Segment
22 Second Leg Section of Bracket Member
23 Slot in Elongated Linear Segment
104 Duct Hanging Bracket Member
110 Elongated Linear Segment of Bracket Member
112 First End of Bracket Member
113 Second End of Bracket Member
114 First Leg Section of Bracket Member
115 Aperture in First Leg Section
117 Aperture in Second Leg Section
118 L-Shaped Stop Member
119 Aperture in Elongated Linear Segment
120 Leg Section and Stop Assembly
121 Aperture in Elongated Linear Segment
122 Second Leg Section of Bracket Member
204 Duct Hanging Bracket Member
210 Elongated Linear Segment of Bracket Member
212 First End of Bracket Member
213 Second End of Bracket Member
214 First Leg Section of Bracket Member
215 Aperture in First Leg Section
217 Aperture in Second Leg Section
218 Aperture in Elongated Linear Segment
221 Aperture in Elongated Linear Segment
222 Second Leg Section of Bracket Member
304 Duct Hanging Bracket Member
310 Elongated Linear Segment of Bracket Member
312 First End of Bracket Member
313 Second End of Bracket Member
314 First Leg Section of Bracket Member
315 Aperture in First Leg Section
317 Aperture in Second Leg Section
318 V-Shaped Stop Member
319 Aperture in Elongated Linear Segment
320 Leg Section and Stop Assembly
321 Aperture in Elongated Linear Segment
322 Second Leg Section of Bracket Member
404 Duct Hanging Bracket Member
410 Elongated Linear Segment of Bracket Member
412 First End of Bracket Member
413 Second End of Bracket Member
414 First Leg Section of Bracket Member
415 Aperture in First Leg Section
417 Aperture in Second Leg Section
418 U-Shaped Stop Member
419 Aperture in Elongated Linear Segment
421 Leg Section and Stop Assembly
421 Aperture in Elongated Linear Segment
422 Second Leg Section of Bracket Member
504 Duct Hanging Bracket Member
510 Elongated Linear Segment of Bracket Member
512 First End of Bracket Member
513 Second End of Bracket Member
514 First Leg Section of Bracket Member
515 Aperture in First Leg Section
517 Aperture in Second Leg Section
518 Stop Member
519 Aperture in Elongated Linear Segment
520 Leg Section and Stop Assembly
521 Aperture in Elongated Linear Segment
522 Second Leg section of Bracket Member
Construction
FIGS. 1 and 2 illustrate a heating, ventilation and air conditioning (HVAC) duct 2 which is suspended by the preferred embodiment of the duct hanging bracket member 4 . Each side of the HVAC duct 2 is provided with a duct hanging bracket member 4 which is fixed at its upper end 6 to the underside of a joist 8 by one or more fasteners 9 , such as a screw or nail.
FIGS. 3, 4 , and 5 illustrate the preferred embodiment of the duct hanging bracket member 4 . The bracket member 4 includes an elongated linear segment 10 which is deployed in a substantially vertical orientation when the duct hanging bracket member 4 is employed to suspend an HVAC duct 2 . The bracket member 4 has a first end 12 and a second end 13 . At the first end 12 of the elongated linear segment 10 is formed a first leg section 14 which comprises a first segment 16 disposed at a substantial perpendicular from the axis of elongated linear segment 10 . A first aperture 15 is provided centrally in the first leg section 14 for entry of a fastener 9 , such as a screw, there through. The fastener 9 secures the bracket member first end 12 to a joist 8 or similar support surface.
The second end 13 of the elongated linear segment 10 opposes the first end 12 thereof and has affixed thereto a second leg section 22 which extends at a perpendicular from the second end 13 of elongated linear segment 10 . The second leg section 22 is linear and extends in a direction from elongated linear segment 10 which opposes the direction of the first leg section 14 from the elongated linear segment 10 . A second aperture 17 through the second leg section 22 is provided to permit another fastener, such as a sheet metal screw, to be passed through the aperture 17 and be affixed to a duct sidewall, thereby securing the bracket member second leg section 22 to the HVAC duct 2 .
A stop member 18 , such as a tab or a shelf, is mounted to elongated linear segment 10 to extend therefrom generally in parallel to the second leg section 22 . The stop member 18 is spaced from the top of the bracket member second leg section 22 a distance substantially equal to the height of the HVAC duct 2 to be suspended by the duct hanging bracket member 4 . In the preferred embodiment, the bracket member 4 is fabricated from sheet metal, and the stop member 18 is formed by punching it from the middle portion of elongated linear segment 10 , although other means of mounting or forming the stop member 18 are contemplated, such as attachment by welding, adhesives or by fasteners. A slot 23 remains in the elongated linear section 10 after the stop member 18 is formed. The stop member 18 functions to abut the top of the HVAC duct 2 to be suspended by the duct hanging bracket member 4 . The stop member 18 resists the upward displacement of the HVAC duct 2 when a fastener, such as a sheet metal screw, is driven into the bottom of the HVAC duct after passing through the preformed second aperture 17 . Additionally, third and fourth apertures 19 and 21 are formed in the elongated leg section segment 10 between the stop member 18 and the second leg section 22 to provide openings for additional fasteners, such as sheet metal screws, to fasten the duct hanging bracket member 4 to the HVAC duct 2 .
FIG. 6 discloses an alternate embodiment of the invention wherein the HVAC duct hanging bracket member 104 includes a planar, elongated vertical segment 110 having a first end 112 and a second end 113 . A combined leg and stop assembly 120 is fastened to the first end 112 of the vertical segment 110 . The leg and stop assembly 120 includes an L-shaped stop member 118 fastened perpendicularly at one end to the elongated segment first end 112 , with a first leg section 114 fastened perpendicularly at the other end of the L-shaped stop member 118 , with the first leg section 114 extending beyond the extended plane of the elongated vertical segment 110 . A first aperture 115 is provided at one end of the first leg section 114 for entry of a fastener to secure the bracket member first end 112 to a joist or similar support surface.
A second leg section 122 extends at a perpendicular from the second end 113 of the elongated linear segment 110 , and is essentially parallel to the leg of the L-shaped stop member 118 fastened to the linear segment first end 112 . A second aperture 117 through the second leg section 122 is provided to permit another fastener, such as a sheet metal screw, to be passed through the aperture 117 and be affixed to a duct sidewall, thereby securing the bracket member second leg section 122 to the HVAC duct 2 . Apertures 119 and 121 in the elongated linear segment 110 are provided for further mounting the duct hanging member 104 to the sidewall of a duct being hung, while the aperture 117 centrally located in the second leg section 122 provides an opening for a sheet metal screw to pass though and engage the lower wall of the duct to be hung. The stop member 118 provides a stop for the top of the duct to be hung to facilitate entry of a sheet metal screw into the bottom of the duct 2 .
The distance between the bracket member second leg section 122 and the stop member 118 is substantially equal to the height of the HVAC duct 2 to be suspended by the duct hanging bracket member 104 . Again, the bracket member 104 is preferably fabricated from sheet metal for strength, durability, and ease of manufacture.
FIG. 7 shows a simplified alternative embodiment of the duct hanging member 204 wherein an elongated vertical segment 210 is provided with a first leg section 114 at its first end 212 and a second leg section 222 at its second end 213 . The first leg section 214 and second leg section 222 are each perpendicular to the elongated vertical segment 210 and extend therefrom in opposing directions. Each leg section 214 , 222 has a centrally located aperture 215 , 217 , respectively, for securing the bracket member 204 to a support surface and the duct to be hung. Apertures 219 and 221 are provided for further mounting the duct hanging member 204 to the sidewall of a duct being hung, while the aperture 217 , centrally located in the second leg section 222 , provides an opening for a sheet metal screw to pass though and engage the lower wall of the duct to be hung. In this embodiment, the bracket member 204 is sized to hold the HVAC duct 2 tightly against the joist 8 or other support surface. Again, the bracket member 204 is preferably fabricated from sheet metal for strength, durability, and ease of manufacture.
FIG. 8 discloses another alternate embodiment of the duct hanging member 304 . The elongated vertical segment 310 is connected to the combined leg and stop assembly 320 , similar to the assembly 120 described for FIG. 6 . In this embodiment, the stop member 318 is V-shaped and composed of two sections joined at an acute angle. The first leg section 314 extends beyond the extended plane of the elongated vertical segment 310 . A first aperture 315 is provided at one end of the first leg section 314 for entry of a fastener to secure the bracket member first end 312 to a joist or similar support surface.
A second leg section 322 extends at a perpendicular from the second end 313 of the elongated linear segment 310 , and is essentially parallel to the leg of the V-shaped stop member 318 fastened to the linear segment first end 312 . A second aperture 317 through the second leg section 322 is provided to permit another fastener, such as a sheet metal screw, to be passed through the aperture 317 and be affixed to a duct sidewall, thereby securing the bracket member second leg section 322 to the HVAC duct 2 . Apertures 319 and 321 are provided for further mounting the duct hanging member 304 to the sidewall of a duct being hung, while the aperture 317 centrally located in the second leg section 322 provides an opening for a sheet metal screw to pass though and engage the lower wall of the duct to be hung. The stop member 318 provides a stop for the top of the duct to be hung to facilitate entry of a sheet metal screw into the bottom of the duct 2 .
The distance between the bracket member second leg section 322 and the stop member 318 is substantially equal to the height of the HVAC duct 2 to be suspended by the duct hanging bracket member 304 . Again, the bracket member 304 is preferably fabricated from sheet metal for strength, durability, and ease of manufacture.
FIG. 9 illustrates another embodiment of the duct hanging member 404 invention. The duct hanging member 404 comprises an elongated linear segment 410 jointed to a second leg section 422 at the second end 413 thereof At the first end 412 of the elongated linear segment 410 is attached the leg and stop member assembly 420 . The stop member 418 comprises a U-shaped member interposed between the linear segment first end 412 and the first segment 416 of the first leg section 414 attached thereto. The first and second leg sections 414 , 422 are oriented perpendicular to the elongated linear segment 410 and in opposition to each other. The U-shaped stop member 418 is in spaced relationship from the second leg section 422 so as to accommodate a HVAC duct 2 there between. The first and second leg sections each have an aperture 415 , 417 , respectively. The first leg section aperture 415 is used to fasten the bracket member 404 to an overhead support surface, while the second leg section aperture 417 functions to fasten a HVAC duct 2 lower wall to the bracket member 404 . Additional apertures 419 , 421 are provided in the elongated linear segment 410 for additional fasteners to secure the duct 2 to the bracket member 404 . Again, the bracket member 404 is preferably fabricated from sheet metal for strength, durability, and ease of manufacture.
The duct hanging bracket members 104 , 304 , and 404 are preferably fabricated from sheet metal by stamping and forming a single linear piece into the respective configurations shown. This method of manufacture allows the intricate structure of the combined leg and stop member assemblies 120 , 320 and 420 respectively, to be formed from the first end of the planar elongated linear segment of each of these bracket members.
FIG. 10 illustrates a duct hanging member 504 , which may be molded of polymeric resin or plastic material. The hanging member 504 comprises an elongated linear segment 510 with a first leg section 514 perpendicularly formed at one end and a second leg section 522 perpendicularly formed at an opposite end. The two leg sections 514 , 522 are oriented in opposition to each other, and each contains a centrally located aperture 515 , 517 for a fastener. Adjacent the first leg section 514 is a stop member 518 oriented essentially perpendicular to the elongated linear segment 510 and in opposition to the first leg section 514 . The stop member 518 resists the upward displacement of the HVAC duct 2 when a fastener, such as a sheet metal screw, is driven into the bottom of the HVAC duct 2 after passing through the preformed second aperture 517 . Additionally, third and fourth apertures 519 and 521 are formed in the elongated leg section segment 510 between the stop member 518 and the second leg section 522 to provide openings for additional fasteners, such as sheet metal screws, to fasten the duct hanging bracket member 504 to the HVAC duct 2 . The plastic composition of this bracket member 504 provides for light weight with ease in handling and installation without concern for cuts and abrasions that can occur when using brackets made of sheet metal.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention.
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A duct hanging bracket device that easily fastens to both an air handling duct and a support structure is disclosed. The device includes an elongated linear segment with opposing parallel legs at each end. The legs each have an aperture, one for fastening to the duct and the other for fastening to the support surface. A stop member is spaced from one leg, such that the duct fits between the leg and the stop member, allowing for easy fastening of the duct to the leg.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for making a stackable package, and more particularly to a method for making a stackable package having a redistribution layer and a through via.
[0003] 2. Description of the Related Art
[0004] FIG. 1 shows a cross-sectional view of a conventional stackable package. The conventional stackable package 1 comprises an interposer 10 and a chip 20 . The interposer 10 comprises a body 11 , a plurality of through vias 12 , a plurality of conductive traces 13 , a plurality of pads 14 and a plurality of solder balls 15 . The body 11 has a first surface 111 and a second surface 112 . The through vias 12 penetrate through the body 11 , and are exposed to the first surface 111 and the second surface 112 . The conductive traces 13 are disposed on the first surface 111 of the body 11 , and electrically connected to the through vias 12 . The pads 14 are disposed on the second surface 112 of the body 11 , and electrically connected to the through vias 12 . The solder balls 15 are disposed on the pads 14 . The chip 20 is disposed on the interposer 10 . The chip 20 comprises a plurality of chip pads 21 and a plurality of bumps 22 . The bumps 22 are disposed between the chip pads 21 and the conductive traces 13 , and the chip 20 is electrically connected to the interposer 10 by the bumps 22 .
[0005] The conventional stacked package 1 has the following disadvantages. The chip 20 of the conventional stacked package 1 is electrically connected to exterior elements by the interposer 10 . However, the interposer 10 increases the thickness of the product, and the manufacturing processes of the interposer 10 is too complicated, so that the manufacturing cost is increased. Moreover, the gap between the bumps 22 of the chip 20 is too small, so that an underfill (not shown) is difficult to be formed therein to encapsulate the bumps 22 .
[0006] Therefore, it is necessary to provide a method for making a stackable package to solve the above problems.
SUMMARY OF THE INVENTION
[0007] The present invention is directed to a method for making a stackable package. The method comprises the following steps: (a) providing a first carrier having a surface; (b) disposing at least one chip on a surface of the first carrier, wherein the chip comprises a first surface, a second surface, an active circuit layer and at least one conductive via, the active circuit layer is disposed in the chip and exposed to the second surface, the conductive via is disposed in the chip and connected to the active circuit layer; (c) forming a molding compound on the surface of the first carrier, so as to encapsulate the chip, wherein the molding compound comprises a surface attached to the surface of the first carrier; (d) removing the first carrier, so as to expose the second surface of the chip and the surface of the molding compound; (e) forming a first redistribution layer (RDL) and at least one first bump, wherein the first redistribution layer (RDL) is disposed on the second surface of the chip and the surface of the molding compound, and electrically connected to the conductive via by the active circuit layer, the first bump is disposed on the first redistribution layer (RDL), and electrically connected to the active circuit layer and the conductive via by the first redistribution layer (RDL); (f) providing a second carrier; (g) disposing a surface of the first redistribution layer (RDL) on the second carrier; (h) removing part of the chip and part of the molding compound, so as to expose the conductive via to the first surface of the chip, and form a through via; (i) forming a second redistribution layer (RDL) on the first surface of the chip, wherein the second redistribution layer (RDL) is electrically connected to the through via; and (j) removing the second carrier.
[0008] The present invention is further directed to a method for making a stackable package. The method comprises the following steps: (a) providing a first carrier having a surface; (b) disposing at least one chip on a surface of the first carrier, wherein the chip comprises a first surface, a second surface and an active circuit layer, the active circuit layer is disposed in the chip and exposed to the second surface; (c) forming a molding compound on the surface of the first carrier, so as to encapsulate the chip, wherein the molding compound comprises a surface attached to the surface of the first carrier; (d) removing the first carrier, so as to expose the second surface of the chip and the surface of the molding compound; (e) forming a first redistribution layer (RDL) and at least one first bump, wherein the first redistribution layer (RDL) is disposed on the second surface of the chip and the surface of the molding compound, and electrically connected to the active circuit layer, the first bump is disposed on the first redistribution layer (RDL), and electrically connected to the active circuit layer by the first redistribution layer (RDL); (f) providing a second carrier; (g) disposing a surface of the first redistribution layer (RDL) on the second carrier; (h) removing part of the chip and part of the molding compound; (i) forming at least one through via in the chip, wherein the through via is connected to the active circuit layer and exposed to the first surface of the chip; (j) forming a second redistribution layer (RDL) on the first surface of the chip, wherein the second redistribution layer (RDL) is electrically connected to the through via; and (k) removing the second carrier.
[0009] Therefore, the second redistribution layer enables the stackable package to have more flexibility to be utilized. Moreover, the through via is formed in the chip, and electrically connected to the first redistribution layer (RDL), and an extra element is unnecessary. As a result, the manufacturing cost and the size of the product are reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a cross-sectional view of a conventional stackable package;
[0011] FIG. 2 is a flow chart of a method for making a stackable package according to a first embodiment of the present invention;
[0012] FIGS. 3 to 9 are schematic views of the method for making a stackable package according to the first embodiment of the present invention;
[0013] FIG. 10 is a flow chart of a method for making a stackable package according to a second embodiment of the present invention;
[0014] FIGS. 11 to 18 are schematic views of the method for making a stackable package according to the second embodiment of the present invention; and
[0015] FIGS. 19 to 20 are schematic views showing the application of a stackable package according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0016] FIG. 2 shows a flow chart of a method for making a stackable package according to a first embodiment of the present invention. First, as shown in FIG. 3 and step S 21 , a first carrier 31 is provided. The first carrier 31 has a surface 311 . As shown in step S 22 , at least one chip 32 is disposed on the surface 311 of the first carrier 31 . The chip 32 comprises a first surface 321 , a second surface 322 , an active circuit layer 323 and at least one conductive via 326 . The active circuit layer 323 is disposed in the chip 32 , and exposed to the second surface 322 . The conductive via 326 is disposed in the chip 32 , and connected to the active circuit layer 323 .
[0017] In this embodiment, the chip 32 is a known-good die, and the second surface 322 of the chip 32 is adhered to the surface 311 of the first carrier 31 by an adhesive 33 . Moreover, the chip 32 further comprises at least one hole 325 . The conductive via 326 comprises a first insulating layer (not shown) and a conductor (not shown). The first insulating layer is disposed on a side wall of the hole 325 , and defines a first groove (not shown). The conductor fills up the first groove. However, in other embodiments, a second chip (not shown) can be disposed side by side with the chip 32 on the surface 311 of the first carrier 31 , and the second chip is also a known-good die. It is understood that, the form of the second chip has no limitation, and the second chip can comprise a conductive via or not. Moreover, the conductive via 326 can further comprise a second insulating layer (not shown). The conductor is only disposed on a side wall of the first groove, and defines a second groove (not shown), and the second insulating layer fills up the second groove. In the present invention, only when the chip 32 is a known-good die, the chip 32 can be disposed on the first carrier 31 , therefore the yield rate is increased.
[0018] As shown in FIG. 4 and step S 23 , a molding compound 34 is formed on the surface 311 of the first carrier 31 , so as to encapsulate the chip 32 . The molding compound 34 comprises a second surface 342 attached to the surface 311 of the first carrier 31 . In this embodiment, the second surface 342 of the molding compound 34 is level with the second surface 322 of the chip 32 . The molding compound 34 is used as a support of the chip 32 , so as to increase the thickness and the strength of the chip 32 . Therefore, a first surface 341 of the molding compound 34 is used as a supporting surface of the following manufacturing process, so as to facilitate processing the second surface 322 of the chip 32 .
[0019] As shown in FIG. 5 and step S 24 , the first carrier 31 is removed, preferably, the adhesive 33 is removed at the same time, so as to expose the second surface 322 of the chip 32 and the second surface 342 of the molding compound 34 . Meanwhile, the molding compound 34 is used as a support of the chip 32 , therefore a first redistribution layer (RDL) 35 and at least one first bump 36 are formed, and another carrier is not needed, as shown in step S 25 . The first redistribution layer (RDL) 35 is disposed on the second surface 322 of the chip 32 and the second surface 342 of the molding compound 34 , and electrically connected to the conductive via 326 by the active circuit layer 323 . The first bump 36 is disposed on the first redistribution layer (RDL) 35 , and electrically connected to the active circuit layer 323 and the conductive via 326 by the first redistribution layer (RDL) 35 .
[0020] In this embodiment, the first redistribution layer (RDL) 35 comprises to a protective layer 352 , a first circuit layer 353 and an under ball metal layer (UBM) 354 . The first circuit layer 353 is disposed in the protective layer 352 . The protective layer 352 has a first surface 355 and a second surface 356 . The second surface 356 has at least one second opening, so as to expose part of the first circuit layer 353 . The under ball metal layer (UBM) 354 is disposed in the second opening, and electrically connected to the first circuit layer 353 . The first bump 36 is disposed on the under ball metal layer (UBM) 354 . Therefore, the first redistribution layer (RDL) 35 is used to re-distribute the position of the under ball metal layer (UBM) 354 and the first bump 36 , to match the position of electrical contact points of other package. As a result, the stackable package 2 ( FIG. 9 ) made by the method according to the present invention is more flexible in application.
[0021] As shown in FIG. 6 and step S 26 , a second carrier 37 is provided. As shown in step S 27 , a surface 351 of the first redistribution layer (RDL) 35 is disposed on the second carrier 37 by a glue layer 38 , and the glue layer 38 encapsulates the first bump 36 . In this embodiment, the glue layer 38 is a peelable glue layer, and formed by spin coating. Therefore, the glue layer 38 protects the first bump 36 , and the second carrier 37 is used as a support of the first redistribution layer (RDL) 35 . Therefore, a surface 371 of the second carrier 37 is used as a supporting surface of the following manufacturing process, so as to facilitate processing the first surface 341 of the molding compound 34 .
[0022] As shown in FIG. 7 and step S 28 , part of the chip 32 and part of the molding compound 34 are removed, so as to expose the conductive via 326 ( FIG. 6 ) to the first surface 321 of the chip 32 , and a through via 324 is formed. That is, the conductive via 326 is substantially the same as the through via 324 , and the difference between the conductive via 326 and the through via 324 is that the through via 324 is exposed to the first surface 321 of the chip 32 . In this embodiment, the first surface 321 of the chip 32 and part of the first surface 341 of the molding compound 34 are ground first, and then trimmed by chemical-mechanical polishing (CMP). However, in other embodiments, part of the chip 32 and part of the molding compound 34 can be removed only by chemical-mechanical polishing (CMP). In this embodiment, part of the through via 324 is exposed to the first surface 321 of the chip 32 , and forms a contact point.
[0023] As shown in FIG. 8 and step S 29 , a second redistribution layer (RDL) 39 is formed on the first surface 321 of the chip 32 . The second redistribution layer (RDL) 39 is electrically connected to the through via 324 . In this embodiment, the second redistribution layer (RDL) 39 comprises a protective layer 391 , a second circuit layer 392 and an under ball metal layer (UBM) 393 . The second circuit layer 392 is disposed in the protective layer 391 . The protective layer 391 has a first surface 394 and a second surface 395 . The second surface 395 has at least one second opening, so as to expose part of the second circuit layer 392 . The under ball metal layer (UBM) 393 is disposed in the second opening, and electrically connected to the second circuit layer 392 . Therefore, the second redistribution layer (RDL) 39 is used to re-distribute the position of the contact point of the through via 324 , to match the position of electrical contact points of other package. As a result, the stackable package 2 ( FIG. 9 ) made by the method according to the present invention is more flexible in application.
[0024] As shown in FIG. 9 and step S 30 , the second carrier 37 and the glue layer 38 are removed, and meanwhile, the stackable package 2 according to the present invention is formed. Preferably, the glue layer 38 can choose to be softened by heated or under ultraviolet ray according to the characteristic of the material of the glue layer 38 , so as to remove the glue layer 38 . In this embodiment, the glue layer 38 is a peelable material with better thermoplasticity, so that the glue layer 38 can be softened by heating, so as to remove the glue layer 38 . However, in other embodiments, the glue layer 38 can be a material that can be softened under ultraviolet ray, so that the glue layer 38 can be softened by providing ultraviolet ray, so as to remove the glue layer 38 . Therefore, the glue layer 38 protects the first bump 36 during the manufacturing process.
[0025] FIG. 10 shows a flow chart of a method for making a stackable package according to a second embodiment of the present invention. FIGS. 11 to 18 show schematic views of the method for making a stackable package according to the second embodiment of the present invention. The method for making a stackable package according to the second embodiment is substantially the same as the method for making a stackable package according to the first embodiment ( FIGS. 3 to 9 ), and the same elements are designated by the same reference numbers.
[0026] The difference between the method according to the second embodiment and the method according to the first embodiment is that after the first carrier 31 is provided (step S 31 ), the chip 32 , which does not comprise the conductive via 326 as shown in FIG. 11 , is disposed on the surface 311 of the first carrier 31 (step S 32 ). Then, the same processes as the method according to the first embodiment are conducted, that is, as shown in FIG. 12 , the molding compound 34 are formed (step S 33 ). Then, as shown in FIG. 13 , the first carrier 31 is removed (step S 34 ). Meanwhile, the molding compound 34 is used as a support of the chip 32 , therefore the first redistribution layer (RDL) 35 and the first bump 36 are formed (step S 35 ), and another carrier is not needed. Then, as shown in FIG. 14 , the second carrier 37 is provided (step S 36 ), and the surface 351 of the first redistribution layer (RDL) 35 is disposed on the second carrier 37 by the glue layer 38 (step S 37 ). Then, as shown in FIG. 15 , part of the chip 32 and part of the molding compound 34 (step S 38 ) are removed.
[0027] Then, as shown in FIG. 16 , a through via 324 is formed in the chip 32 (step S 39 ). The through via 324 is connected to the active circuit layer 323 , and exposed to the first surface 321 of the chip 32 . In the end, the same processes as the method according to the first embodiment are conducted, that is, as shown in FIG. 17 , the second redistribution layer (RDL) 39 is formed (step S 40 ). Then, as shown in FIG. 18 , the second carrier 37 and the glue layer 38 are removed (step S 41 ), so as to form the stackable package 2 according to the present invention.
[0028] Moreover, as shown in FIG. 19 , after the stackable package 2 according to the present invention is formed, a second package 3 is further stacked on the stackable package 2 , so as to form a double-layered stacked package. It is understood that, at least one conductive element (for example, a second bump 40 ) is disposed between and electrically connects the second package 3 and the second redistribution layer (RDL) 39 of the stackable package 2 . Preferably, a third package 4 can be further stacked on the second package 3 , so as to form a third-layered stacked package. Preferably, the stackable package 2 is a processor, the second package 3 is a radio frequency (RF) device, and the third package 4 is a memory. However, in other embodiments, as shown in FIG. 20 , the stackable package 2 can further comprise a second chip 41 disposed side by side with the chip 32 , and the second chip 41 is also a known-good die. The form of the second chip 41 has no limitation, and the second chip 41 can comprise a conductive via or not.
[0029] Therefore, the second redistribution layer (RDL) 39 is used to re-distribute the position of the contact point of the through via 324 , to match the position of electrical contact points of other package. As a result, the stackable package 2 ( FIG. 9 ) made by the method according to the present invention is more flexible in application, for example, the stackable package 2 according to the present invention can be applied to the three following situation. First, the molding compound 34 of the stackable package 2 encapsulates a plurality of chips 32 , and after another package having the same size of the stackable package 2 is stacked thereon, a singulation process is conducted. Second, the molding compound 34 of the stackable package 2 encapsulates a plurality of chips 32 , and after a plurality of chips are stacked thereon, a singulation process is conducted. Third, a singulation process is conducted to the stackable package 2 first, and then, another chip is stacked thereon. Moreover, the through via 324 is formed in the chip 32 , and electrically connected to the first redistribution layer (RDL) 35 , and an extra element is unnecessary. As a result, the manufacturing cost and the size of the product are reduced.
[0030] While several embodiments of the present invention have been illustrated and described, various modifications and improvements can be made by those skilled in the art. The embodiments of the present invention are therefore described in an illustrative but not restrictive sense. It is intended that the present invention should not be limited to the particular forms as illustrated, and that all modifications which maintain the spirit and scope of the present invention are within the scope defined by the appended claims.
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The present invention relates to a method for making a stackable package. The method includes the following steps: (a) providing a first carrier; (b) disposing at least one chip on the first carrier; (c) forming a molding compound so as to encapsulate the chip; (d) removing the first carrier; (e) forming a first redistribution layer and at least one first bump; (f) providing a second carrier; (g) disposing on the second carrier; (h) removing part of the chip and part of the molding compound; (i) forming a second redistribution layer; and (j) removing the second carrier. Therefore, to the second redistribution layer enables the stackable package to have more flexibility to be utilized.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of and apparatus for scanning tape with a scanning head, and more particularly to such a method and apparatus for use in recording and/or playing back video signals on an elongated recording medium, such as magnetic tape.
2. Description of the Prior Art
Conventional video signal record and/or playback systems for recording and/or playing back video signals under raster scanning system, such as television signals, include the vertical track scanning system, such as the four-head video recording system provided by Ampex Corporation, the helical scanning system, and the arc track scanning system, for example. Home video cassette recorders, typically employ the helical scanning. The helical scanning system is advantageous in that track patterns are formed in straight on a tape with a certain video track angle maintained with respect to the longitudinal direction of the tape, giving rise to higher recording density per unit length of tape, variable recording density dependent upon the video track angle, and a closer and more uniform contact of a video head with the tape.
In the helical scanning system, however, a recording tape runs in contact with a rotary drum of magnetic heads with a certain angle maintained between the longitudinal direction of the tape and the circumferencial direction of the head drum. In order to accomplish a stable running of the tape on the magnetic head, however, precise and accurate adjustment may be required in the head assembly and tape driving mechanism.
With a video cassette system using a video tape cassette, a stable driving of tape requires the tape to be oriented or directed essentially both at the exit from the tape supply reel and at the entrance to the tape winding reel of the cassette in such a manner that the tape runs at a constant height and in parallel with respect to a reference plane, which is parallel to a main surface of the tape cassette, with the sidewise direction of the tape perpendicular to the reference plane. For that purpose, the so-called VHS system, for example, employs the so-called M-type loading, in which the tape guiding system essentially includes a magnetic head rotary drum inclined with respect to a tape by a predetermined angle, a pair of tape guide posts provided in slant near the periphery of the rotary drum and far from the imaginary line connecting the exit and the entrance, and a pair of vertical posts for maintaining a part of the tape in contact therewith by a predetermined angle. This is complicated in structure. In addition, in order to make a close contact with a portion of tape on a part of the circumferential surface of the rotary drum by means of the pair of guide posts inclined with respect to the reference plane, and to maintain the height of the tape with respect to the reference plane constant with a tolerance of submicrometers, extensive accuracy is required in manufacturing and mechanically adjusting the elements involved in the tape running mechanism.
In order to increase recording capacity per video cassette, it is also required to design video tape which is very thin, for example, less than twenty micrometers thick. Such thin video tape is so insufficient in strength of the base material used as to fail to oppose the forces raised in the longitudinal direction of the pair of guide posts. Therefore, an edge of the tape may sometimes ride the flanges of the posts. In the case of a video cassette recorder using a thinner tape material, mechanical accuracy should be much more increased in the tape running mechanism.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a method of and apparatus for scanning tape with a ascanning head in which tape runs stably without the provision of complicated mechanism requiring accurate adjustment.
In accordance with the invention, a method of scanning tape including a recording medium with a scanning head comprises the steps of: running the head along the circumference of a circle having a central axis inclined by a predetermined angle with respect to a reference direction; guiding the tape along the elliptical circumferential surface of an elliptical cylinder with the longitudinal direction of the tape substantially perpendicular to the reference direction and the sidewise or width direction of the tape substantially parallel to the reference direction, said elliptical cylinder being formed by a generatrix which includes a point on the circumference of the circle and is substantially parallel to the reference direction, while the point moves along the circumference of the circle; and scanning the tape with the scanning head while the scanning head runs on a portion of the circumference of the circle, said portion of the circumference of the circle being associated with a sector of the circle which sector has a radius substantially perpendicular to the reference direction and extends to both sides of the radius each by a substantially equal angle about the central axis.
Also, in accordance with the invention, apparatus for scanning tape including a recording medium with a scanning head comprises: a rotary circular body having a central axis inclined by a predetermined angle with respect to a reference direction, and rotatable about the central axis; at least three scanning heads supported by the circular body along the circumference of the body with a substantially equal angular spacing provided therebetween and tape guide means for guiding the tape along the elliptical circumferential surface of an elliptical cylinder with the longitudinal direction of the tape substantially perpendicular to the reference direction and the sidewise or width direction of the tape substantially parallel to the reference direction, said elliptical cylinder being formed by a generatrix which has a point on the circumference of the circle and is substantially parallel to the reference direction, while the point moves along the circumference of the circle; said tape guide means being adapted to scan the tape with one of the scanning heads while the one of the scanning heads runs along a portion of the circumference of the circle, said portion of the circle being associated with a sector of the circle which sector has a radius substantially perpendicular to the reference direction and extends to both sides of the radius each by half an angle formed by adjacent two of the scanning heads with respect to the central axis.
The tape scanning system in accordance with the present invention will hereinafter be referred to as the "elliptical scanning system" in view of tape running along the circumferential surface of an elliptical cylinder.
As clear from the following description, the system in accordance with the invention is a sort of helical scanning system, in which track patterns on a tape form approximately a portion of a sinusoidal curve. It will be noted that the more magnetic heads arranged on a circular rotating body, or rotary disk, the more approximately linear portion, of a sinusoidal curve available. Of course, the azimuth recording is applicable to the elliptical scanning system, and the H alignment (horizontal scanning line alignment) is possible if only approximately linear portions of the sinusoidal curves are used as recording tracks.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and features of the invention will become more apparent from a consideration of the following detailed description taken in conjunction with the accompanying drawings in which:
FIG 1 shows schematically the principle applicable to a tape scanning system in accordance with the present invention;
FIG. 2 is a perspective view schematically showing an embodiment of a tape scanning apparatus in accordance with the invention; and
FIGS. 3A, 3B, 3C, 4 and 5 are views useful for understanding the detailed functions and operations of the scanning system in accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, the principle of the tape scanning system in accordance with the invention will be described. In the figure, a curve 100 depicts a circle having the center O. Circle 100 is inclined so that it has a normal ON at center O forming an angle α with respect to a segment of line OM, which is parallel in a reference direction, e.g. the direction from the top to the bottom of the figure.
While a point C on circle 100 is moving along circle 100, a segment of straight line DE including point C and extending in the reference direction, i.e. in parallel with the segment of line OM forms an elliptical cylinder 102. The segment of line DE is therefore a generatrix of elliptical cylinder 102. Although FIG. 1, which is a perspective view, depicts the FIG. 102 as if it were a circular cylinder, it is a elliptical cylinder having a central axis including the segment of line OM, a short axis of ellipse including a segment of line EM, and a long axis of ellipse including a segment of line OA. As shown in the figure, the segment of line ON having a point N on short axis EM is inclined to the left by an angle α, circle 100 thus inclining to the left by the same angle. In other words, circle 100 is inclined to the left by the angle α about the segment of line OA corresponding to the long axis of ellipse 104 with respect to a reference plane, e.g. a plane including ellipse 104. Ellipse 104 formed as a trace of point E has its long radius a and short radius b satisfying the following expressions:
a=OC=OA,
b=EM=OC·cos α=a·cos α (1)
In accordance with the present invention, along the circumference of circle 100 n scanning heads, for example, magnetic heads run with a substantially equal angular spacing about circle 100 with respect to each other. The spacing angle 2φ(=∠POP') between the adjacent heads are therefore
2φ=2π/n (2)
An elongated recording medium 106, such as a magnetic tape, having an effective width w, which is available for recording video signals, for example, is in contact with a portion of the circumferential surface of elliptical cylinder 102, i.e. cylindrical surface 108 over the region including points P and P' on circle 100 so as to include at least angle 2φ with respect to center O, as shown in the figure. In that case, tape 106 is so oriented or directed as to have its longitudinal direction parallel to a reference plane, e.g. a plane including ellipse 104, that is, parallel to the direction from left to right in the figure. In addition, tape 106 is in contact with a portion of cylindrical surface 108 so that the long axis of ellipse 104 including the segment of line OA divides equally the angle 2φ=∠POP' into two.
For example, in the case of a magnetic tape video signal recording system recording on a magnetic tape video signals formed in accordance with raster scanning, such as television signals, a plurality of horizontal scanning lines involved in one field may be recorded on a track PP' within the effective width w of magnetic tape 106. In the case of a recording head assembly having four magnetic heads arranged on circle 100, 2φ=π/2.
In FIG. 2, there is shown a rotary magnetic head assembly for a video tape recorder or video cassette recorder to which the invention is advantageously applicable. The illustrative embodiment includes a rotary disk 200 which is inclined by angle α with respect to a plane including ellipse 104 shown in FIG. 1. Disk 200 corresponds to circle 100 shown in FIG. 1, and is driven by a motor, not shown, by way of a rotary shaft 202 connected thereto, in the direction of arrow 204. Thus, rotary shaft 202 includes at its center the segment of line ON depicted in FIG. 1. The inclination angle α may advantageously be in the order of 5° through 6°, approximately. Disk 200 is a thin and low cylinder, as shown, having a circumferential or cylindrical surface 206 on which four magnetic heads 208 are disposed with the angular spacing between heads substantially equal to 90 degrees, for example.
In association with circumferential surface 206 of disk 200, tape guide members 210A and 210B are provided as shown in FIG. 2. Tape guides 210A and 210B are fixed on a base, not shown, which has a main surface parallel to the reference plane, for example. The base may, for example, be in parallel with a main surface of a tape cassette, not shown, which includes magnetic tape 106. Tape guides 210A and 210B have a curved surface as shown in the figure and are completely within elliptic cylindrical surface 108 of elliptic cylinder 102 to form a portion thereof. Between tape guide members 210A and 210B, a gap or spacing 212 is formed which has a substantially uniform width. From spacing 212, a portion of cylindrical surface 206 of disk 200 is exposed.
In FIG. 2, at the points corresponding to the points P' and P shown in FIG. 1, guide posts 214 and 216 are provided, respectively. Guide posts 214 and 216 are biased by appropriate springs, not shown, toward the center of disk 200 to be in contact with guide members 210A and 210B. Guide posts 214 and 216 may be separate from guide members 210A and 210B, namely, that is not in direct contact with guide members 210A and 210B. It is sufficient to arrange the central axis of the cylindrical surface formed by guide members 210A and 210B in parallel with the central axes of guide posts 214 and 216. Magnetic tape 106, depicted by a chain line, runs in the spacing between guide post 214 and guide members 210A and 210B over and in contact with the surface of guide members 210A and 210B to the spacing between guide post 216 and guide members 210A and 210B in the direction of arrow 218.
The height of tape 106, that is, the position of tape 106 in the direction from the top to the bottom of the figure is restricted by flanges 220 and 222 of guide posts 214 and 216, respectively.
While disk 200 rotates in the direction of arrow 204, magnetic head 208 records a track corresponding to a circular arc P'P within the effective recording width w of tape 106. As magnetic tape 106 is driven by a tape driving mechanism, not shown, in the direction of arrow 218, a plurality of such tracks P'P are subsequently formed on tape 106.
Now, a consideration will be made on track P'P recorded on tape 106. In the x, y and z coordinates which has the original point corresponding to point O, shown in FIG. 1, an xy plane including the original point O and parallel to ellipse 104, and the z axis including the original point O and normal to the xy plane, i.e. parallel to the direction from the bottom to the top of FIG. 1, circle 100 and ellipse 104 are illustrated as in FIGS. 3A, 3B and 3C. In those figures, ellipse 104, which is a projection of circle 100 on the xy plane, crosses the x and y axes at points A and B, and a perpendicular line to the x axis from the point Q, which is a projection of point P on the circumference of circle 100 onto the xy plane, intersects the x axis at point R. A circle 300 having the same radius as of circle 100, i.e. the long axis a (=OA) of ellipse 104 crosses the extension of the segment of line RQ at a point T. Then,
∠PRQ=α,
∠POA=φ.
The eccentric angle θ is defined by the formula,
∠TOA=θ,
then ellipse 104 is defined by
x=a·cos θ, (2)
y=b·sin θ, (3)
and the eccentricity thereof is defined by ##EQU1## The height of point P, i.e. the length PQ is expressed by ##EQU2## Thus, the height of point P traces a sinusoidal curve with respect to the eccentric angle θ. Usually, if the angle α is very small (e.g. 5°) so as to make ellipse 104 ultimately close to a true circle, then track P'P formed on tape 106 is approximately sinusoidal.
If θ is small, namely, less than about π/6 (=30°), then it is approximated by a straight line,
y=akθ=a (sin α)θ.
In general, as discussed above, since α is very near to zero, for example, five degrees, it is approximated by a straight line,
y=aαθ
In other words, a track formed in the region corresponding to θ of less than 30 degrees may be approximately a straight line. Accordingly, in order to utilize only that portion of the track, disk 200 may be designed to have six or more magnetic heads 208 provided with the spacing between the adjacent heads substantially equal to each other.
The track pattern formed on magnetic tape 106, that is, the pattern approximated by the above expression (5) plots the curve 400 as shown in FIG. 4. In FIG. 4, the abscissa shows the length of arc AQ=s of ellipse 104 and the ordinate shows the distance PQ=z as a function of s. In the figure, there is also shown the preceding track 402 recorded while tape is 106 running. The variable s is defined by ##STR1## This integration is determined in terms of elliptical integration. If α is small, then the ellipse comes near a circle so that s=aθ, the track pattern on tape 106 being approximate to a sinusoidal curve, as discussed above.
On magnetic tape 106, the distance or pitch in the angular (θ) direction between tracks 400 and 402 is designated by p, and the distance between adjacent tracks in the direction of width of a track, namely, in the direction perpendicular to the moving direction of magnetic head 208 with respect to magnetic tape 106 (the tangential direction of the track patterns) is depicted by d. The overlapping ratio ξ of adjacent tracks is defined by ##EQU3## where d o is the distance between the adjacent tracks when s=0. Taking account of an angle η of the tangent of a track formed with respect to the direction of pitch p, the following formula is approximately established,
d=p sin η,
and since at point A, η=α, the overlapping ratio ξ at an appropriate point on a track is ##EQU4## where O≦θ≦π/2, and O≦η<α<π/2.
From expression (7), it will be appreciated that when θ=π/2, ξ=1, so that the adjacent tracks are completely overlapped, a rotary disk having two magnetic heads would be impractical. Accordingly, in order to make ξ less than unity, it is necessary to provide three or more magnetic heads on a rotary disk. Taking account of azimuth recording technique, it is more preferable to design a rotary disk having four or more even number of magnetic heads. For example, designing disk 200 with four magnetic heads and using tracks within the region formed by the angle θ=π/4, ξ=0.29, which means that approximately thirty percent of the adjacent tracks are overlapped with each other at the end portions of the tracks, θ=45°. Consequently, in order to make tracks almost straight and less overlapping between the adjacent tracks, it is preferable to design a rotary disk having a greater number of magnetic heads. It is to be noted that the overlapping ratio represented by the expression (7) is the same as that of the so-called circular arc track scanning system.
Now, considering a tilt, which is a contact angle formed by a contact or head surface of magnetic head 208 with respect to magnetic tape 106, as clear from FIG. 2, side or circumferential surface 206 of disk 200 is always in parallel contact with the recording surface of tape 106 because driving shaft 202 is inclined by angle α with respect to the reference direction, i.e. the z axis. Namely, the entire contact surface of magnetic head 208 is not always in contact with tape 106. In FIG. 5, the head surface or contact surface of magnetic head 208 is illustrated in slant by a contact angle ψ with respect to the surface PQ of magnetic tape 106. Then,
∠POQ=ψ,
where ψ changes from ψ=O at θ=O through ψ=α at θ=π/2.
From FIG. 5, it will be appreciated that
PQ=z=a sin ψ,
and combining this with expressions (4) and (5),
sin ψ=sin α sin θ. (8)
In general, α and ψ take a value close to zero, the expression (8) is approximated by
ψ≈α sin θ. (9)
It is clear therefrom that in order to decrease tilt angle ψ, disk 200 is preferably designed so as to have a small inclination α and a relatively large number of magnetic heads, namely, it is preferable to minimize the angle θ within which head 208 is in contact with tape 106.
According to expression (9), if disk 200 has four heads, i.e. θ=π/4 (45°) with α=5°, for example, then ψ=3.5. This means that in the case of disk 200 having four magnetic heads 208 with equal angular spacing between the adjacent heads, the maximum contact angle ψ is 3.5°, namely, the contact angle ψ takes the values between 0° through 3.5°. If the height h, FIG. 5, of the contact surface of head 208 is 20 micrometers, for example, then the "distance" δ, FIG. 5, of the contact surface or head surface of head 208 from the surface PQ of the tape 106 is ##EQU5## Such an amount of the distance may advantageously be compensated for by the flexibility of pliability of tape 106, as well as by designing the contact surface of head 208, which surface is curved with respect to the direction parallel to the direction of the generatrix of the cylinder containing the circumferential surface of disk 200, i.e. the direction of driving shaft 202, or which surface is variable in its direction in response to the relative orientation of the recording surface of tape 106 to head 208.
The tape scanning system in accordance with the present invention will thus facilitate a recording tape to run or be guided on the level with respect to the running direction thereof, resulting in improving the stability of tape running. This does not require such critical mechanical accuracy of the tape guiding mechanism and the head assembly of the tape scanning system as required in the conventional helical scanning system. Particularly, in the case of a video tape cassette recorder, the tape running on a level with respect to the main or reference surface of a tape cassette used removes undesired forces applied thereto except for the direction in which the tape runs to be guided in its natural position. A portion of the tape extracted from a tape cassette, when loaded in a deck, is shorter than that of a conventional M loading or U loading system. It is possible to design a video tape cassette from which a portion of tape is not taken out of the cassette, when loaded in a deck, as in the case of an audio tape recorder.
The above description is directed to magnetic recording of video signals formed in accordance with the raster scanning system. However, the invention is not restricted thereto. For example, alternatively to the magnetic heads, optical recording may be applied thereto which employs a laser head and/or an optical head including a light emitting diode and a photosensitive device. The invention is also applicable to recording and/or playing back signals in a digital form, such as data signals, including signals transmitted via a telecommunication satellite, for example.
While the present invention has been described in terms of a specific illustrative embodiment, it is to be appreciated to be susceptible of modification by those skilled in the art within the spirit and scope of the appended claims.
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In a method and apparatus for scanning tape including a recording medium with a scanning head, the head runs along the circumference of a circle having a central axis inclined by a predetermined angle with respect to a reference direction. The tape is guided along the elliptical circumferential surface of an elliptical cylinder with the longitudinal direction of the tape substantially perpendicular to the reference direction and the width direction of the tape substantially parallel to the reference direction, the elliptical cylinder being formed by a generatrix which includes a point on the circumference of the circle and is substantially parallel to the reference direction, while the point moves along the circumference of the circle. The tape is scanned with the scanning head while the scanning head runs along a portion of the circumference of the circle, the portion of the circumference of the circle being associated with a sector of the circle which sector has a radius substantially perpendicular to the reference direction and extends to both sides of the radius each by a substantially equal angle about the central axis.
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BACKGROUND OF THE INVENTION
This invention relates to heating efficiency and, more particularly, to a system for increasing furnace efficiency.
The recent public concern over fuel consumption in this country and throughout the world has emphasized the importance of energy efficient appliances. One particular device which uses substantial energy is the ordinary furnace for home or business. The commonly used oil and gas fired forced air furnaces consume substantial quantities of natural resources in short supply.
Furnace efficiency, however, is affected by external factors as well as its internal construction. Most forced air furnaces use air from the surrounding room for combustion. This promotes a draft within the building because air from elsewhere within the building moves to replace the air used in combustion. Also, cold air from outside the building is drawn through the cracks in the building and through the window and door frames to further create drafts. The end result is a decrease in the heating efficiency of the furnace and an increase in fuel consumption.
One solution to this problem is to supply outside air, rather than room air, directly into the furnace for combustion, as suggested in the following U.S. Pat. Nos. 4,038,963; 3,805,764; 3,906,925; 2,711,683; 2,764,972. However, previous efforts to supply outside air for combustion have not proven satisfactory because the amount of cold outside air entering the furnace has not been adequately controlled.
A further problem contributing to furnace inefficiency is the unnecessary loss of heat through the chimney flue or exhaust. When the furnace is shut off, residual heat promotes convection currents which cause warm air drawn from the furnace room to leave through the chimney. A manually operated damper located in the flue has proven cumbersome, impractical and undependable because it must be opened or shut each time the furnace operates or shuts off. U.S. Pat. No. 3,906,925 has suggested a motor driven damper activated by the furnace thermostat, but this unnecessarily complicated system apparently depends on the special damper motor and lacks a back-up method of operating the damper. Thus, it is subject to the danger of a heat build-up due to a closed damper and an operating furnace in the event of a malfunction.
BRIEF SUMMARY OF THE INVENTION
In keeping with one aspect of the invention, a duct is provided between the combustion chamber of a forced air furnace and the outside of the building to supply outside, unheated air for combustion. A damper is positioned within this duct to control the supply of outside air. An additional damper is provided within the flue or exhaust duct leading from the furnace through the chimney. The dampers are mounted on a common shaft to provide simultaneous operation of both. The dampers are activated electrically and in synchronization with the thermostat controlling the furnace. A back-up power circuit for the dampers is provided by the circuit including the furnace blower. In addition, the dampers can be operated manually.
The above mentioned and other features of this invention and the manner of obtaining them will become more apparent, and the invention itself will be best understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of a house having a heating system which incorporates the invention.
FIG. 2 is a circuit diagram of the control box and the existing wiring of the furnace, together with a perspective view of the outside air duct as constructed according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIG. 1, a system for increasing heating efficiency in accordance with the teachings of this invention employs a conventional oil or gas fired forced air furnace 10. For illustration purposes, the furnace is shown in the basement of a home 2, but neither the location of the furnace nor the type of structure to be heated are critical to the invention. The furnace has the three conventional ducts 12, 14 and 16 leading to and from the furnace. Duct 12 is an exhaust duct leading from the furnace through the chimney 4 and carries the end products of combustion from the furnace to the ambient atmosphere. Duct 14 carries air heated by the furnace to various areas of the house, where the air is released through vents 20. Duct 16 returns cooled air, which enters the duct through vents 22 in the rooms of the house, to the furnace.
Most conventional furnaces simply draw air from the basement or room in which they are situated for combustion. However, the present invention includes a fourth duct 18 leading between the furnace and the outside of the house. Duct 18 provides outside air to the furnace for combustion. Thus, with this source of outside air, convection currents caused by the draw of air by the furnace for combustion are diminished, and the influx of cold outside air through door and window frames is reduced.
This invention also provides means for controlling the infiltration of cold air through duct 18 and the escape of heated air through exhaust duct 12. A pair of dampers 24 and 26 are positioned within ducts 12 and 18. The dampers are capable of obstructing or permitting the free flow of air through the ducts. Desirably, the dampers are pieces of sheet metal shaped to correspond to the cross-section of the duct--usually rectangular. Preferably, dampers 24 and 26 are mounted on a rotatable common shaft 28 which positions the dampers to obstruct or permit air flow through the ducts. The shaft can be rotated either manually, as by handle 30, or electro-mechanically, as by control box 32.
FIG. 2 shows in more detail the rotation means 28 and 32 and damper 24 within a portion of duct 18. If desired, handle 30 can be turned so as to rotate shaft 28 and position damper 24 perpendicular to, or parallel to, the flow of air in duct 18.
FIG. 2 also shows the contents of control box 32 in relationship to existing wiring and components of a conventional forced air furnace. Box 32 contains a first solenoid 34 with a core 36 attached to handle 30 of shaft 28. Connected to the solenoid and core are a switch 38 and a buzzer or alarm 40. Box 32 also contains a second solenoid 42 with a spring loaded core 44 which operates switches 46 and 48. When the second solenoid 42 is not energized, switch 48 is open and switch 46 is closed. A test button switch 50 is wired across switch 48 and is accessible from the outside of control box 32. Power on-off switches 52 and 54 are connected to switches 46 and 48 respectively.
These components of control box 32 are appropriately connected to existing wiring of the furnace system. Solenoid 42 is wired across a third solenoid 56 which controls the fuel gas or oil supply valve 58. Buzzer 40 is connected to the 110 volt power supply 59 which leads directly to the furnace fan motor 60. Power on-off switch 54 is connected to the 110 volt power supply which leads to the stepdown transformer 62. Power on-off switch 52 is connected to the low speed motor winding 64 of fan motor 60. Both of the power switches are normally maintained in the "on" position.
With the above described improvements, the heating efficiency of an ordinary forced air furnace will be significantly increased in a safe and reliable manner. Under ordinary circumstances, the house or room thermostat 65 will control the activation of the furnace by energizing solenoid 56 which opens oil or gas supply valve 58. Simultaneously, solenoid 42 is energized, thereby closing switch 48 and opening switch 46.
When switch 48 is closed, solenoid 34 is activated so as to rotate shaft 28 and position dampers 24 and 26 to allow the free flow of air through ducts 18 and 12. Also, the activation of solenoid 34 opens switch 38, thereby preventing the buzzer 40 from activating. When the thermostat cuts power to the solenoids, the dampers return to the closed position and obstruct air flow in the ducts.
If the room thermostat fails to directly activate the dampers, a back-up power circuit derived from the furnace fan is automatically employed to open the dampers. In most conventional forced air furnaces, the furnace fan is activated by a special thermostat (not shown) which often operates the fan even after the furnace shuts off to eliminate residual heat. The low speed winding 64 of the furnace fan motor 60 operates only for the heating system. If a central air conditioning system is joined to the same motor, only the high speed winding 66 operates during operation of the air conditioner. In either case, the high speed winding is isolated from the heating system by switch 67. Once the furnace thermostat activates the low speed winding through switch 68, power flows through power on-off switch 52, bypassing switches 54 and 48, to solenoid 34, which opens the dampers. Of course, if the thermostat actually energized solenoid 42, as would normally occur, switch 46 would open and power would flow to solenoid 34 and the dampers through power on-off switch 54.
Test button 50 controls power to the dampers independently of the thermostat. Thus, it can be used to test the operation of the dampers and also to insure that power is available to the system from the 110 volt power supply. Should a malfunction occur whereby solenoid 34 fails to energize and open the dampers, power from the furnace fan circuit will activate alarm 40 through closed switches 38 and either 46 or 48. If necessary, handle 30 can be used to manually override the electrical circuits and control the operation of the dampers.
The many advantages of this system are apparent. First, the invention provides a compact system for increasing heating efficiency which is adaptable to the existing construction of conventional forced air furnaces. Second, cold air infiltration through the windows and door frames and cold air accumulation around the furnace are reduced, and warm air surrounding the furnace which is otherwise lost through the chimney is conserved. Third, the system provides coordinated and simultaneous control of dampers in the outside air and exhaust ducts. Fourth, two alternate power circuits plus a manual override control for the dampers provides reliability and safety. Fifth, the alarm and testing controls built into the system actively monitor the operation of the system and provide added security.
While the principles of the invention have been described above in connection with specific apparatus and applications, it is to be understood that this description is made only by way of example and not as a limitation on the scope of the invention.
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A conventional forced air furnace is provided with a source of outside air for use in combustion. The amount of outside air admitted to the furnace and the amount of heated air lost through the chimney are regulated by simultaneously operable dampers synchronized with the operation of the furnace. Alternate power circuits and an alarm system for the dampers are provided.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application Ser. No. 60/944,150, entitled “Battery Charger with Integrated Cell Balancing” and filed on Jun. 15, 2007, the content of which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] Rechargeable batteries are typically charged by a source of constant voltage/constant current CV/CC) with crossover voltage, e.g., 3.7 V. Initially the battery is charged using a constant current (i.e., in CC mode) until the crossover point is reached (e.g., 3.7V), at which point the charger switches to constant voltage mode to maintain the voltage at the terminal of the rechargeable battery at substantially about the crossover voltage. The charging period required to achieve 90-100% capacity is typically 2-4 h, with the CC stage being around 40 minutes at 1 C charging rate (i.e., a charging rate corresponding to a charging current level that would charge a battery in one hour). Generally, at the conclusion of the CC stage the rechargeable battery achieves a charge level of 60-70% of the charge capacity of the battery. The CV stage of the charging process generally take 1-3 hours to complete. During that time the charging current level decreases and typically reaches a level corresponding to a charge rate of 0.1 C by the time the charging process is concluded.
[0003] One factor limiting the expediency of the charging rechargeable batteries is the danger of causing the charger and/or battery to overheat. Such overheating may damage the charger and/or battery, and further pose a safety risk. Consequently, conventional chargers are configured to apply charging current corresponding to charge rates of about 1 C. To protect against overheating conditions, temperature sensors are sometimes used to monitor the temperature of the charger and/or the battery, thus enabling the charger to undertake remedial or preemptive actions in the event of the detection of overheating conditions (e.g., terminating the charging current if the battery's temperature exceeds a safety limit of, for example, 45° C.)
SUMMARY
[0004] In one aspect, a battery charger includes circuitry with integrated cell balancing and automatic cell configuration determination that automatically adapts output current to different battery configurations.
[0005] The following are embodiments within the scope of this aspect.
[0006] The integrated cell balancing within the battery charger may include a regulated switching power supply to charge a pack of cells, which maybe either a one series (1 S), two series (2S), three series (3S), or four series (4S). The cell balancing may continuously attempt to bring all the cells to the same voltage, by applying a resistive load to all but the cell with the smallest voltage in the pack. The integrated cell balancing within the battery charger may include a controller that monitors electrical and temperature conditions inside the charger, maintains proper individual cell voltages, detects fault conditions and displays charger status and charge progress. The battery charger may include circuitry to sense the battery voltage on output terminals of the charger and the individual cell voltages on inter-cell connection ports. The battery charger may determine the battery configuration connected to the charger and adjust the output voltage and balancing according to the determined configuration. The battery charger may monitor individual cell voltages to maintain all cell voltages equal to each other within a specified tolerance. The battery charger may include a first connector for the main charge path; and an auxiliary connector attached to inter-cell points in the pack to the charger for balancing and individual cell voltage monitoring. The battery charger may sense how many inter-cell connections are attached to the charger and determines how many cells are in series in the pack. The battery charger may use inter-cell connections to drain small amounts of current from the higher voltage cells to accomplish cell voltage balancing. The circuitry of the battery charger may sample input and output cell voltages and an inductor current at regular time intervals. The battery charger may determine the number of cells connected to the charger by measuring the impedance across each possible cell connection, with a high impedance between two terminals indicating no cell connected to the terminals and a low impedance along with at least a volt of dc voltage indicating a cell connected to those terminals. The battery charger may be configured such that if the charger senses that one of the cells in the string is at or above its target value, the charger adjusts the total output voltage lower to keep that cell at its target value to drain current from that cell that is at or above the target voltage value. The battery charger may be configured to perform cell balancing and configuration determination about every millisecond. The battery charger may have a resistive load applied to the cells by turning on a transistor that connects a resistor across the terminals of the higher-voltage cell, with the value of the resistor determining a balancing current. The battery charger may perform no balancing action if the cell voltages are within 10 millivolts of each other. The battery charger may include a thermistor or other temperature sensing component disposed inside the charger near the charger's hottest power components.
[0007] In an additional aspect, a battery charger includes circuitry to sense battery voltage on output terminals of the charger, circuitry to sense individual cell voltages on inter-cell connection ports of the charger, and circuitry to determine whether one of the cells in the string is at or above its target value, and to adjust the total output voltage lower to keep that cell at its target value to drain current from that cell that is at or above the target voltage value.
[0008] In an additional aspect, a battery charger includes circuitry to charge a nanophosphate cell in about 15 minutes, the circuitry including integrated cell balancing and with the circuitry automatically adapting to different connected battery configurations.
[0009] One or more of the foregoing aspects may provide one or more of the following advantages.
[0010] Because LFP chemistry is robust and can accept fast charge current, the charger is capable of recharging such a battery in about 15 minutes. However, in order to raise the current limit, the power components would have to be increased in size and capability in order to handle the higher currents and power levels. Charge balancing of different cell configurations is integrated into the charger. The charge balancing continuously attempts to bring all the cells in a pack of cells to the same voltage whether the pack is fully charged or not. The charge balancing mitigates against over heating and/or overcharging of the cells.
[0011] The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0012] FIG. 1 shows a block diagram of a charger that automatically adapts to different output battery configurations.
[0013] FIG. 2 is a schematic of charger connections showing alternative battery configurations.
[0014] FIG. 3 is a schematic showing components of the charger's power stage.
[0015] FIG. 4 is a schematic showing balancing integrated into charger.
[0016] FIG. 5 is a plot of charging voltage and current vs. time showing balancing stage and indications.
[0017] FIG. 6 is a flow chart depicting exemplary charging operation of the charger.
DETAILED DESCRIPTION
[0018] Referring now to FIG. 1 a charger 12 configured to charge a rechargeable battery 130 having at least one rechargeable electrochemical cell. Exemplary cells are those based on lithium-iron-phosphate (LiFePO 4 ) chemistry and in particular high-power lithium ion batteries using A123 proprietary Nanophosphate™ technology and available from A123 Systems, Inc. Arsenal on the Charles 321 Arsenal Street Watertown, Mass. 02472.
[0019] Such a battery (which is sometimes referred to as a secondary battery) includes cells having, in some embodiments, lithium titanate anode material, and lithiated-iron-phosphate cathode materials adapted to enable fast recharge of rechargeable batteries based on such materials. LiFePO 4 chemistry has low internal resistance (R) and therefore heat losses resulting from the internal resistance for batteries based on such chemistry, which are proportional to power losses (I 2 R, where I is the charging current applied to the battery) will be small. Because of the low internal resistance of batteries based on LiFePO 4 chemistry, such battery can accept large charging currents. The details of Nanophosphate™ technology chemistry and its role in improved electrical conductivity of lithium battery electrodes may be found in U.S. Pat. No. 7,338,734, which is incorporated here in its entirety by reference.
[0020] The battery charger 12 has integrated cell balancing that automatically adapts to different output battery configurations. The battery charger 12 with integrated cell balancing (hereinafter charger 12 ) includes a regulated switching power supply capable of accepting an input voltage from a DC power source 10 such as a 12V battery, and charging a either a one series 14 (1S), two series 16 , (2S), three series 18 (3S), or four series 20 (4S) pack of “M1” cells a configuration of battery cells obtainable from A123 Systems Watertown Mass. Other cell configurations and other Nanophosphate™ technology or LiFePO 4 cell types can be used. The power supply 10 is controlled by a microprocessor which monitors the electrical and temperature conditions inside the charger 12 , maintains proper individual cell voltages, detects fault conditions and displays the charger status and charge progress.
[0021] The charger 12 provides easy operation with as little human intervention as possible yet is versatile enough to charge a 1S 14 , 2S 16 , 3S 18 , or 4S 20 pack automatically. It does this by first sensing the battery voltage on the main output terminals and the individual cell voltages on the inter-cell connection port (described below). The charger 12 determines what battery configuration is connected and adjusts the output voltage and balancing strategy accordingly. Whenever there is a valid input power supply 10 and a compatible battery 14 , 16 , 18 , or 20 connected, the charger 12 monitors the individual cell voltages and attempts to keep all the cell voltages equal to each other.
[0022] The charger 12 activates status lights 12 a during the charge process to indicate heavy charging, light charging plus balancing, charge complete and error modes. In addition, a charger microcontroller, e.g., a microcontroller, a microprocessor, state machine and so forth (not shown in FIG. 1 ) within the charger 100 monitors temperature and voltages and takes appropriate actions such as shutting down or reducing current to prevent damage to the charger 12 or the battery 14 , 16 , 18 , or 20 .
[0023] Referring to FIG. 2 , charger connections for alternative battery configurations 14 , 16 , 18 , and 20 are shown. The input connects to, e.g., a 10-15V power source 10 typically a 12V battery—by clamping onto its terminals with, e.g., alligator clip type connectors. Other DC sources can be used, e.g., a power pack that is supplied AC voltage and converts it to a suitable DC voltage. An input diode 28 ( FIG. 3 ) prevents damage from a reverse polarity mistake. The battery 14 , 16 , 18 , or 20 is connected to the output through a connector 22 , e.g., a “Dean-type” connector for the main charge path. An auxiliary connector 24 attaches the inter-cell points in the pack to the charger 12 for balancing and individual cell voltage monitoring.
[0024] Referring now to FIG. 3 , components of the charger's power conversion stage are shown. The power conversion stage converts incoming unregulated DC voltage between, e.g., 10 and 15V to a regulated voltage compatible with the detected battery configuration on the output. The power conversion stage includes a single stage buck-boost switching regulator circuit that is controlled by the charger microcontroller 26 that was discussed previously. The charger microcontroller 26 typically will include non-volatile memory storing firmware to cause the charger microprocessor to perform the above functions. The charger microprocessor can be a digital processor, digital signal processor, a microprocessor, hard-wired controller, and so forth.
[0025] The power circuits include an input diode 28 (D 1 ), to prevent problems due to mis-wiring, a series switch 30 (Q 1 ) that turns on and off, e.g., about 125 thousand times a second, an inductor 36 (L) with inductor DC resistance 36 a to store energy between switch cycles, an output diode 32 (CR 1 ) to transfer energy from the inductor to the output. The output diode 32 only conducts for a portion of the switch cycle. Note that the input power supply 10 has voltage V 1 , and output load 14 (or 16 , 18 , or 20 ) has a voltage Vo. Also note that, although the inductor 36 is connected to the capacitor 34 when the output diode 32 is conducting, an effective LC filter is formed such that a train of input voltage pulses is converted to a DC output voltage.
[0026] For more details on a Buck Boost power supply, see Application Report SLVA059A—“Understanding Buck-Boost Power Stages in Switch Mode Power Supplies” by Everett Rogers, March 1999—Revised November 2002, which is incorporated herein by reference in its entirety.
[0027] The charger microprocessor senses current and voltage and adjusts the ratio of on-time vs. off-time of series switch 30 to control the output voltage and current into the charging battery. There are two limits that the charger microprocessor controls in its output, a voltage limit and a current limit. During recharge, if the battery's voltage is below that of the voltage limit, the controller limits the current going into the battery. During this constant current mode, the current going into the battery is relatively steady at the current limit level, while its terminal voltage steadily climbs. When the battery is mostly recharged, its voltage reaches the voltage limit, at which point the charger microprocessor, now in constant voltage mode, limits the voltage going into the battery. During this constant voltage mode, the output voltage is constant, while the output current steadily declines to zero.
[0028] The bulk of the charge transferred to a connected battery occurs in the constant current mode of recharge. The amount of charge transferred is the integration of current over the time. In the case of a relatively constant current, the integration is simply a multiplication of current by time. So in order to transfer a charge C in T time, one needs to set the current (I) to C/T, since C=1×T in a constant current charging mode. In this particular charger, the current limit is set to about (4/hour)*C rating of the battery. For example, for a 26650 battery (obtainable from A123 Inc.) (4/hour)*2.3 amp-hour is about 10 amps (actually 9.2 amps). In other words, 10 amps going into a 2.3 amp-hour battery will charge the battery in about a quarter of an hour or 15 minutes. Once the output voltage limit is reached, the output current tails off non-linearly with time, but essentially, most of the charge is replenished in the battery. Charge completely finished, when the charge current naturally falls to zero while holding its terminal voltage at, e.g., 3.5V or so (for Lithium Iron Phosphate LFP batteries).
[0029] Because LFP chemistry is robust and can accept fast charge current, the charger is capable of recharging such a battery in about 15 minutes. The charge time is dependent on the recharge current limit set in the charger controller. By way of example, a 5 minute charger can also be provided by simply increasing the current limit to (12/hour)*C or 30 amps. However, in order to raise the current limit, the power components would have to be increased in size and capability in order to handle the higher currents and power levels.
[0030] Referring now to FIG. 4 , a charge balancing of different cell configurations is integrated into the charger, as shown. The charger continuously attempts to bring all the cells (in this example, in a 4S pack) to the same voltage, by applying a resistive load 46 a - e to all but the cell with the lowest voltage in the pack. When the cell voltages are within 10 millivolts of each other no balancing action is performed. The sensing and balancing actions are performed, e.g., every 200 milliseconds whenever the input voltage is within range, or there are no other errors detected in the system or connections. It also continues to balance the cells whether the pack is fully charged or not.
[0031] The resistive loads 46 a - e are applied to the cells by turning on a corresponding transistor 48 a,b,c , or d that connects a resistor 46 a, b, c, d , or e across the terminals of the higher-voltage cell 38 . The value of this resistor determines how much balancing current can be achieved while the power dissipating qualities of the resistors 46 a - e and the switching transistors 48 a - d need to be capable of this balancing current.
[0032] The charger microcontroller 26 senses how many inter-cell connections are attached to the charger 12 and determines how many cells are in series in the pack 14 , 16 , 18 , or 20 . (Again, in this case, 4S pack 20 is illustrated.) The charger 12 uses these inter-cell connections to drain small amounts of current from higher-voltage cells to lower-voltage cells for cell balancing. The charger microcontroller 26 samples the input and output cell voltages and the inductor current. This sampling of the input and output voltages may be done at regular timer intervals, e.g., every millisecond. Alternatively, voltage sampling intervals may be based on a comparison between an instantaneous voltage level and a reference voltage set by the charger microcontroller. For example, a sample may take place each time the difference between the instantaneous voltage level and the reference voltage is below some threshold, e.g., about 10 mV. Alternatively, the voltage sampling intervals may be based on a comparison of voltage rise times to over cycle times set by the charger microcontroller. For example, a voltage sample may take place when the voltage rise time exceeds the cycle time.
[0033] The charger determines how many cells are connected to the charger by measuring the impedance across each possible cell connection. A high impedance between two terminals indicates that there is no cell connected to them whereas, a low impedance along with at least some minimum dc voltage, e.g., 1 volt of dc voltage, indicates a cell is connected to those terminals. The number of cells determined to be connected on the output will affect how much voltage is demanded at the battery pack's terminals.
[0034] The charger microcontroller 26 also samples the temperature near the power components and takes a reading on the status of the connections to the battery pack. This sampling of the temperature may be done at regular timer intervals, e.g., about 200 milliseconds. The charger 12 also includes a thermistor or other temperature sensing component that is disposed inside the charger near the charger's hottest power components. The charger 12 monitors the thermistor five times every second for changes in resistance that would correspond to changes in temperature. When this temperature is determined to exceed a first predefined limit, the microprocessor or other components cause the charger to cease producing output current until the temperature falls to a second predefined temperature below the first predefined temperature. The temperatures are selected in accordance with the temperature tolerances for the components used in the charger.
[0035] The charger 12 also monitors the input voltage and will shut off the charge current if the input voltage is above, e.g., 15V or below, e.g., 10V. The charger 12 typically regulates the output voltage to precisely control the cell voltages. However, if for some reason, the output voltage rises out of control above a safe operating point, the charger 12 will shut down the output current. The charger 12 also verifies that the battery pack connections are made correctly. The charger 12 checks for reversed inter-cell connections or missing connections. If any problems are detected it will light the error indicator in the status lights 12 a and cease charging current.
[0036] Referring now to FIG. 5 , a plot of charging voltage and current vs. time, along with balancing stage and indications is shown. The charger monitors the output current fed into the batteries and the balancing circuits. If the output current is less than, e.g., about 100 milliamps, the charge complete light within the status lights 12 a will be lit. At this point charge current is shut off completely, but balancing may be ongoing. If the output current is, e.g., more than about 100 milliamps but less than about 200 mA, and the pack voltage is less than its nominal target value (either 3.6 V, 7.2 V 10.8 V, or 14.4 V), the light charging plus balancing and heavy charging lights within the status lights 12 a will blink. In this mode, the charger output current has been throttled back in order to prevent overcharging one or more cells while the cells are brought into balance.
[0037] The charging current vs. time plot in FIG. 5 reflects this description. The current threshold 50 represents the transition from the heavy charging to the light charging plus balancing modes, and takes place at an instant of time 52 . The smaller current threshold 54 represents the transition between light charging, balancing and charged modes, and takes place at a later instant of time 56 .
[0038] As for the charging voltage vs. time plot, at the instant of time 52 , in the beginning of the balancing stage, the charger must control the increase in the overall pack voltage because the highest voltage in the cell is being regulated. Once balancing is achieved at time instant 56 , the individual cell voltages are within, e.g., 10 mV of each other and the target voltage has been achieved.
[0039] Referring now to FIG. 6 , a typical charging regimen 60 for the charger 12 is shown. The charging regimen 60 determines 62 if there is a valid input power supply and a compatible battery connected. The charging regimen 60 controls charging by sensing 64 battery voltage on the main output terminals and the individual cell voltages on the inter-cell connection ports. The charging regimen 60 then determines 66 the battery configuration connected to the charger 12 . The charging regimen 60 then adjusts 68 the output voltage and balancing strategy accordingly to the determined battery configuration. The charging regimen 60 next senses 70 individual cell voltages and activates balancing currents as needed. The charging regimen 60 then adjusts 72 the output voltage as necessary to keep any one cell from exceeding voltage limits.
[0040] The charging regimen 60 activates 74 status lights during the charge process, as discussed above. The charger monitors temperature and voltages and takes appropriate actions such as shutting down or reducing current to prevent damage to the charger or the battery if these are exceeded.
OTHER EMBODIMENTS
[0041] A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.
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A battery charger containing circuitry including integrated cell balancing and automatic cell configuration determination is presented. The charger automatically adapts output current to different battery configurations. The charger also ensures that all the cells within a battery configuration are at roughly the same voltage.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 11/373,939, filed Mar. 13, 2006, now U.S. Pat. No. 8,424,147, which in turn is a continuation of International Patent Application No. PCT/FR2004/050417, filed Sep. 8, 2004, and claims the benefit under §119(a)-(d) of French Patent Application No. 03 50559, filed Sep. 17, 2003, the entireties of which are incorporated herein by reference.
FIELD OF THE INVENTION
The invention relates to a brush having germicidal properties for applying mascara.
BACKGROUND OF THE INVENTION
Mascara is a cosmetic product used to color and/or thicken eyelashes. This composition is applied to the eyelashes with a brush that is traditionally attached to the plug that seals the bottle containing the mascara composition. In doing this, once the bottle is first opened, successive applications of the mascara with this brush and reinserting the brush into the bottle containing the mascara itself thus leads to a risk of contamination of the cosmetic composition with germs, and notably bacteria or fungi (i.e., germs picked up by the brush when in contact with the user's skin or eyelashes). These germs enter into the cosmetic composition, thus leading to a relatively fast termination of the mascara's usability, in fact requiring that it should be discarded relatively quickly in order to limit the possible risks of the multiplication of these germs in the mascara, in any case well before the cosmetic composition is used up.
To remedy this disadvantage, it has long been suggested that the mascara composition should contain preservatives, i.e. additives which can avoid and at least limit the growth of these germs. It has been shown, however, that such preservatives are irritants and can cause reactions in the eye, very close to the area where the mascara is applied. Moreover, the use of such preservatives can lead to the creation of resistant bacterial strains which can develop in the eye, risking the accompanying pathological consequences.
In a related field, concerning oral hygiene, the proposal has been made, notably in document WO 99/35911, to produce a toothbrush whose bristles are made of a plastic material containing a compound with antimicrobial activity, the component notably comprising a halogenated hydrocarbon, notably triclosan.
Experience has shown, however, that while germicidal activity can indeed be demonstrated, the salting out of this antimicrobial compound is observed, notably in the oral cavity. While such salting out has no effects, or at least no harmful effects, in toothbrush applications, it is unacceptable in the case of mascara, where such salting out would occur in the cosmetic composition itself, which could affect its composition and, furthermore, would not provide any increase in the duration of use of the mascara applicator brush.
SUMMARY OF THE INVENTION
Indeed, the object of the present invention is, on the one hand, to increase the useful lifetime of the mascara applicator brush, and therefore to optimize the use-by date for such a product. The present invention also aims to decrease, as much as possible, the quantity of preservatives included in the cosmetic composition, avoiding the salting out of the germicide in the mascara as much as possible.
In the following description and claims, the term “large anion” refers to an anion selected from the group consisting of:
anions of the carboxylate (oleate, for example) or alkyl sulphate (lauryl sulphate, for example) type, with an alkyl chain having a number of carbons greater than 10; polyanions of the polycarboxylate type (polyacrylate, for example); or other anions of the silicate or polyphosphate type.
In the following description and claims, the term “large cations” refers to a cation selected from the group consisting of:
quaternary ammoniums bearing at least one alkyl chain having a number of carbons greater than 8; cationic polymers of the ammonium polyacrylate type; polyiminium hydrochlorides and notably polyhexamethylene biguanide (PHMB); and polymers bearing quaternary ammonium functions and notably quaternary polyammoniums.
The present invention provides a mascara applicator brush comprising polymer bristles coated with a germicidal composition produced using a mixture including at least one large cation and at least one large anion, one or the other or both developing germicidal properties.
Implementation of this particular mixture thus allows a compound with germicidal properties to bind to the bristles on the brush, experience showing that it is not salted out into the mascara. At the same time, this compound provides the satisfactory development of germicidal properties and in all cases in compliance with the goal sought by the present invention.
Advantageously, the polymer constituting the bristles of the brush is a polyamide, and preferably polyamide 6.12.
It is possible, however, to envisage implementing a synthetic polymer chosen from the group including polyurethane, polyethylene, polypropylene, polyester, polyacrylic, modacrylic, alone or in mixtures.
The polymer constituting the bristles of the brush can also be an artificial or natural polymer.
According to another aspect of the invention, the cation implemented comes from a polyiminium salt (hydrochloride, for example), and notably polyhexamethylene biguanide, more commonly known as PHMB. This cation can also be made of a quaternary ammonium salt, notably quaternary polyammonium.
In one advantageous production method, the large anion is derived from a sodium polyacrylate salt, sodium silicate, sodium polyphosphate, sodium oleate or sodium lauryl sulphate.
The Applicant has observed that particularly interesting results can be obtained in terms of germicidal properties and the absence of salting out into the mascara when the composition of the invention combines sodium oleate and PHMB, advantageously in 50/50 mole proportions.
The present invention also relates to a method for depositing such a germicidal composition onto the mascara applicator brushes.
This method includes:
performing cold soaking of the brush in a mixture of at least one large cation salt and at least one large anion salt, one or the other or both having germicidal properties; then performing a rinsing step to eliminate excess substance not bound to the bristles of the brush; and then performing a drying step to eliminate the water contained in the brushes.
In other production methods, the anion and cation salts can be mixed successively, one before the other and vice-versa.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 represent an illustrative graph of the germicidal action of the composition of the invention against Escherichia coli CIP 53.126 under normal conditions of use.
FIG. 3 represents an illustrative graph of the germicidal action of the composition of the invention against Staphylococcus aureus CTP 4.83 under normal conditions of use.
DETAILED DESCRIPTION OF THE INVENTION
The present invention and its advantages can be seen in the following examples, and are supported by the appended drawing figures.
Example 1
Preparation of Brushes with Germicidal Properties
5300 brushes, produced using polyamide 6.12 bristles with a diameter of 80 micrometers (representing a weight of 1500 grams) are placed in 10 liters and treated as follows:
Prepare 4.5 kg of a solution of sodium oleate at 0.69 wt. %: dissolve 31.05 g pure sodium oleate in approximately 500 ml warm soft water, fill to 4.5 kg with cold soft water. Prepare 4.5 kg of a solution of Cosmocil CQ (PHMB sold by Avecia at 20% by weight in water) at 0.5% by weight: dissolve 112.5 g Cosmocil CQ (at 20% in water) in 500 ml cold soft water; fill to 4.5 kg with cold soft water. Add the 4.5 kg of Cosmocil CQ solution at 0.5% into the reactor (total volume of liquid: 9 liters for a bath ratio of 6). Stir the bath. Add the 4.5 kg of sodium oleate solution at 0.69% into the reactor while stirring. Continue stirring.
The brushes are removed from the reactor, then rinsed in soft water and dried.
The weight increase of the brushes is 1.84%.
Example 2
Microbiological Results of the Brush Treated According to the Invention with Mascara Absent
The purpose of this example is to test the germicidal properties of the composition of the invention when applied according to the method in example 1 to various types of fibres constituting a mascara brush.
The composition tested is the following:
COSMOCIL CQ® bactericide manufactured by AVECIA in a 20% solution: —((CH 2 ) 3 —NH—CNH—NH—CNH—NH—(CH 2 ) 3 C) n —HCl, n=16 anion: SODIUM OLEATE manufactured by RIEDEL DEHAEN: CH 3 (CH 2 ) 7 CH═CH(CH 2 ) 7 CO 2 NaC 17 H 33 CO 2 Na=304.4
The composition of the invention is applied to three different types of brushes, respectively:
1. polyamide 6.12
2. polyamide 6.6
3. polyamide 6 (two origins)
In practice, each brush sample is immersed in the COSMOCIL CQ/SODIUM OLEATE solution stirred for several hours at ordinary temperature. The bath ratio, liquid mass/brush mass, is between 3 and 10 (more advantageously, 6). The brushes are rinsed, centrifuged and dried.
For samples corresponding solely to the STRAND 14 and STRAND 14R references in polyamide 6.12, the brushes are previously rinsed in hot water and dried at 80° C.
The treated brushes are, depending on the case, post-treated by rinsing with soft water, whether cold or not.
The dry matter content of each tested sample is represented in the following table:
TABLE 1
Results
Pre-
Molar
Post-
Dry matter
Samples
Support
treatment
ratio
treatment
content
Strand 14
PA 6.12
Rinse with
l/l
2.04%
Strand 14R
water and
l/l
rinsed
2.04%
dry at
80° C.
A2
PA 6.12
l/l
4.46%
B2
PA 6.6
l/l
5.02%
C2
PA 6
l/l
4.93%
Ref. A
D2
PA 6
l/l
3.96%
Ref. B
A2R
PA 6.12
l/l
rinsed
3.42%
B2R
PA 6.6
l/l
rinsed
3.11%
C2R
PA 6
l/l
rinsed
3.05%
Ref. A
D2R
PA 6
l/l
rinsed
6.36%
Ref. B
The following microbiological test was then performed on each sample: The fibres are placed in suspension in the peptone broth contaminated with five different germs:
Escherichia coli CIP 53.126 (for STRAND 14 and STRAND 14R only) Staphylococcus aureus CIP 4.83 (except for STRAND 14 and STRAND 14R samples) Pseudomonas aeruginosa CIP 82.118 (except for STRAND 14 and STRAND 14R samples) Candida albicans IP 48.72 (except for STRAND 14 and STRAND 14R samples) Aspergillus niger IP 1431.33 (except for STRAND 14 and STRAND 14R samples)
The evolution of contamination is measured for the bacteria every day for one week and at D+1, D+5 and D+7 for yeasts and moulds. Values are given in CFU/ml. Each test is performed in triplicate.
The results are given in tables 2 to 6 below.
TABLE 2
Escherichia coli CIP 53.126
Time
STRAND 14
STRAND 14R
D0
1.67 × 10 5
1.60 × 10 5
D + 1
<2
<2
D + 2
<2
<2
D + 5
<2
<2
D + 6
<2
<2
D + 7
<2
<2
D + 8
<2
<2
TABLE 3
Staphylococcus aureus CIP 4.83
Time
A2
A2R
B2
B2R
C2
C2R
D2
D2R
D0
2.8 × 10 4
3.0 × 10 4
4.0 × 10 4
3.7 × 10 4
7.0 × 10 4
6.0 × 10 4
5.1 × 10 4
8.4 × 10 4
D + 1
<2
<2
<2
<2
<2
<2
<2
<2
D + 2
<2
<2
<2
<2
<2
<2
<2
<2
D + 5
<2
<2
<2
<2
<2
<2
<2
<2
D + 6
<2
<2
<2
<2
<2
<2
<2
<2
TABLE 4
Pseudomonas aeruginosa CIP 82.118
Time
A2
A2R
B2
B2R
C2
C2R
D2
D2R
D0
2.8 × 10 4
2.4 × 10 4
3.2 × 10 4
3.3 × 10 4
5.0 × 10 4
5.7 × 10 4
4.6 × 10 4
7.9 × 10 4
D + 1
<2
2.2 × 10 2
<2
9.5 × 10 2
3.0 × 10 2
2.6 × 10 2
<2
13
D + 2
<2
2.4 × 10 3
<2
1.6 × 10 3
1.8 × 10 3
1.0 × 10 3
<2
4.4 × 10 2
D + 5
<2
2.5 × 10 2
3.7 × 10 2
6.4 × 10 3
3.8 × 10 5
1.9 × 10 4
<2
9.5 × 10 3
D + 6
<2
<2
<2
<2
<2
<2
<2
<2
TABLE 5
Candida albicans IP 48.72
Time
A2
A2R
B2
B2R
C2
C2R
D2
D2R
D0
2.8 × 10 4
4.1 × 10 4
5.1 × 10 4
4.7 × 10 4
4.2 × 10 4
4.5 × 10 4
4.5 × 10 4
4.4 × 10 4
D + 1
<2
<2
<2
<2
<2
<2
<2
<2
D + 5
<2
<2
<2
<2
<2
<2
<2
<2
D + 6
<2
<2
<2
<2
<2
<2
<2
<2
TABLE 6
Aspergillus niger IP 1431.33
Time
A2
A2R
B2
B2R
C2
C2R
D2
D2R
D0
1.6 × 10 4
1.5 × 10 4
2.1 × 10 4
3.8 × 10 4
1.7 × 10 4
2.6 × 10 4
4.0 × 10 4
2.2 × 10 4
D + 1
<2
<2
<2
<2
<2
<2
<2
<2
D + 5
<2
<2
<2
<2
<2
<2
<2
<2
D + 6
<2
<2
<2
<2
<2
<2
<2
<2
We observe that the STRAND 14 (not rinsed) and STRAND 14R (rinsed) samples are effective against Escherichia coli CIP 53.126.
We also observe that samples A2, B2, C2 and D2 present good antibacterial and antifungal activity. Indeed, we observe a rapid decrease: count lower than 2 CFU/ml in 24 hours.
Against the Pseudomonas aeruginosa CIP 82.118 strain, samples A2 and D2 present good antibacterial activity, since a rapid decrease is observed to a threshold under 2 CFU in 24 hours. Likewise, samples B2 and C2 present good antibacterial activity in 6 days, since the decrease reaches a threshold under 2 CFU/ml.
Measurement of the Salting Out of the Germicidal Composition into the Mascara
This measurement of salting out into the mascara is performed under normal conditions of use, i.e. at the level of the actual cosmetic compound contained in the bottle. It consisted in quantifying or detecting the bactericidal matter, COSMOCIL®, bound to the bristles of the brush according to the method previously described.
For this, the brushes are placed in contact continuously for 8 days at ambient temperature and at 40° C. Negative controls and COSMOCIL® (20% solution) are used to calibrate the measurement device used.
The various measurements made show that, in all cases, detection is below 0.003%.
Example 3
Measurement of the Antimicrobial Activity of PURCILON® Fibres Mounted on a Brush Under Real Conditions of Use
In this example, we verify the antimicrobial activity of fibres treated with PURCILON® mounted on a brush under real conditions of use, i.e. for mascara.
Composition of PURCILON®: Polyamide 6.12 with 4.7% dry material content (similar to the A2R reference) treated according to the method described above on 1000 brushes.
Material and Method
Mascara Base
The base formula chosen is black water-resistant mascara with the following preservative system:
Ethyl para-hydroxybenzoate (E POB)
0.20%
Methyl para-hydroxybenzoate (M POB)
0.10%
Propyl para-hydroxybenzoate (P POB)
0.155%
Benzyl alcohol, methyl-4-hydroxybenzoate,
0.50%
propyl-4-hydroxybenzoate
This base also contains matter that can facilitate the action of the preservatives such as:
Tetrasodium salt of 0.10% ethylenediaminetetraacetic acid (EDTA) Glycerine, water, 1,2-octanediol, PEG-8, 3% sodium polyacrylate Butylene glycol 1% The preservative was validated according to criteria B of the European pharmacopoeia.
Strains
The protective power of the mascara was studied for the following microbial strains:
Escherichia coli CIP 53.126 Staphylococcus aureus CIP 4.83
The strains are maintained by deep freezing. They are used after Trypcase soy agar subculturing.
Experimental Protocol
Controls and Trials Performed
The trials performed with the treated fibres and mascara with preservatives are called Ft trials.
At the same time, controls are made using the same protocol:
Ta: treated, non-contaminated fibres placed in contact with mascara without preservatives, which is used to verify the cleanliness of the treated fibres as well as that of the small bottles. Tb: non-treated, non-contaminated fibres placed in contact with mascara without preservatives, which is used to verify the cleanliness of the non-treated fibres as well as that of the small bottles. Tc: treated, contaminated fibres placed in contact with mascara without preservatives, which is used to verify the real incidence of the bactericidal effect of the treated fibres. Td: non-treated, contaminated fibres placed in contact with mascara containing preservatives, which is used to verify the incidence of the preservative system in the mascara on decreasing the germ concentration. Te: non-treated, contaminated fibres placed in contact with mascara without preservatives.
The principle consists in contaminating the brushes by soaking them in a germ solution and then inserting them into the small mascara bottles containing 6 grams of the Cilpur® formula and then monitoring the evolution of the contamination over time.
Each stock solution of germs is placed in the empty small bottles which are previously decontaminated with gamma rays. The diaphragm in the bottle provides a good calibration of the volume retained on the brush (estimated volume: 0.0708 ml over 10 trials).
The protective power of the fibres was studied using:
two stock solutions of E. coli calibrated to obtain an initial contamination of approximately 10 8 CFU/ml for S1 and 10 7 CFU/ml for S2. one stock solution of S. aureus calibrated to obtain an initial contamination of approximately 10 5 CFU/ml.
To evaluate the initial quantity of germs, the brush is used to retrieve:
for E. coli , 0.5 g±0.05 g mascara in 9 ml Eugon LT100 (neutralising diluent). for S. aureus, 0.25 g±0.01 g mascara in 9 ml Eugon LT100.
Then, 0.5 ml of each sample is inoculated. The agars are then incubated at 30-35° C. The small bottles are sealed with the brushes and stored at 20-25° C.
Checks Performed on E. coli:
The bottles are checked after 24 hours of contact time for the first contamination. Two other overcontaminations are then performed on the same mascara bottles with the same brushes and checks on the evolution of contaminations are performed after 6 hours and 24 hours of contact.
Checks Performed on S. aureus:
The bottles are checked after 1, 2 and 6 hours of contact for the first two contaminations. For the third overcontamination, the checks are performed after 1, 2, 6 and 24 hours of contact.
All trials and controls are performed in triplicate as are the agar inoculation, which makes it possible to perform a statistical assessment of the results and to eliminate abnormal values.
Results and Discussion
Populations are determined using the results of viable germ counts. After eliminating the abnormal values, an average of the various trials is calculated.
Escherichia coli:
The trials performed with solutions S1 and S2 are fairly similar as can be seen in FIGS. 1 and 2 .
A sharp decrease in germs is observed for trials Td and Ft (approximately 2 log in 6 hours). Comparison with the results obtained for trials Tc and Te can be used to determine that this log reduction is directly linked to the action of the preservatives present in the mascara.
Trials Td and Ft, notably with solution S2, demonstrate an improvement in the log reduction when the action of the preservatives in the mascara is combined with those present in the treated fibres. The smaller the initial population of viable germs, the greater this improvement. Trials Tc and Te back up this hypothesis of a synergistic action between the preservatives present in the mascara and in the treated fibres.
Staphylococcus aureus:
As was the case for E. coli , a sharp decrease in germs is observed for trials Td and Ft ( FIG. 3 ). Comparison with the results obtained for trials Tc and Te can be used to determine that this log reduction is directly linked to the combined action of the preservatives present in the mascara and the germicide present in the treated fibres.
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A mascara applicator brush is provided, including polymer bristles which are coated with a germicidal composition. The aforementioned composition is made from a mixture based on at least one large cation and at least one large anion, in which one or both develop germicidal properties.
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RELATED APPLICATIONS
This application is a continuation-in-part of PCT/CA98/00803 filed Aug. 20, 1998, now at the national phase, and claiming priority on Canadian patent application serial number 2,210,251 filed Aug. 25, 1997, now abandoned.
BACKGROUND OF THE INVENTION
(a) Field of the Invention
The invention relates to the identification of gro-1 gene and four other genes located within the same operon and to show that the gro-1 gene is involved in the control of a central physiological clock.
(b) Description of Prior Art
The gro-1 gene was originally defined by a spontaneous mutation isolated from of a Caenorhabditis elegans strain that had recently been established from a wild isolate (J. Hodgkin and T. Doniach, Genetics 146: 149-164 (1997)). We have shown that the activity of the gro-1 gene controls how fast the worms live and how soon they die. The time taken to progress through embryonic and post-embryonic development, as well as the life span of gro-1 mutants is increased (Lakowski and Hekimi, Science 272: 1010-1013, (1996)). Furthermore, these defects are maternally rescuable: when homozygous mutants (gro-1/gro-1) derive from a heterozygous mother (gro-1/+), these animals appear to be phenotypically wild-type. The defects are seen only when homozygous mutants derive from a homozygous mother (Lakowski and Hekimi, Science 272: 10101013, (1996)). In general, the properties of the gro-1 gene are similar to those of three other genes, clk-1, clk-2 and clk-3 (Wong et al., Genetics 139: 1247-1259 (1995); Hekimi et al., Genetics, 141: 1351-1367 (1995); Lakowski and Hekimi, Science 272: 1010-1013, (1996)), and this combination of phenotypes has been called the Clk (“clock”) phenotype. All four of these genes interact to determine developmental rate and longevity in the nematode. Detailed examination of the clk-1 mutant phenotype has led to the suggestion that there exists a central physiological clock which coordinates all or many aspects of cellular physiology, from cell division and growth to aging. All four genes have a similar phenotype and thus appear to impinge on this physiological clock.
It would be highly desirable to be provided with the molecular identity of the gro-1 gene.
SUMMARY OF THE INVENTION
One aim of the present invention is to provide the molecular identity of the gro-1 gene and four other genes located within the same operon.
In accordance with the present invention there is provided a gro-1 gene which has a function at the level of cellular physiology involved in developmental rate and longevity, wherein gro-1 is located within an operon and gro-1 mutants have a longer life and a altered cellular metabolism relative to the wild-type.
In accordance with a preferred embodiment, the gro-1 gene of the present invention codes for a GRO-1 protein having the amino acid sequence set forth in FIGS. 3A-3B (SEQ ID. NO:2).
The gro-1 gene is located within an operon which has the nucleotide sequence set forth in SEQ. ID NO:1 and which also codes for four other genes, referred as gop-1, gop-2, gop-3 and hap-1 genes.
In accordance with a preferred embodiment, the gop-1 gene of the present invention codes for a GOP-1 protein having the amino acid sequence set forth in FIGS. 13A-13C (SEQ ID. NO:4).
In accordance with a preferred embodiment, the gop-2 gene of the present invention nodes for a GOP-2 protein having the amino acid sequence set forth in FIG. 14 (SEQ ID. NO:5).
In accordance with a preferred embodiment, the gop-3 gene of the present invention codes for a GOP-3 protein having the amino acid sequence set forth in FIGS. 15A-15B (SEQ ID. NO:6).
In accordance with a preferred embodiment, the hap-1 gene of the present invention codes for a HAP-1 protein having the amino acid sequence set forth in FIG. 16 (SEQ ID. NO:7).
In accordance with a preferred embodiment of the present invention, the gro-1 gene is of human origin and has the nucleotide sequence set forth in FIG. 8 (SEQ ID. NO:3).
In accordance with a preferred embodiment of the present invention, there is provided a mutant GRO-1 protein which has the amino acid sequence set forth in FIG. 3 C.
In accordance with the present invention there is also provided a GRO-1 protein which has a function at the level of cellular physiology involved in developmental rate and longevity, wherein said GRO-1 protein is encoded by the gro-1 gene identified above.
In accordance with a preferred embodiment of the present invention, there is provided a GRO-1 protein which has the amino acid sequence set forth in FIGS. 3A-3B (SEQ ID. NO:2).
In accordance with a preferred embodiment of the present invention, there is provided a GOP-1 protein which has the amino acid sequence set forth in FIGS. 13A-13C (SEQ ID. NO:4).
In accordance with a preferred embodiment of the present invention, there is provided a GOP-2 protein which has the amino acid sequence set forth in FIG. 14 (SEQ ID. NO:5).
In accordance with a preferred embodiment of the present invention, there is provided a GOP-3 protein which has the amino acid sequence set forth in FIGS. 15A-15B (SEQ ID. NO:6).
In accordance with a preferred embodiment of the present invention, there is provided a HAP-1 protein which has the amino acid sequence set forth in FIG. 16 (SEQ ID. NO:7).
In accordance with the present invention there is also provided a method for the diagnosis and/or prognosis of cancer in a patient, which comprises the steps of:
a) obtaining a tissue sample from said patient; b) analyzing DNA of the obtained tissue sample of step a) to determine if the human gro-1 gene is altered; wherein alteration of the human gro-1 gene is indicative of cancer.
In accordance with the present invention there is also provided a mouse model of aging and cancer, which comprises a gene knock-out of murine gene homologous to gro-1.
In accordance with the present invention there is provided the use of compounds interfering with enzymatic activity of GRO-1, GOP-1, GOP-2, GOP-3 or HAP-1 for enhancing longevity of a host.
In accordance with the present invention there is provided the use of compounds interfering with enzymatic activity of GRO-1, GOP-1, GOP-2, GOP-3 or HAP-1 for inhibiting tumorous growth.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A illustrates the genetic mapping of gro-1;
FIG. 1B illustrates the physical map of the gro-1 region;
FIG. 2A illustrates cosmid clones able to rescue the gro-1 (e2400) mutant phenotype;
FIG. 2B illustrates the genes predicted by Genefinder, the relevant restriction sites and the fragments used to subclone the region;
FIGS. 3A-3C illustrate the genomic sequence and translation of the C. elegans gro-1 gene (SEQ ID NO: 2 and 66);
FIG. 3D illustrates the predicted mutant protein (SEQ ID NO: 64 and 65);
FIG. 4A illustrates the five genes of the gro-1 operon (SEQ. ID. NO:1);
FIG. 4B illustrates the transplicing pattern of the five genes of the gro-1 operon;
FIGS. 5A-5B illustrates the alignment of gro-1 with the published sequences of the E. coli (P16384) and yeast (PO7884) enzymes;
FIG. 6 illustrates the biosynthetic step catalyzed by DMAPP transferase (MiaAp in E. coli , Mod5p in S. cerevisiae , and GRO-1 in C. elegans );
FIG. 7 illustrates the alignment of the predicted HAP-1 amino acid sequence with homolgues from other species (SEQ ID NO: 69, 7, 70 and 71);
FIG. 8 illustrates the full mRNA sequence of human homologue of gro-1 referred to as hgro-1 (SEQ. ID. NO:3);
FIGS. 9A-9B illustrates a comparison of the conceptual amino acid sequences for GRO-1 (SEQ ID NO: 2) and hgro-1p(SEQ ID NO: 63);
FIG. 10 illustrates a conceptual translation of a partial sequence of the Drosophila homologue of gx-o-1 (AA816785) (SEQ ID NO: 72);
FIG. 11 illustrates the structure of pMQB (SEQ ID NO: 73 and 2);
FIG. 12 illustrates construction of pMQ18;
FIGS. 13A-13C illustrate the genomic sequence and translation of the gop-1 gene (SEQ ID NO: 73 and 4);
FIG. 14 illustrates the genomic sequence and translation of the gop-2 gene (SEQ ID NO: 74 and 75);
FIGS. 15A-15B illustrate the genomic sequence and translation of the gop-3 gene (SEQ ID NO: 75 and 6); and
FIG. 16 illustrates the genomic sequence and translation of the hap-1 gene (SEQ ID NO: 6 and 77).
DETAILED DESCRIPTION OF THE INVENTION
The Gro-1 Phenotype
In addition to the previously documented phenotypes, we recently found that gro-1 mutants were temperature-sensitive for fertility. At 25° the progeny of these mutants is reduced so much that a viable strain cannot be propagated. In contrast, gro-1 strains can easily be propagated at 15 and 20° C.
We also discovered that the gro-1 (e2400) mutation increases the incidence of spontaneous mutations. As gro-1(e2400) was originally identified in a nonstandard background (Hodgkin and Doniach, Genetics. 146: 149-164 (1997)), we first backcrossed the mutations 8 times against N2, the standard wild type strain. We then undertook to examine the gro-1 strain and N2 for the occurrence of spontaneous mutants which could be identified visually. We focused on the two class of mutants which are detected the most easily by simple visual inspection, uncoordinated mutants (Unc) and dumpy mutants (Dpy). We examined 8200 wild type worms and found no spontaneous visible mutant. By contrast, we found 6 spontaneous mutants among 12500 gro-1 mutants examined. All mutants produced entirely mutant progeny indicating that they were homozygous.
Name Orientation Sequence (5′-3′) SEQ ID NO: SHP91 forward CGAACACTTTATATTTCTCG SEQ. ID. NO:8 SHP92 reverse GATAGTTCCCTTCGTTCGGG SEQ. ID. NO:9 SHP93 forward TTTCTGGATTTTAACCTTCC SEQ. ID. NO:10 SHP94 forward TTTCCGAGAAGTCACGTTGG SEQ. ID. NO:11 SHP95 reverse TACAGGAATTTTTGAACGGG SEQ. ID. NO:12 SHP96 forward CTTCAGATGACGTGGATTCC SEQ. ID. NO:13 SHP97 forward GGAATCCGAAAAAGTGAACT SEQ. ID. NO:14 SHP98 forward AAGAGATACACTCAATGGGG SEQ. ID. NO:15 SHP99 reverse ATCGATACCACCGTCTCTGG SEQ. ID. NO:16 SHP109 reverse TTGAATCTACACTAATCACC SEQ. ID. NO:17 SHP100 reverse CCAATTATCTTTTCCAGTCA SEQ. ID. NO:18 SHP110 forward ACATTATAAAGTTACTGTCC SEQ. ID. NO:19 SHP118 forward TTTTAGTTAAAGCATTGACC SEQ. ID. NO:20 SHP119 reverse ACATCTTTATCCATTTCTCC SEQ. ID. NO:21 SHP120 forward TGCAAAGGCTCTGGAACTCC SEQ. ID. NO:22 SHP129 reverse AAAAACCACTTGATATAAGG SEQ. ID. NO:23 SHP130 reverse CATCCAAAAGCAGTATCACC SEQ. ID. NO:24 SHP134 forward TTAATTGGATGCAAGCACCCC SEQ. ID. NO:25 SHP135 reverse ATTACTATACGAACATTTCC SEQ. ID. NO:26 SHP138 forward TTGTAAAGGCGTTAGTTTGG SEQ. ID. NO:27 SHP139 forward CAGGAGTATTTGGTGATGCG SEQ. ID. NO:28 SHP140 forward CGACGGGGAGAAGGTGACGG SEQ. ID. NO:29 SHP141 reverse AAAACTTCTACCAACAATGG SEQ. ID. NO:30 SHP142 reverse CGTAATCTCTCTCGATTAGC SEQ. ID. NO:31 SHP143 reverse CCGTGGGATGGCTACTTGCC SEQ. ID. NO:32 SHP144 reverse TGGATTTGTGGCACGAGCGG SEQ. ID. NO:33 SHP145 reverse TTGATTGCCTCTCCTCGTCC SEQ. ID. NO:34 SHP146 reverse ATCAACATCTGATTGATTCC SEQ. ID. NO:35 SHP151 forward CAGCGAGCGCATGCAACTATATATTGA SEQ. ID. NO:36 GCAGG SHP159 forward AATAAATATTTAAATATTCAGATATACC SEQ. ID. NO:37 CTGAACTCTACAG SHP160 reverse AAACTGTAGAGTTCAGGGTATATCTGA SEQ. ID. NO:38 ATATTTAAATATTTATTC SHP161 forward GTACGTGGAGCTCTGCAACTATATATT SEQ. ID. NO:39 GAGCAGG SHP162 reverse ATGACACTGCAGGATAGTTCCCTTCGT SEQ. ID. NO:40 TCGGG SHP163 forward GTGTTGCATCAGTTCATTCC SEQ. ID. NO:41 SHP164 forward GCTGTGCTAGAAGTCAGAGG SEQ. ID. NO:42 SHP165 reverse GTTCTCCTTGGAATTCATCC SEQ. ID. NO:43 SHP170 reverse AGTATATCTAGATGTGCGAGTCTCTGC SEQ. ID. NO:44 CAATT SHP171 reverse AGTAATTGTACATTTAGTGG SEQ. ID. NO:45 SHP172 forward ATTAACCTTACTTACTTACC SEQ. ID. NO:46 SHP173 forward CTAAACTAAGTAATATAACC SEQ. ID. NO:47 SHP174 reverse GTTGATTCTTTGAGCACTGG SEQ. ID. NO:48 SHP175 forward AATTCGACCAATTACATTGG SEQ. ID. NO:49 SHP176 reverse AACATAGTTGTTGAGGAAGG SEQ. ID. NO:50 SHP177 forward AATTAATGGAGATTCTACGG SEQ. ID. NO:51 SHP178 forward TCAGCATCTAGAAATGCAGG SEQ. ID. NO:52 SHP179 reverse CGAATGTCAACATTCACTGG SEQ. ID. NO:53 SHP180 forward CTTAACCTGATGTGTACTCG SEQ. ID. NO:54 SHP181 forward ATGAAGCTTTAGAGGATGCC SEQ. ID. NO:55 SHP182 forward CGACGAATTTCTGGAGTCGG SEQ. ID. NO:56 SHP183 reverse ACTGCATTATCCATTAATCC SEQ. ID. NO:57 SHP184 reverse CACCCAAATAACATCTATCC SEQ. ID. NO:58 SHP185 forward TTTAACCTCATCTTCGCTGG SEQ. ID. NO:59 SHP190 forward ATGTTCCGCAAGCTTGGTTC SEQ. ID. NO:60 SL1 forward TTTAATTACCCAAGTTTGAG SEQ. ID. NO:61 SL2 forward TTTTAACCCAGTTACTCAAG SEQ. ID. NO:62
Positional Cloning of Gro-1
gro-1 lies on linkage group III, very close to the gene clk-1. To genetically order gro-1 with respect to clk-1 on the genetic map, 54 recombinants in the dpy-17 to lon-1 interval were selected from among the self progeny of a strain which was unc-79(e1030)++clk-1(e2519) lon-1(e678)+/+dpy-17(e164) gro-1(e2400)+sma-4,(e729). Three of these showed neither the Gro-1 nor the Clk-1 phenotypes, but carried unc-79 and sma-4, indicating that these recombination events had occurred between gro-1 and clk-1. From the disposition of the markers, this showed that the gene order was dpy-17 gro-1 clk-1 lon-1, and the frequency of events indicated that the gro-1 to clk-1 distance was 0.03 map units. In this region of the genome, this corresponds to a physical map distance of ˜20 kb.
Several cosmids containing wild-type DNA spanning this region of the genome were tested by microinjection into gro-1 mutants for their ability to complement the gro-1(e2400) mutation (FIG. 1 ). gro-1 was mapped between dpy-17 and lon-1 on the third chromosome, 0.03 m.u. to the left of clk-1 (Fig. A).
Based on the above genetic mapping, gro-1 was estimated to be approximately 20 kb to the left of clk-1. Eight cosmids (represented by medium bold lines) were selected as candidates for transformation rescue (FIG. 1 B). Those which were capable of rescuing the gro-1(e2400) mutant phenotype are represented as heavy bold lines (FIG. 1 B).
Of these, only B0498, C34E10 and ZC395 were able to rescue the mutant phenotype. Transgenic animals were fully rescued for developmental speed. In addition, the transgenic DNA was able to recapitulate the maternal rescue seen with the wild-type gene, that is, mutants not carrying the transgenic DNA but derived from transgenic mothers display a wild type phenotype. The 7 kb region common to the three rescuing cosmids had been completely sequenced, and this sequence was publicly available.
We generated sabclones of ZC395 and assayed them for rescue (FIG. 2 ). The common 6.5 kb region is blown up in part B. B0498 has not been sequenced and therefore its ends can not be positioned and are therefore represented by arrows.
One subclone pMQ2, spanned 3.9 kb and was also able to completely rescue the growth rate defect and recapitulate the maternal effect. The sequences in pMQ2 potentially encodes two genes. However, a second subclone, pMQ3, which contained only the first of the potential genes (named ZC395.7 in FIG. 2 A), was unable to rescue.
Furthermore., frameshifts which would disrupt each of the two genes' coding sequences were constructed in pMQ2 and tested for rescue. Disruption of the first gene (in pMQ4) did not eliminate rescuing ability, but disruption of the second gene (in pMQ5) did. This indicates that the gro-1 rescuing activity is provided by the second predicted gene.
pMQ2 was generated by deleting a 29.9 kb SpeI fragment from ZC395, leaving the left-most 3.9 kb region containing the predicted genes ZC395.7 and ZC395.6 (FIG. 2 B). pMQ3 was created in the same fashion, by deleting a 31.4 kb NdeI fragment from ZC395, leaving only ZC395.7 intact. In pMQ4, a frameshift was induced in ZC395.7 by degrading the 4 bp overhang of the ApaI site. A frameshift was also induced in pMQ5 by filling in the 2 bp overhang of the NdeI site found in the second exon of ZC395.6. These frameshifts presumably abolish any function of ZC395.7 and ZC395.6 respectively. The dotted lines represent the extent of frameshift that resulted from these alterations.
To establish the splicing pattern of this gene, cDNAs encompassing the 5′ and 3′ halves of the gene were produced by reverse transcription-PCR and sequenced (FIG. 3 ).
This revealed that the gene is composed of 9 exons, spans ˜2 kb, and produces an mRNA of 1.3 kb. To confirm that this is indeed the gro-1 gene, genomic DNA was amplified by PCR from a strain containing the gro-1(e2400) mutation and the amplified product was sequenced. A lesion was found in the 5th exon, where a 9 base-pair sequence has been replaced by a 2 base-pair insertion, leading to a frameshift (FIG. 3 C). FIG. 3C illustrates those residues which differ from wild type are in bold.
The reading frame continues out-of-frame for another 33 residues before terminating.
FIGS. 3A-B illustrate the coding sequence in capital letters, while the introns, and the untranslated and intergenic sequence are in lower case letters. The protein sequence is shown underneath the coding sequence. Position 1 of the nucleotide sequence is the first base after the SL2 trans-splice acceptor sequence. Position 1 of the protein sequence is the initiator methionine. All PCR primers used for genomic and cDNA amplification are represented by arrows. For primers extending downstream (arrows pointing right) the primer sequence corresponds exactly to, the nucleotides over which the arrow extends. But for primers extending upstream (arrows pointing left) the primer sequence is actually the complement of the sequence under the arrow. In both cases the arrow head is at the 3′ end of the primer. The sequence of the two primers which flank gro-1 (SHP93 and SHP92) are not represented in this figure. Their sequences are: SHP93 TTTCTGGATTTTAACCTTCC (SEQ. ID. NO:10) and SHP92 GATAGTTCCCTTCGTTCGGG (SEQ. ID. NO:9). The wild type splicing pattern was determined by sequencing of the cDNA. Identification of the e2400 lesion was accomplished by sequencing the e2400 allele. The e2400 lesion consists of a 9 bp deletion and a 2 bp insertion at position 1196, resulting in a frameshift.
Gro-1 is Part of a Complex Operon ( FIGS. 3A-3B )
Amplification of the 5′ end of gro-1 from cDNA occurred only when the trans-spliced leader SL2 was used as the 5′ primer, and not when SL1 was used. SL2 is used for trans-splicing to the downstream gene when two genes are organized into an operon (Spieth et al., Cell 73: 521-532 (1993); Zorio et al., Nature 372: 270-272 (1994)). This indicates that at least one gene upstream of gro-1 is co-transcribed with gro-1 from a common promoter. We found that sequences from the 5′ end of the three next predicted genes upstream of gro-1 (ZC395.7, C34E10.1, and C34E10.2) all could only be amplified with SL2. Sequences from the fourth predicted upstream gene (C34E10.3), however, could be amplified with neither spliced leader, suggesting that it is not trans-spliced. The distance between genes in operons appear to have an upper limit (Spieth et al., Cell 73: 521-532 (1993); Zorio et al., Nature 372: 270-272 (1994)), and no gene is predicted to be close enough upstream of C34E10.3 or downstream of gro-1 to be co-transcribed with these genes. Our findings suggest therefore that gro-1 is the last gene in an operon of five co-transcribed genes (FIG. 4 ).
Nested PCR was used to amplify the 5 end of each gene. SL1 or SL2 specific primers were used in conjunction with a pair of gene-specific primers cDNA generated by RT-PCR using mixed stage N2 RNA was used as template in the nested PCR. FIG. 4A illustrates a schematic of the gro-1 operon showing the coding sequences of each gene and the primers (represented by flags) used to establish the trans-splicing patterns.
FIG. 4B illustrates the products of the PCR with SL1 and SL2 specific primers for each of the five genes. The sequences of the primers used are as follows: SL1: TTTAATTACCCAAGTTTGAG (SEQ. ID. NO:61), SL2: TTTTAACCCAGTTACTCAAG (SEQ. ID. NO:62), SHP141: AAAACTTCTACCAACAATGG (SEQ. ID. NO:30), SHP142: CGTAATCTCTCTCGATTAGC (SEQ. ID. NO:31), SHP143: CCGTGGGATGGCTACTTGCC (SEQ. ID. NO:32), SHP144: TGGATTTGTGGCACGAGCGG (SEQ. ID. NO:33), SHP145: TTGATTGCCTCTCCTCGTCC (SEQ. ID. NO:34), SHP146: ATCAACATCTGATTGATTCC (SEQ. ID. NO:35), SHP130: CATCCAAAAGCAGTATCACC (SEQ. ID. NO:24); SHP119: ACATCTTTATCCATTTCTCC (SEQ. ID. NO:21), SHP95: TACAGGAATTTTTGAACGGG (SEQ. ID. NO:12), SHP99: ATCGATACCACCGTCTCTGG (SEQ. ID. NO:16).
The gene immediately upstream of gro-1, has homology to the yeast gene HAM1, and we have renamed the gene hap-1. We have established its splicing pattern by reverse transcription PCR and sequencing. This revealed that hap-1 is composed of 5 exons and produces an mRNA of 0.9 kb. We also found that sequences which were predicted to belong to ZC395.7 (now hap-1) are in fact spliced to the exons of C34E10.1. This is consistent with our finding that hap-1 is SL2 spliced as it puts the end of the C34E10.1 very close to the start of hap-1 (FIG. 4 ).
The Gro-1 Gene Product
Conceptual translation of the gro-1 transcript indicated that it encodes a protein of 430 amino acids highly similar to a strongly conserved cellular enzyme: dimethylallyldiphosphate:tRNA dimethylallyltransferase (DMAPP transferase). FIG. 5 shows an alignment of gro-1 with the published sequences of the E. coli (P16384) and yeast (P07884) enzymes. Residues where the biochemical character of the amino acids is conserved are shown in bold. Identical amino acids are indicated further with a dot. The ATP/GTP binding site and the 0.30 C 2 H 2 zinc finger site are predicted and hot experimental. The point at which the gro-1(e2400) mutation alters the reading frame of the sequence is shown. The two alternative initiatior methionines in the yeast sequence, and the putative corresponding methionines in the worm sequence, are underlined.
Database searches also identified a homologous human expressed sequence tag (Genbank ID: Z40724). The human clone has been used to derive a sequence tagged site (STS). This means that the genetic and physical position of the human gro-1 homologue is known. It maps to chromosome 1, 122.8 cR from the top of Chr 1 linkage group and between the markers D1S255 and D1S2861. This information was found in the UniGene database or the National Center for Biotechnology Information (NCBI). We have sequenced Z40724 by classical methods but found that Z40724 is not a full length cDNA clone as it does not contain an initiator methionine nor the poly A tail. We used the sequence of Z40724 to identify further clones by database searches. We found one clone (Genbank ID: AA332152) which extended the sequence 5′ by 28 nucleotides, as well as one clone (Genebank ID: AA121465) which extended the sequence substantially in the 3′ direction but didn't include the poly A tail. We then used AA121465 to identify an additional clone (AA847885) extending the sequence to the poly A tail. FIG. 8 shows the full sequence with the putative initiator ATG shown in bold and the sequence of Z60724 is shown underlined. A comparison of the conceptual amino acid sequences for GRO-1 (SEQ ID NO:2) and hgro-1p as deduced from SEQ ID NO:3, is shown in FIG. 9 . Amino acid identities are indicated by a dot. Both sequences contain a region with a zinc finger motif which is shown underlined.
An additional metazoan homologue is represented by Drosophila EST: Genbank accession: AA816785. In E. coli i and other bacteria, the gene encoding DMAPP transferase is called miaA (a.k.a trpX) and is called modS in yeast. DMAPP transferase catalyzes the modification of adenosine 37 of tRNAs whose anticodon begins with U (FIG. 6 ).
In these organisms the enzyme has been shown to use dimethylallyldiphosphate as a donor to generate dimethylallyl-adenosine (dma 6 A37), one base 3′ to the anticodon (for review and biochemical characterization of the bacterial enzyme see Persson et al., Biochimie 76: 1152-1160 (1994); Leung et al., J Biol Chem 272: 13073-13083 (1997); Moore and Poulter, Biochemistry 36: 604-614 (1997)). In earlier literature this modification is often referred to as isopentenyl adenosine (i 6 A37).
The high degree of conservation of the protein sequence between GRO-1 and DMAPP in S. cerevisiae and E. coli suggest that GRO-1 possesses the same enzymatic activity as the previously characterized genes. The sequence contains a number of conserved structural motifs (FIG. 5 ), including a region with an ATP/GTP binding motif which is generally referred to as the ‘A’ consensus sequence (Walker et al., EMBO J 1: 945-951 (1982)) or the ‘P-loop’ (Saraste et al., Trends Biochem Sci 15: 430-434 (1990)).
In addition, at the C-terminal end of the GRO-1 sequence, there is a C2H2 zinc finger motif as defined by the PROSITE database. This type of DNA-binding motif is believed to bind nucleic acids (Klug and Rhodes, Trends Biochem Sci 12: 464-469 (1987)). Although there appears to be some conservation between the worm and yeast sequences in the C-terminus end of the protein (FIG. 5 ), including in the region encompassing the zinc finger in GRO-1, the zinc finger motif per se is not conserved, in yeast but is present in humans (FIG. 9 ).
In yeast DMAPP transferase is the product of the MOD5 gene, and exists in two forms: one form which is targeted principally to the mitochondria, and one form which is found in the cytoplasm and nucleus. These two forms differ only by a short N-terminal sequence whose presence or absence is determined by differential translation initiation at two “in frame” ATG codons. (Gillman et al., Mol & Cell Biol 11: 2382-90 (1991)). The gro-1 open reading frame also contains two ATG codons at comparable positions, with the coding sequence between the two codons constituting a plausible mitochondrial sorting signal (FIGS. 3 and 5 ). It is likely therefore that DMAPP transferase in worms also exists in two forms, mitochondrial and cytoplasmic.
It should be noted, however, that the sequence of hgro-1 shows only one in-frame methionine before the conserved ATP/GTP binding site ( FIG. 9 ) As we cannot be assured to have determined the sequence of the full length transcript, it is possible that further 5′ sequence might reveal an additional methionine. Alternatively, in humans, the mechanism by which the enzyme is targeted to several compartments might not involved differential translation initiation. In this context, it should be noted that the sorting signals which can be predicted from the sequence of hgro-1p are predicted to be highly ambiguous by the prediction program PSORT II. Furthermore, a conceptual translation of the Drosophila sequence (AA816785) predicts only one initiator methionine before the ATP/GTP binding site as well as several in-frame stop codons upstream of this start (FIG. 10 ), suggesting that no additional upstream ATG could serve as translation initiation site. In the figure, stop codons are indicated by stop, methionines are indicated by Met, and the conserved ATP/GTP binding site is underlined.
Expression Pattern of GRO-1
We have also constructed a reporter gene expressing a fusion protein containing the entire GRO-1 amino acid sequence fused at the C-terminal end to green fluorescent protein (GFP); The promotor of the reporter gene is the sequence upstream of gop-1 (FIGS. 13 A- 13 C), the first gene in the operon (see FIG. 4 ). The promotor sequence is 306 bp long starting 32 nucleotides upstream of the gop-1 ATG. It is fused at the exact level upstream of gro-1 where trans-splicing to SL2 normaly occurs.
The genes gop-2 ( FIG. 14 ) and gop-3 ( FIGS. 15A-15B ) are also located in the operon (see FIG. 4 ), the second and third genes in the operon.
We first construct the clone pMQ8 in which gro-1 is directly under the promoter for the whole operon using the hybrid primers SHP160 (SEQ. ID. NO, 38) and SHP159 (SEQ. ID. NO:37) and the flanking primers SHP161 (SEQ. ID. NO:39) and SHP162 (SEQ. ID. NO:40) in sequential reactions each followed by purification of the products and finally cloning into pUC18 (FIG. 11 ).
Primers SHP151, (SEQ. ID. NO:36) and SHP170 (SEQ. ID. NO:44) where then used to amplify part of the insert in pMQ8 and clone in pPD95.77 (gift from Dr Andrew Fire) which was designed to allow a protein of interest to be transcriptionally fused to Green Fluorescent Protein (GFP) (FIG. 12 ).
The reporter construct fully rescues the phenotype of a gro-1(e24.00) mutant upon injection and extrachromosomal array formation, indicating that the fusion to the GFP moiety does not significantly inhibit the function of GRO-1. Fluorescent microscopy indicated that gro-1 is expressed in most or all somatic cells. Furthermore, the GRO-1::GFP fusion protein is localized in the mitochondria, in the cytoplasm as well as in the nucleus.
The Hap-1 Gene Product ( FIG. 16 )
hap-1 is homologous: to the yeast gene HAM1 as well as to sequences in many organisms including bacteria and mammals (FIG. 7 ).
The origin of the worm and yeast sequence is as described above and below. The human, sequence was inferred from a cDNA sequence assembled from expressed sequence tags (ESTs); the accession numbers of the sequences used were: AA024489, AA024794, AA025334, AA026396, AA026452, AA026502, AA026503, AA026611, AA026723, AA035035, AA035523, AA047591, AA047599, AA056452, AA115232, AA115352, AA129022, AA129023, AA159841, AA160353, AA204926, AA226949, AA227197 and D20115. The E. coli sequence is a predicted gene (accession 1723866).
Mutations in HAM1 increase the sensitivity of yeast to the mutagenic compound 6-N-hydroxylaminopurine (HAP), but do not increase spontaneous mutation frequency (Nostov et al., Yeast 12: 17-29 (1996)). HAP is an analog of adenine and in vitro experiments suggest that the mechanism of HAP mutagenesis is its conversion to a deoxynucleoside triphosphate which is incorporated ambiguously for dATP and dGTP during DNA replication (Abdul-Masih and Bessman, J Biol Chem 261 (5): 2020-2026 (1986)). The role of the Ham1p gene product in increasing sensitivity to HAP remains unclear.
Explaining the Pleiotropy of MiaA and Gro-1
Mutations in miaA, the bacterial homologue of gro-1, show multiple phenotypes and affect cellular growth in complex ways. For example, in Salmonella typhimurium , such mutations result in 1) a decreased efficacy of suppression by some suppressor tRNA, 2) a slowing of ribosomal translation, 3) slow growth under various nutritional conditions, 4) altered regulation of several amino acid biosynthetic operons, 5) sensitivity to chemical oxidants and 6) temperature sensitivity for aerobic growth (Ericson and Björk, J. Bacteriol. 166: 1013-1021 (1986); Blum, J. Bacteriol. 170: 5125-5133 (1988)). Thus, MiaAp appears to be important in the regulation of multiple parallel processes of cellular physiology. Although we have not yet explored the cellular physiology of gro-1 mutants along the lines which have been pursued in bacteria, the apparently central role of miaA is consistent with our findings that gro-1, and the other genes with a Clk phenotype, regulate many disparate physiological and metabolic processes in C. elegans (Wong et al., Genetics 139: 1247-1259(1995); Lakowski and Hekimi, Science 272: 1010-1013 (1996); Ewbank et al., Science 275: 980-983 (1997)).
In addition to the various phenotypes discussed above, miaA mutations increase the frequency of spontaneous mutations (Connolly and Winkler,
J Bacteriol 173(5): 1711-21 (1991); Connolly and Winkler, J Bacteriol 171: 3233-46 (1989)). As described in the previous section we have preliminary evidence that gro-1(e2400) also increases the frequency of spontaneous mutations in worms.
How can the alteration in the function of MDAPP transferase result in so many distinct phenotypes? Bacterial geneticists working with miaA have generally suggested that this enzyme and the tRNA modification it catalyzes have a regulatory function which is mediated through attenuation (e.g. Ericson and Björk, J. Bacteriol. 166: 1013-1021 (1986)). Attenuation is a phenomenon by which the transcription of a gene is interrupted depending on the rate at which ribosomes can translate the nascent transcript. Ribosomal translation is slowed in miaA mutants, and thus, through an effect on attenuation, could affect the expression of many genes whose expression is regulated by attenuation.
gro-1(e2400) also produces pleiotropic effects and, in addition, displays a maternal-effect, suggesting that it is involved in a regulatory process (Wong et al., Genetics 139: 1247-1259 (1995). However, attenuation involves the co-transcriptional translation of nascent transcripts, which is not possible in eukaryotic cells were transcription and translation are spatially separated by the nuclear membrane. If the basis of the pleiotropy in miaA and gro-1 is the same, then a mechanism distinct from attenuation has to be involved. Below we argue that this mechanism could be the modification by DMAPP transferase of adenine residues in DNA in addition to modification of tRNAs.
A Role for Gro-1 in DNA Modification?
We observed that gro-71 can be rescued by a maternal effect, so that adult worms homozygous for the mutation, but issued from mother carrying one wild type copy of the gene display a wild type phenotype, in spite of the fact that such adults are up to 1000 fold larger than the egg produced by their mother. It is unlikely that enough wild type product can be deposited by the mother in the egg to rescue a adult which is 1000 times larger. This observation suggests therefore that gro-1 can induce an epigenetic state which is not altered by subsequent somatic growth. One of the best documented epigenetic mechanisms is imprinting in mammals (Lalande, Annu Rev Genet 30: 173-196 (1996)) which is believed to rely on the differential methylation of genes (Laird and Jaenisch, Annu Rev Genet 30: 441-464; Klein and Costa, Mutat Res 386: 103-105 (1997)). Modification of bases in DNA have also been linked to regulation of gene expression in the protozoan Trypanosoma brucei . The presence of beta-D-glucosyl-hydroxy-methyluracil in the long telomeric repeats of T. brucei correlates with the repression of surface antigen gene expression (Gommers-Ampt et al., Cell 75: 112-1136 (1993); van Leeuwen et al., Nucleic Acids Res 24: 2476-2482 (1996)).
gro-1 and miaA increase the rate of spontaneous mutations, which is generally suggestive of a role in DNA metabolism, and can be related to the observation that methylation is linked to spontaneous mutagenesis, genome instability, and cancer (Jones and Gonzalgo, Proc. Natl. Acad. Sci. USA, 94: 2103-2105 (1997)).
Does gro-1 have access to DNA? Studies with mod5, the yeast homologue of gro-1, have shown that there are two forms of Mod5p, one is localized to the nucleus as well as to the cytoplasm, and the other form is localized to the mitochondria as well as the cytoplasm (Boguta et al., Mol. Cell. Biol. 14: 2298-2306 (1994)). The nuclear localization is striking as isopentenylation of nuclear-encoded tRNA is believed to occur exclusively in the cytoplasm (reviewed in Boguta et al., Mol. Cell. Biol. 14: 2298-2306 (1994)). Furthermore, studies of a gene maf1 have shown that when mod5 is mislocalized to the nucleus, the efficiency of certain suppressor tRNA is decreased, an effect known to be linked to the absence of the tRNA modification (Murawski et al., Acta Biochim. Pol. 41: 441-448 (1994)). Finally, as described in the previous section, gro-1 contains a zinc finger, a nuclei acid binding, motif. The zinc finger could bind tRNAs, but as it is in the C-terminal domain of gro-1 and human hgro-1 that has no equivalent in miaA, it is clearly not necessary for the basic enzymatic function. We speculate that it might be necessary to increase the specificity of DNA binding in the large metazoan genome. It should also be noticed that the second form of Mod5p which is localized to mitochondria also has the opportunity to bind and possibly modify DNA as it has access to the mitochondrial genome. See the previous section entitled “A role for gro-1 in a central mechanism of physiological coordination” for an alternative possibility as to the function of GRO-1 in the nucleus.
MiaA and Gro-1 are Found in Complex Operons
We have found that gro-1 is part of a complex operon of five genes (FIG. 4 ). It is believed, that genes are regulated coordinately by single promoters when they participate in a common function (Spieth et al., Cell 73: 521-532 (1993)). In some cases, this is tit well documented. For example, the proteins LIN-15A and LIN-15B which are both required for vulva formation in C. elegans , are unrelated products from two genes transcribed in a common operon (Huang et al., Mol Biol Cell 5 (4): 395-411 (1994)) One of the genes in the gro-1 promoter is hap-1, whose yeast homologue has been shown to be involved in the control of mutagenesis (Nostov et al., Yeast 12: 17-29 (1996)). Under the hypothesis that gro-1 modifies DNA, it suggest an involvement of hap-1 in this or similar processes. The presence in the same operon also suggest that all five genes might collaborate in a common function. The phenotype of gro-1 suggests that this function is regulatory. In this context, it should be noted that miaA also is part of a particularly complex operon (Tsui and Winkler, Biochimie 76: 1168-1177 (1994)), although, except for miaA/gro-1, there are no other homologous genes in the two operons.
A Role for Gro-1 in a Central Mechanism of Physiological Coordination
We have speculated that the genes with a Clk phenotype might participate in a central mechanism of physiological coordination, probably including the regulation of energy metabolism clk-1 encodes a mitochondrial protein (unpublished observations), 4and its homologue in yeast has also been shown to be mitochondrial (Jonassen, T (1998) Journal of Biological Chemistry 273: 3351-3357). The yeast clk-1 homologue is involved in the regulation of the biosynthesis of ubiquinone (Marbois, B. N. and Clarke, C. F. (1996) Journal of Biological Chemistry 271: 2995-3004). Ubiquinone, also called coenzyme Q, is central to the production of ATP in mitochondria., In worms, however, we have found that clk-1 is not strictly required for respiration. How might gro-1 fit into this picture?
One link is that dimethylallyldiphosphate is known to be the precursor of the lipid side-chain of ubiquinone. In bacteria, ubiquinone is the major lipid made from DMAPP. In eukaryotes cholesterol and its derivatives are also made from DMAPP. Interestingly, C. elegans requires cholesterol in the growth medium for optimal growth. This link, however, remains tenuous in particular in the absence of an understanding of the biochemical function of CLK-1.
In several bacteria, the adenosine modification carried out by DMAPP transferase is only the first step in a series of further modification of this base (Persson et al., Biochimie 76: 1152-1160 (1994)). These additional modifications have been proposed to play the role of a sensor for the metabolic state of the cell (Buck and Ames, Cell 36: 523-531 (1984); Persson and Björk, J. Bacteriol. 175: 7776-7785 (1993)). For example, one of the subsequent steps, the synthesis of 2-methylthio-cis-ribozeatin is carried out by a hydroxylase encoded by the gene miaE. When the cells lack miaE they become incapable of using intermediates of the citric acid cycle such as fumarate and malate as the sole carbon source.
Another link to energy metabolism springs from the recent biochemical observations of Winkler and coworkers using purified DMAPP transferase ( E. coli MiaAp) (Leung et al., J Biol Chem 272: 13073-13083 (1997)). These investigators observed that the enzyme in competitively inhibited by phosphate nucleotides such as ATP or GTP. Furthermore, using their estimation of K m of the enzyme and its concentration in the cell, they calculate that the level of inhibition of the enzyme in vivo, would exactly allow the enzyme to modify all tRNAs but any further inhibition would leave unmodified tRNAs. This suggests that the exact level of modification of tRNA (or of DNA) could be exquisitely sensitive to the level of phosphate nucleotides. Superficially, this is consistent with the phenotypic observations. The state of mutant cells which lack DMAPP transferase entirely would be equivalent of cells where very high levels of ATP would completely inhibit the enzyme. Such cells might therefore turn down the ATP generating processes in response to the signal provided by undermodified tRNAs (or DNA).
More generally, GRO-1 could act in the crosstalk between nuclear and mitochondrial genomes. The nuclear and mitochondrial genomes both contribute gene products to the mitochondrion energy-producing machinery and these physically separate genomes must therefore exchange information somehow to coordinate their contributions (reviewed in Poyton, R. O and McEwen J. E. (1996) Annu. Rev. Biochem. 65: 563-601) Furthermore, the energy producing activity of the mitochondria is essential to the rest of the cell, and the needs of a particular cell at a particular time must be somehow convey to the organelle to regulate its activity. GRO-1 could participate in this coordination in the following manner. GRO-1 is found in three compartments, the nucleus, the cytoplasm and the mitochondria (see above), and thus has the opportunity to regulate gene expression in more that one way. How could its action coordinate gene expression between compartment? GRO-1 could partition between the mitochondria and the nucleus and its relative distribution could be determined by the amount of RNA (or mtDNA) in the mitonchodria (Parikh, V. S. et al. (1987) Science 235: 576-580). For example, if the cell is rich in mitochondria, much GRO-1 will be bound there which could result in a relative depletion of activity in the cytoplasm with regulatory consequences on the translation machinery. Binding of GRO-1 in the nucleus could have similar consequences and provide information about nuclear gene expression to the translation machinery.
While the invention has been described in connection with specific embodiments thereof, it will be understood that it is capable of further modifications and this application is intended to cover any variations, uses, 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 within the art to which the invention pertains and as may be applied to the essential features hereinbefore set forth, and as follows in the scope of the appended claims.
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The invention relates to the identification of gro-1 gene and to demonstrate that the gro-1 gene is involved in the control of a central physiological clock. Also disclosed are four other genes located within the same operon as the gro-1 gene.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a developer dispersing device which can be used, for example, for dry two-component development. The invention is applicable to electro-photographic apparatuses, such as copiers, printers, facsimile machines, etc.
2. Discussion of the Background
A typical electrophotographic apparatus is illustrated in FIG. 20 and comprises a photoconductive drum 2 as a charge receiving member and a charging device 1. The photoconductive drum 2 rotates at a predetermined speed in the direction indicated by the arrow sequentially in relation to a plurality of processing stations disposed about its rotational path of movement. As illustrated in FIG. 20, the charging device 1 initially contacts the surface of the photoconductive drum 2 at a predetermined pressure and charges the photoconductive drum 2 to a substantially uniform potential, either positive or negative. Downstream at exposure device 3, light rays reflected from an original document are reflected through a lens and projected onto a charge portion of the surface of the photoconductive drum 2 to selectively dissipate the charge thereon. Such selective charge dissipation records an electrostatic latent image on a circumference of the photoconductive drum 2 corresponding to the informational area contained within an original document.
Thereafter, the photoconductive drum 2 rotates downstream to a developing device 4 where a developer mix (for example carrier particles and toner) are passed into contact with the latent electrostatic image. The toner particles are attracted away from the carrier beads by the latent electrostatic image to thereby form toner powder images on the surface of the photoconductive drum 2. The development station may apply one or more or colors of developer material.
Also illustrated in FIG. 20 is a paper copy sheet 5 which is advanced into contact with the development latent image at a transfer device 6. The toner powder image is thereafter transferred from the photoconductive drum 2 to the paper 5. After transfer, the toner image is fixed on paper 5 by a fixing device 7, and photoconductive drum 2 is discharged by a discharger device 9. Residual toner on the photoconductive 2 is removed by a cleaning device 8.
FIG. 21 illustrates in detail the development device 4. In FIG. 21, a toner hopper 10, a dispersing roller 11 and a developing sleeve 12 are illustrated. Toner is supplied into the toner hopper 10 by rotation of a toner supply device 15. This supplies toner onto the dispersing roller 11 which supplies toner to the developing sleeve 12. FIG. 21 also illustrates a doctor blade 13 for controlling the quantity of toner on the developing sleeve 12 as well as a developing area 14.
In conventional arrangements, a lateral difference of toner density in the dispersing roller 11 causes an unevenness of image density on a copied paper. When an original document comprises a lateral difference of image ratio or information ratio and the original document is copied a plurality of times, some parts which have a high image ratio or a high information ratio consume a lot of toner, and this causes the toner density of these parts to become extremely lower than the toner density of the other parts.
Accordingly, dispersing rollers not only have to have the function of mixing newly supplied toner with stock toner, but also have to have the function of pumping up the toner and also laterally or longitudinally dispersing toner. If a dispersing roller does not correctly longitudinally or laterally disperse toner, the toner supplied to the dispersing roller will form a lump or the like. This will cause an unevenness of image density. Accordingly, a dispersing roller which not only longitudinally disperses toner, but also shakes and mixes the toner, is necessary.
An example of a conventional screw-type dispersing roller is illustrated in Japanese Document 55-6997. Although the dispersing roller in Japanese Document 59-6997 achieves a lateral transfer of toner, the mechanism is expensive and requires a maximum amount of space. Additionally, it does not achieve the desired amount of radial and lateral toner movement which is necessary to achieve an even image density.
FIGS. 22 and 23 of the present application also illustrate conventional dispersing devices in the form of dispersing plates or wings. Both types of toner dispersing devices illustrated in FIGS. 22 and 23 can achieve some form of lateral toner transfer between cells 160, however, utilization of only the plates 170 cannot assure a positive transfer of toner between cells. In the toner transfer devices illustrated in FIGS. 22 and 23, toner is transferred from one cell to another via a gap between the plates and the hopper. If the plates 170 are large, toner transfer between cells is difficult, while if the plates are small, the mixture of toner is not sufficient. Also, these types of devices do not provide the desired combination of radial and lateral transfer of toner.
Finally, Japanese documents 64-24282 and 3-105370, which also disclose conventional toner dispersing devices, illustrate devices which are not capable of achieving a sufficient lateral transfer of toner in combination with a radial movement of toner for achieving an even image density.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide for a developer dispersing device which can be used in a development apparatus and can efficiently mix toner, can laterally or longitudinally transfer the toner, and at the same time can achieve a desired amount of radial movement of the toner. The developer dispersing device of the present invention can therefore achieve a highly efficient mixture of a dry two-component toner in the form of a toner and carrier.
The developer dispersing device of the present invention comprises a rotatable shaft having first and second ends for mounting in a development apparatus housing; a plurality of spaced plate members longitudinally mounted along a length of the rotatable shaft, each of the plate members radially extending from the rotatable shaft and being inclined with respect to a rotational axis of the shaft for longitudinally moving a toner along the length of the shaft upon rotation of the shaft; and an inclined pumping plate attached to the shaft and longitudinally extending along the length of the shaft. The pumping plate and adjacently positioned plate members form cells for the toner along the length of the rotatable shaft. The pumping plate has a longitudinal axis which intersects the rotational axis of the shaft, such that a first end portion of the pumping plate is positioned on one side of the rotational axis of the shaft at the first end of the shaft, and a second end portion of the pumping plate is positioned on a second opposite side of the rotational axis of the shaft at the second end of the shaft. The pumping plate radially and longitudinally moves the toner with respect to the shaft upon rotation of the shaft.
The present invention also relates to a developer dispersing device in which a plurality of inclined pumping plates can be positioned within each cell defined by adjacently positioned plate members and each of the plate members extend at an incline with respect to the rotational axis of the shaft between the adjacently positioned plate members. The plurality of inclined pumping plates radially and longitudinally move the toner upon a rotation of the shaft.
The present invention also relates to a developer dispersing device in which a plurality of spaced radial blade means are longitudinally mounted on and extend along a length of a shaft. Each of the radial blade means comprise first and second opposing members which face each other with the shaft centrally extending therebetween. Each of the first and second opposing members comprise an end portion with an edge that is substantially perpendicular to a longitudinal axis of the shaft.
The present invention also relates to a developer dispersing device in which a rotatable pumping plate has first and second ends for permitting the pumping plate to be mounted in a development apparatus housing. The device also includes a plurality of circular dispersing wings mounted on the rotatable pumping plate at an angle with respect to an axis of rotation of the pumping plate for laterally moving toner along a length of the rotatable pumping plate.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 illustrates a first embodiment of the developer dispersing device of the present invention;
FIG. 2 is a further view of the developer dispersing device of FIG. 1;
FIGS. 3(a) and 3(b) are further views of the developer dispersing device of FIG. 2;
FIGS. 4(a), 4(b), 4(c) and 4(d) illustrate a toner movement utilizing the developer dispersing device of FIG. 1;
FIG. 5 illustrates a second embodiment of the developer dispersing device of the present invention;
FIGS. 6(a) and 6(b) illustrate a third embodiment of the developer dispersing device of the present invention;
FIGS. 7(a) and 7(b) are views of a blade and shaft arrangement of the developer dispersing device;
FIGS. 8(a) and 8(b) are further views of a blade and shaft arrangement of the developer dispersing device;
FIG. 9 is a fourth embodiment of the developer dispersing device of the present invention;
FIG. 10 is a fifth embodiment of the developer dispersing device of the present invention;
FIGS. 11(a), 11(b), 11(c), 11(d) and 11(e) are views of different embodiments of the pumping plate illustrated in FIG. 10;
FIGS. 12(a), 12(b) and 12(c) are views of different embodiments of the combination of the pumping plate and dispersing wings illustrated in FIG. 10;
FIGS. 13(a) and 13(b) illustrate toner movement utilizing the developer dispersing device of FIG. 10;
FIG. 14 illustrates a toner movement in the embodiment of FIG. 10;
FIG. 15 is a sixth embodiment of the developer dispersing device of the present invention;
FIGS. 16(a) and 16(b) are views of the developer dispersing device of FIG. 15;
FIG. 17 illustrates a toner movement in the developer dispersing device of, for example, FIG. 10;
FIG. 18 is an isolated view of the dispersing wing of the developer dispersing device;
FIG. 19 is a view of a toner movement in the developer dispersing device of FIG. 15;
FIG. 20 is a schematic illustration of an electrophotographic apparatus;
FIG. 21 shows a toner hopper, dispersing roller and developing sleeve arrangement;
FIG. 22 shows a conventional developer dispersing device; and
FIG. 23 shows a conventional developer dispersing device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, and more particularly to FIG. 1 thereof, FIG. 1 illustrate a first embodiment of the developer dispersing device of the present invention. In FIG. 1, a rotatable shaft 20 which can be rotated by any well known rotational device is illustrated. Mounted on the rotatable shaft 20 are a plurality of elliptically-shaped plates 21 which as illustrated in FIG. 3(a) can be positioned at an angle with respect to the rotational axis 20a of the shaft 20. The plates 21 can define a helical configuration on the shaft 20 to promote mixture and movement of toner along the shaft 20. Also mounted on the shaft 20 is a pumping plate 22 as further illustrated in FIG. 1. The combination of the pumping plate 22 and adjacently positioned elliptical plates 21 form cells 22a for receiving toner such as two-component toner.
As illustrated in FIG. 2, one end of the pumping plate 22 is positioned at one end of the shaft 20 at an angle α with respect to the rotational axis 20a of the shaft 20. Therefore, the longitudinal axis of the plate 22 intersects the rotational axis 20a of the shaft 20, such that at one end of the shaft 20 the pumping plate 22 is positioned on one side of the rotational axis 20a, while at the other end of the shaft 20, the pumping plate 22 is positioned on an opposite side of the rotational axis 20a of the shaft 20.
The larger the angle α illustrated in FIG. 2, the more efficient operation will be achieved by the developer dispersing device of FIG. 2.
FIG. 3(a) shows that the plate 22 can have a slight taper from one end of the shaft 20 to the other end of the shaft 20 to also achieve a better combination of lateral and radial movement of toner. FIG. 3(b) illustrates a side view of the developer dispersing arrangement of FIG. 3(a).
FIGS. 4(a)-4(b) sequentially show the movement of toner utilizing the developer dispersing device of FIG. 1. As set forth above, the developer dispersing device of the present invention is particularly applicable to two-component toner. As illustrated by 1-2-3, upon rotation of the shaft 20, the plate 22 radially pumps up toner and at the same time, the elliptical plates 21 laterally push the toner in a direction of the arrows. It is noted that the toner is also laterally or longitudinally transferred by the inclination of the plate 22 in a direction of the arrows.
As illustrated by 4-5 the toner still is transferred by the inclined plate 22 in the direction of the arrows. 5-8 illustrate the reverse movement of 1-4 on the opposite side of the developer dispersing device.
Therefore, due to the elliptical and helical nature of the elliptical plates 21, and the inclined configuration of the pumping plate 22, toner is mixed, radially displaced, and is also laterally displaced by not only the elliptical plates 21, but also the inclined plate 22. This achieves an efficient and even transfer and mixture of toner and provides for an even image density. This also permits newly supplied toner to be positively mixed with stock toner.
FIG. 5 shows a second embodiment of the developer dispersing device of the present invention. In FIG. 5, the elliptical pumping plates 21 are similar to that illustrated in FIG. 1. However, in FIG. 5, a plurality of separate inclined pumping plates 23 are disclosed. As illustrated in FIG. 5, each of the inclined pumping plates 23 are disposed at an angle with respect to the rotational axis 20a of the shaft 20, and are separately positioned within each respective cell 22a defined by the elliptical plates 21. As further illustrated in FIG. 5, each pumping plate 23 includes a first end portion positioned on one side of the axis 20a and a second end portion positioned on a second opposite side of the axis 20a. The larger the inclination of the pumping plates 23, the better lateral shaking and dispersing of toner will be achieved. Thus, an efficient developer dispersing device which achieves a maximum lateral and radial displacement and mixture of toner can be realized. Additionally, each plate 23 can have a different inclination depending on the desired mixture of toner and size of paper.
FIGS. 6(a) and 6(b) illustrate a third embodiment of the developer dispersing device of the present invention. FIG. 6(a) is a top view while FIG. 6(b) is a side view. As illustrated in FIG. 6(a), plates in the form of twisted portions 24 are illustrated and as shown in FIG. 6(b), can be in the form of two half-screws so as to achieve a desired transfer in two directions. As shown in FIG. 6(a), the end portion of the plates 24 run parallel to the rotational axis 20a of the shaft 20, and as illustrated in FIG. 6(b), the end portions also include flat portions having an edge 240 which is substantially perpendicular to the rotational axis 20a of the shaft 20. This arrangement permits the desired amount of shaking force and lateral transportation which can achieve an even image density. Additionally, this specific arrangement permits an efficient radial and lateral movement of the toner.
FIGS. 7(a), 7(b), 8(a) and 8(b) illustrate the relationship between the plates and the rotational axis of the shaft. As illustrated in FIGS. 7(a) and 7(b), the portion marked by A can be twisted to achieve the configuration of FIGS. 6(a) and 6(b). As illustrated in FIGS. 8(a) and 8(b), an inclined angle β of the elliptical plate can be changed so as to control the amount of toner which is transferred between cells.
FIG. 9 illustrates a fourth embodiment of the developer dispersing device of the present invention. FIG. 9 is similar to the embodiment of FIGS. 6(a) and 6(b) but includes an additional plate 26 which is parallel to the rotational axis 20a of the shaft 20. The additional plate 26 has the effect of increasing the dispersal force upon rotation of the shaft 20 so as to achieve an efficient lateral and radial movement of the toner in combination with a mixture of the toner.
FIG. 10 illustrates a fifth embodiment of the developer dispersing device of the present invention. In FIG. 10, a pumping plate shaft is illustrated by the reference numeral 27. The pumping plate shaft 27 is rotatable about the rotational axis 27a. Circular dispersing wings 28 are mounted on the pumping plate 27. Dispersing wings 28 include openings 280 for permitting movement of toner. For purposes of illustration, FIG. 10 only shows the top half of the dispersing wings 28 and pumping plate shaft 27.
FIGS. 11(a)-11(e) show different possible configurations of the pumping plate shaft 27. The pumping plate shaft 27 can also have a reinforcing portion 27b, 27c as illustrated in FIGS. 11(d) and 11(e).
FIGS. 12(a)-12(c) illustrate possible configurations for the dispersing wings 28.
FIGS. 13(a) and 13(b) illustrate movement of toner upon the rotation of the pumping plate shaft 27 of the developer dispersing device illustrated in FIG. 10. Numbers 1-2-3-4 show the lateral transfer of the toner along the wings 28.
Numbers 4-5-6-7-8 also show the lateral transfer of the toner along the wings 28 upon further rotation of the pumping plate shaft 27. As illustrated in FIG. 13(b), if the wings 28 have no opening, the toner will move along the wings 28 as shown by the dotted line in FIG. 13(b). If there is an opening in the wings 28, the toner can move from one cell to the other as illustrated by the arrow in FIG. 14. The opposite side of the developer dispersing device illustrated in FIG. 14 will achieve a toner movement in the opposite direction than the direction illustrated in FIG. 14. It is further noted that a transfer can be achieved due to an opening between a case in which the developer dispersing device is rotatably mounted and the pumping plate shaft 27.
FIG. 15 shows a sixth embodiment of the developer dispersing device of the present invention. FIG. 15 is similar to the embodiment of FIG. 10 but includes ribs 29. In order to more clearly understand the invention, FIG. 15 only shows one-half of the dispersing wings 28. The ribs 29 are capable of more positively guiding toner between the cells 40 upon rotation of the plate 27.
As illustrated in FIG. 16(a), when an angle θ is defined as:
0°<θ<90°,
the angle φ should be -90°≦φ<0. This range of the angle φ provides for good toner movement.
Additionally, as illustrated in FIG. 16(b), if h is equal to the height of the rib 29 with respect to the pumping plate shaft 27, while H is equal to the height of a dispersing wing 28 with respect to the plate 27, then h ≦ H/2. If h is greater than H/2, then a lateral toner movement will be inhibited.
FIG. 17 show a toner movement of toner utilizing the embodiment of FIG. 10. Toner movement of toner illustrated by the arrow 45 in FIG. 17 cannot be transferred to the next cell. As illustrated in FIG. 18, if D is the height of the toner, and d is the height of the opening of the wing 28, then the toner defined by (D-d) cannot be transferred to the next cell. This is illustrated by the arrow 45 in FIG. 17.
By utilizing the ribs 29 as illustrated in FIG. 19, toner movement can be guided by the ribs 29 towards the next cell so as to more positively promote a lateral toner transfer. Accordingly, the utilization of the ribs provides for an efficient positive toner transfer.
Obviously, numerous additional 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.
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A developer dispersing device which can be utilized for moving dry two-component toner is applicable to electro-photographic apparatuses such as copiers, printers or facsimile machines. The developer dispersing device includes a rotatable shaft on which pumping plate members and blades are positioned so as to both laterally and radially move toner. The pumping plate member and blades are positioned on the shaft to permit an efficient lateral and radial displacement of the toner in combination with positively mixing newly supplied toner with stock toner so as to provide for an even image density.
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BACKGROUND OF INVENTION
RELATED APPLICATIONS
There are no applications related hereto now filed in this or any foreign country.
FIELD OF INVENTION
This invention relates generally to fasteners for lace type closures and particularly opposed elastic laces releasably joined by plural hooks.
DESCRIPTION OF THE PRIOR ART
The common non-elastic fabric lace associated with plural opposed eyelets to releasably fasten together separated parts of wearing apparel to form closures, particularly in footwear and leggings, has inadequacies notwithstanding the extensive use of this method of closures. The closure lacks some movability and conformability primarily because of its non-elastic nature and is difficult of establishment when cross laced in the ordinary fashion. In the past other improved lace-type methods of eyed closures to accomplish such fastening with differing benefits in particular cases have become known. The instant invention is one of this class.
Obviously, however, if such improved methods are to be at all useful in existing garments they must be compatible in their fastening with the present eyelet structure of the wearing apparel in which they are to be used. Heretofore such improved lace-type fastening methods have evolved along two essential lines; firstly that involving a continuous lace of the normal non-elastic configuration, composed of or containing an elastic element, that is positioned in some fashion between eyelets on both sides of the laced closure, and secondly, a plurality of elastacized members, each associated in some releasable fashion with only the two members of a pair of opposed eyelets, and having no association with other eyelets outside that pair. Each of these systems possesses individual advantages and disadvantages. In the first instance the lacing gives elasticity at any point along the length of the closure as required by strain upon the area at a particular time and also allows for lineal lace adjustment, but there is the inconvenience in establishment, as the lace must be long and individually threaded and adjusted through the several eyelets on each side of the closure. In the second instance there is not the contributory adjustable conformity to varying stress throughout the length of the closure, as the particular elastic functions are limited to one particular pair of opposed eyelets and their associated fasteners; however, the ease and simplicity of fastening is greater because there is no necessity of using a long lace and having to adjust it or lace it by its end or ends through the several eyelets involved. With these factors and this background in mind, the instant invention seeks to provide new and unique lacing that has the advantages of each of the improved types mentioned but is without the disadvantages of either.
SUMMARY OF INVENTION
My invention provides generally paired cooperating elastic laces each associated with plural spaced eyelets on each side of a garment closure to form opposed cooperating loops that are releasably joined by plural rigid hook elements. Preferably the laces are laced alternately through adjacent eyelets and the hook elements are permanently carried on one lace and releasably attachable to the other.
In providing such a closure fastening system it is:
A principal object of my invention to provide an elastic fastening means, for use upon eyelet-type lace-closing structures having paired opposed eyelets adjacent the opposed abutting parts of such laceable closure, that may be rapidly fastened or unfastened after establishment without passing the end of a lace through the various eyelets.
A further object of my invention to provide a fastening means of the nature aforesaid that is contributorily elastically adjustable throughout its length to provide for variations in movement of the proposed members of the laced structure in response to conformal stress thereon.
A further object of my invention to provide a fastening means of the nature aforesaid that is compatible with and may be used upon existing eyelet-type lace closing structures of wearing apparel without modification thereof and may be releasably established therein with minimum effort.
A still further object of my invention to provide a fastener means of the nature aforesaid that is of new and novel design, of simple and economic manufacture, of rugged and durable nature, and otherwise well adapted to the uses and purposes for which it is intended.
Other and further objects of my invention will appear from the following specification, drawings and claims which form a part of this application. It is to be remembered, however, that its accidental features are susceptible of change in design and structural arrangement with only one preferred and practical embodiment being illustrated as required.
BRIEF DESCRIPTION OF DRAWINGS
In the accompanying drawings which form a part of this specification and wherein like numbers of reference refer to similar parts throughout:
FIG. 1 is an isometric view of an ordinary high-top shoe of commerce, with my invention in place thereon, partially fastened and partially unfastened.
FIG. 2 is a diagrammatic representation illustrating a single method of establishing my elastic laces through ordinary eyelets of laceable closures in diagram 2A and a double method of establishment in diagram 2B.
FIG. 3 is a partial enlarged orthographic view of my elastic lace passing through two adjacent eyelets, showing how the lace is frictionally and deformably engaged therewith.
FIG. 4 is an orthographic cross-sectional view of FIG. 3 taken on the line 4--4 thereon in the direction indicated by the arrows.
FIG. 5 is an enlarged isometric view of a particular type of a hooking device that I prefer to use with my invention.
FIG. 6 is a somewhat enlarged partial orthographic view of the hooking device of FIG. 5 in place upon one of the elastic laces of my invention, showing the deformed frictional engagement between the two members.
DESCRIPTION OF PREFERRED EMBODIMENT
Referring now to the drawings in more detail and particularly to that of FIG. 1, it will there be seen that my invention essentially comprises two elastic lace members 10, laced alternately through adjacent eyelets 11 of shoe 12 to form paired opposed loops 13, releaseably fastened together by hook fasteners 14.
My invention is particularly adapted to fasten the adjacent opposed lacing flies 18 of shoes 12 and leggings together, but it is to be understood in this regard that it is equally within the spirit of my invention to fasten laceable closures of garments and other articles of the same type having opposed spaced eyelets in the adjacent fastening parts. The invention is particularly extendable to articles of clothing and various containers, especially plastic or semi-rigid ones.
Lace 10 is an elongate strip of elastic, deformable material of appropriate surface constitution and preferably of substantially a rectangular cross-section as illustrated. I prefer to form this member from rubber, though other materials such as some plastics having like or similar physical properties would undoubtedly serve the purposes of my invention.
The size and physical characteristics of the lace are quite essential to the operation of my invention. The member must be such that loops 13 formed in it are sufficiently elastic and have sufficient physical strength to perform their function. The member must also be yieldably held in position within the eyelets 11 through which it passes, and this requires that the material be sufficiently elastically deformable, as illustrated, and of appropriate surface characteristics to create a frictional engagement between lace 10 and eyelet 11 so that the lace will not under normal circumstances readily pass therethrough but yet under unusual stresses will tend to yield slightly to somewhat equalize the stress throughout the laced closure or a substantial part of it.
To accomplish these purposes I have found rubber to be an ideal material. I prefer to have the cross-section of lace 10 of a width approximately one-fourth greater than the major internal diameter of eyelet 11, and of the thickness of approximately one-third of the internal diameter of the eyelet. The length of the member 10, obviously, will be dependent upon the size of the particular closing being fastened, but this length should be such that the lace may be positioned as hereinafter provided so that in normal unfastened condition it will have substantially no lineal stress within it.
With this sizing and dimensioning of the lace and with its particular physical characteristics, when an elongate stress is applied to the lace on one side of an eyelet as in FIG. 3, the elastic of the lace tends to elongate on that side, but if the pressure be less on that portion of the lace on the opposite side, the lace will tend to bind within the eyelet so that the function aforementioned is attained. This binding is caused by the deformed frictional engagement of the lace on the far side of the strained part contacting the surface of the eyelet on that side. This reaction is necessary to the proper functioning of my invention in the form illustrated in this disclosure.
It is necessary that elastic side laces 10 be positioned through the various eyelets on one side of fastening flap 18 so as to form loops 13 on the fastening side of the closure between eyelets where fastening is desired. This may be accomplished in at least two ways as illustrated in the diagrams of FIG. 2. In diagram 2A, if a single length of lace be threaded alternately through adjacent eyelets 11, firstly on one side of the fastening flap 18 and then the other, the result will be a series of loops 13 formed between each alternate pair of adjacent eyelets, as illustrated. If, however, loops 13 are desired between each adjacent pair of eyelets 11 of a fastening flap 18, lace 10 may be doubled and the two ends of lace 10 there threaded alternately through such eyelets 11, the two ends passing in opposite directions through each eyelet 11, as illustrated in diagram 2B. Either of these methods of positioning the elastic side laces may be used under the spirit of my invention, the particular choice depending upon particular desires of the user.
In either of the lacing methods illustrated in FIG. 2, an elastic lace 10 of the specified size and dimension is deformed in passing through an eyelet 11, and is frictionally engaged or bound therein. Each loop 13 (span of lace between eyelets) thus becomes substantially independent. The elastic property of lace 10 allows extension of loop 13 and provides an additional tightening or binding in the eyelet. The maximum yield of the loop 13 is at a point between eyelets 11; at eyelet 11, where lace 10 is bound, yield is minimal. Thus, there is no necessity to provide fastening at the lace ends (although end fastenings could be provided if desired), because the lace will not slip through the eyelet nearest the lace end because of the lace's frictional engagement or binding therein. The single provision of the extension of lace 10, approximately half the distance between adjacent eyelets 11, beyond the eyelet nearest the lace end is sufficient to insure the maintenance of the lace in the end eyelets.
The elastic laces 10 of my invention are preferably pointed at their ends, or carry some device such as a ferrule, as well known in the art, to aid in their insertion through the eyelets 11 upon establishment. The lace is normally established in place by manual minipulation or if desired a needle-like threading device (not shown) may be employed to assist in this operation.
To render my invention operable, paired opposed loops 13 in the elastic lacing member 10 must be releasably joined. One type of fastener 14 that accomplishes this purpose is illustrated in FIG. 3, but it is to be understood that there obviously are many other fastening devices that would serve this purpose and any that releaseably fastens two adjacent loops together would serve this purpose of my invention and be within its scope and purpose. The fastener illustrated comprises a looped part 15 structurally communicating with a hook part 16, all formed from an elongate, deformable, semi-rigid piece of metal 17 of a wire-like nature. Loop portion 15 may be welded or otherwise solidly formed, or if desired, it may be formed from a metal that may be bent to allow its placement in the same fashion as a hook, without requiring the passing of one end of lace member 10 therethrough for establishment. In fact the member 15 may be a hook similar to that of the hook 16 if desired, though with this arrangement when hooks are then in the non-engaging position it is easy to accidently dis-engage them from a loose lace.
The use of my invention on a shoe is illustrated in FIG. 1. One side lace 10 is established in each adjacent opposed lacing flaps 18 of shoe 12. In this instance a single lace was used, passing alternately through the adjacent eyelets to form alternating loops on the lacing side of the flap between adjacent pairs of eyelets. Laces 10 may be established in this fashion in a particular shoe and left in this position thereafter without any requirement that they be removed or re-established when the shoe is fastened or unfastened. Hook fasteners 14 are established in place upon the elastic side members 10, one hook fastener being distributed for each pair of opposed loops 13 on the fastening side of the fastening flap. The hook fasteners, if the loop portion 15 be rigid, must of necessity be established during placement of the elastic lace member. The hook fasteners may be initially positioned on either side of the fastening flap, or partially on one and partially on the other, though for convenience it is generally preferred to position all of them on the outer fastening flap 18A of the shoe (outer being determined as the shoe would normally be worn).
To use my invention, lace member 10 and hook fasteners 14 are established in place as aforesaid, one hook fastener for each loop 13 of the fastening member on the fastening side of flap 18. The shoe may then be permanently left in this condition as long as is desired. To fasten the closure the shoe is laced upon the foot in normal position and thereafter the elastic laces and hooks manually manipulated to hook the hooked portion 16 of each hook fastener 14 over the laterally adjacent loop of the opposed lace so that paired opposed loops are releaseably fastened to each other. This operation is repeated with each hook-loop combination until each of the adjacent loops is fastened to its paired opposed mate, when the shoe is completely fastened. The shoe is unfastened, for removal, in the reverse fashion.
With many shoes or garments, depending upon size and construction, there may be sufficient elasticity in the fastened closure that the garment may be put on or removed without the complete unhooking of the lacing, or in fact in some instances without any unhooking at all.
It is to be noted from the nature of the invention hereinbefore described, that a laced fastening, particularly in the case of a shoe, completely loosened for either putting on or off when the hooks connecting the laces are dis-engaged, whereas the ordinary laces of commerce must be at least partially removed.
It is further to be noted that my invention may be equally well used upon any lace type closure having co-operating eyelets in adjacent fastening flaps, whether it be upon wearing apparel or upon containers or other articles, the principle being equally applicable to any such use. If the closure to be laced is sufficiently rigid and appropriately pliable, it may not be necessary to have separate eyelet structures, but the device may function equally well upon insertion in holes in the parts to be fastened without any additional support, as especially in the case of sheet plastics.
While the foregoing description is necessarily of a detailed particular character so that a specific embodiment of my invention may be clearly set forth as required, it is to be understood that various rearrangement of parts, multiplications thereof and modifications of detail may be resorted to in connection with the invention without departing from its spirit, scope or essence.
Having thusly described my invention, what I desire to protect by Letters Patent, and,
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A fastener for closure in wearing apparel having adjacent edges with spaced opposed eyelets providing two elongate elastic elements each laced through eyes along one edge of the closure to form adjacent spaced loops with plural hook elements releasably joining opposed loops on each side of the closure. The fastener is particularly adapted for use in boots.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from Japanese Patent Application No. 2008-304803 filed Nov. 28, 2008. The entire content of the priority application is incorporated herein by reference.
TECHNICAL FIELD
The present invention relates to a printing device for printing images based on data in an image file.
BACKGROUND
A conventional printing device well known in the art reads image files representing photographs or other still images (still image files) from a storage medium, and prints out the still images represented by the image files. Recently, there have also been proposals for printing devices capable of printing out not only still image files, but also image files representing motion images (motion image files).
Since a motion image represented by a motion image file is configured of an enormous number of frame images, making it impractical to print all of the frame images, the printing device prints only specific frame images extracted from the file. The printing device is configured to be able to printing a plurality of frame images extracted from a motion image file in an arrangement on a single page, for example.
The conventional printing device is also configured to display a selection screen including a plurality of image files read from the storage medium, prompting the user to select a desired image file to print. The printing device can also display the first frame image of a motion image file as a thumbnail image. When the user selects a motion image file in the selection screen, the printing device prompts the user to specify frame images to print from the motion image file, and subsequently extracts and prints the specified frame images.
However, the conventional printing device described above displays only a thumbnail image of one frame image from the motion image file. Since this frame image may differ from the images that the user will actually be printing, the user must select an image file without knowing exactly what images are available for printing in the motion image file. Thus, in some cases the user will not find a desired printed image in the selected image file and must search through several image files in an effort to find the desired image.
SUMMARY
In view of the foregoing, it is an object of the present invention to provide a printing device that can assist the user in more efficiently selecting image files from which desired images can be obtained for printing.
In order to attain the above and other objects, there is provided a printing device including: an inputting unit that is configured to be capable of inputting at least one image file, each image file representing a motion image; a generating unit that is configured to extract a plurality of frame images from each image file and to generate, for each image file, data of a first output image in which the plurality of extracted frame images are laid out on a single page; a display unit that is configured to display a selection screen in which the display unit displays at least one first display image corresponding to the at least one first output image; a selecting unit that is configured to select one of the at least one first display image displayed; and a printing unit that is configured to print a first output image corresponding to the first display image selected in the selection screen.
According to another aspect of the present invention, there is provided a storage medium storing a program executable on a printing device. The program is provided with a set of program instructions including: inputting at least one image file, each image file representing a motion image; extracting a plurality of frame images from each image file and generating, for each image file, a first output image in which the plurality of extracted frame images are laid out on a single page; displaying a selection screen in which at least one first display image corresponding to the at least one first output image is displayed; selecting one of the at least one first display image displayed in the selection screen; and printing a first output image corresponding to the first display image selected in the selection screen.
According to further aspect of the present invention, there is provided a storage medium storing a program executable on a computer. The program is provided with a set of program instructions including: inputting at least one image file, each image file representing a motion image; extracting a plurality of frame images from each image file and generating, for each image file, a first output image in which the plurality of extracted frame images are laid out on a single page; displaying a selection screen in which at least one first display image corresponding to the at least one first output image is displayed; selecting one of the at least one first display image displayed in the selection screen; and controlling a printing device to print a first output image corresponding to the first display image selected in the selection screen.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a block diagram illustrating an electrical configuration of a multifunctional device including a CPU, an internal memory (RAM) and an LCD unit;
FIG. 2 is an overview illustrating a series of processes the multifunctional device performs;
FIG. 3 is a conceptual diagram explaining storage areas of the RAM in the multifunctional device;
FIG. 4 is a view conceptually illustrating an input image data storage area of the RAM;
FIG. 5 is a view conceptually illustrating a motion image data storage area of the RAM;
FIG. 6A is an explanatory view showing types of file format of motion image files and corresponding numbers associated therewith;
FIG. 6B is an explanatory view showing types of codec of motion image files and corresponding numbers associated therewith;
FIG. 7 is a view conceptually illustrating an LCD position data storage area of the RAM;
FIG. 8A is a view showing an example of a first page of a selection screen shown on the LCD unit of the multifunctional device;
FIG. 8B is a view showing an example of a second page of the selection screen shown in the LCD unit of the multifunctional device;
FIG. 9 is a view indicating, vertical and horizontal layout starting positions at which each thumbnail image is arranged to be displayed on the selection screen;
FIG. 10 is a view conceptually showing an LCD image storage area of the RAM;
FIG. 11 is a flowchart of a media image printing process executed by the CPU of the multifunctional device;
FIG. 12 is a flowchart of an output image generation process in the media image printing process;
FIG. 13A is an explanatory view of an output image data storage area in which frame images extracted from a motion image file are laid out;
FIG. 13B is an explanatory view of the output image data storage area in which a still image is laid out;
FIG. 14 is a flowchart of an LCD image generating process in the media image printing process; and
FIG. 15 is a flowchart of a printing process in the media image printing process.
DETAILED DESCRIPTION
First, a general configuration of a multifunctional peripheral 10 (hereinafter to be referred to as the “MFP 10 ”) according to an embodiment of the present invention will be described with reference to FIG. 1 .
The MFP 10 is provided with various functions, including a printer function, a scanner function, and a color copier function. As shown in FIG. 1 , the MFP 10 is provided with a CPU 14 , a ROM 15 , an internal memory (RAM) 16 , an LCD unit 11 , an input unit 12 , a media card slot 13 , a scanning unit 17 and a printing unit 18 that are interconnected with each other by signal lines.
The CPU 14 performs all computations for the MFP 10 . The ROM 15 has prestored programs that the CPU 14 executes in order to implement processes described later. The RAM 16 temporarily stores results of computations performed by the CPU 14 , inputted data, and the like.
The LCD unit 11 displays images on a compact color liquid crystal display including images of character strings for messages.
The input unit 12 has various operating keys that the user can press, and inputs data based on the pressed keys. More specifically, the input unit 12 includes an Up key, a Down key, a Left, key, and a Right key for moving a cursor up, down, left, and right; and an OK key for accepting a selection. The LCD unit 11 and the input unit 12 serve as a user interface of the MFP 10 .
The scanning unit 17 scans an image of a document placed on a platen and generates image data representing the scanned image. The printing unit 18 prints image data specified in a print command.
The media card slot 13 receives a media card inserted thereinto, such as an SD card and a CompactFlash card (portable, non-volatile storage media). The MFP 10 also has a direct print function for directly reading image files from a media card inserted in the media card slot 13 and printing images represented by the image files.
The image files discussed herein include both still image files representing still images; and motion image files representing motion images and configured of a plurality of frame images. When the image file to be printed is a motion image file, the MFP 10 extracts a prescribed number (nine in the present embodiment) of frame images from the plurality of frame images constituting the motion image represented by the motion image file, and prints an image (an output image) having the extracted frame images laid out on a single page (See FIG. 13A ). When the image file to be printed is a still image file, the MFP 10 prints, as an output image, the still image represented by the still image file on a single page (See FIG. 13B ).
The MFP 10 also displays a selection screen 81 such as that shown in FIG. 2 on the LCD unit 11 , enabling the user to select an image file to be printed from among the plurality of image files stored on the media card and prints images represented by the selected image files. More specifically, the MFP 10 displays output images for all of the image files that are candidates for printing in the selection screen 81 as thumbnail images, from which thumbnail images the user can tell what the output images will look like when the image files are actually printed (hereinafter referred to as the “print images”). The thumbnail images representing still image files and motion image files are the same size.
Next, an overview of a series of processes executed by the MFP 10 will be described with reference to FIG. 2 .
In the processes, the MFP 10 extracts data for nine frame images from each motion image file and generates data of an output image by sequentially laying out each of the nine extracted frame images in a storage area (output image data storage area 33 ) representing a single page, as shown in FIG. 13A . The MFP 10 also generates data of an output image for each still image file in which only one still image represented by the still image file is laid out on a single page, as shown in FIG. 13B . Next, the MFP 10 displays the output image for each image file as a thumbnail image in the selection screen 81 after reducing or enlarging the output image to a prescribed size. When the user selects an image file, the MFP 10 prints the output image of the selected image file.
Next, storage areas of the RAM 16 will be described with reference to FIGS. 3 through 10 .
As shown in FIG. 3 , the RAM 16 is configured with various storage areas for storing different types of data. The storage areas include an input image data storage area 31 , a motion image data storage area 32 , an output image data storage area 33 , an enlarged/reduced image data storage area 34 , a frame image data storage area 35 , a print data storage area 36 , a temporary variable storage area 37 , an LCD position data storage area 38 , and an LCD image storage area 39 .
The input image data storage area 31 serves to store data on image files stored on a media card inserted in the media cart slot 13 . As shown in FIG. 4 , the input image data storage area 31 is divided into an input image ID storage area 51 , an input image filename storage area 52 , and an input image file size storage area 53 .
The input image ID storage area 51 serves to store IDs for image files stored on the media card. The IDs are assigned sequentially beginning from 0 based on the number of image files (hereinafter referred to as “input image IDs”). The input image IDs are assigned to the image files in the order that the files are read from the media card.
The input image filename storage area 52 serves to store filenames of the image files. The input image filename storage area 52 is a 256-byte region, with each byte capable of storing data for one character.
The input image file size storage area 53 serves to store numerical values (values in units of kilobytes in this example) indicating the file sizes of the image files.
The motion image data storage area 32 serves to temporarily store data read from the media card for a motion image file being processed. As shown in FIG. 5 , the motion image data storage area 32 is provided with a format type storage area 61 , a codec type storage area 62 , a horizontal size storage area 63 , a vertical size storage area 64 , a total frame number storage area 65 , an extraction position data storage area 66 and an extraction size data storage area 67 .
The format type storage area 61 stores data of a type of file format for the motion image file being processed. In the present embodiment, the format type storage area 61 may store one of the values 0, 1, or 2 that have been preassigned to one of three file formats, as shown in FIG. 6A .
The codec type storage area 62 stores data of a type of codec for the motion image file being processed. In the present embodiment, the codec type storage area 62 may store one of the values 0, 1, or 2 that have been preassigned to one of three types of codecs, as shown in FIG. 6B .
The horizontal size storage area 63 stores numerical data indicating the number of pixels in the horizontal direction of the motion image file (frame image) being processed.
The vertical size storage area 64 stores numerical data indicating the number of pixels in the vertical direction for the motion image file (frame image) being processed.
The total frame number storage area 65 stores numerical data indicating a total number of frame images (number of frames) constituting the motion image file being processed.
The extraction position data storage area 66 stores data identifying where each of nine frame images extracted from the motion image file being processed is positioned within the motion image file. More specifically, the extraction position data storage area 66 stores numerical values (values in units of bytes in this example) indicating an amount of offset from the beginning of the motion image file to the start of data for each frame image. A motion image file is configured of data for frame images arranged sequentially between header data at the beginning of the file and index data at the end of the file. Thus, the amount of offset is a value indicating the size of data from the start of the motion image file (the start of the header data in this case) to the start of frame image data targeted for extraction. The amount of offset is stored in units of bytes rather than kilobytes in order to accurately identify the position from which the frame image data begins.
In the present embodiment, the MFP 10 automatically identifies nine frame images, including the first image (the first frame), the last image (the last frame), and seven images (seven frames) distributed equally therebetween, by dividing the total number of frames in the motion image file in eight equal intervals. Specifically, the MFP 10 extracts the nine frame images from the motion image file in chronological order and lays out and prints these frame images in the same order. FIG. 13A illustrates the layout of nine frame images denoted as 0 th through 8 th frames. Further, rather than referencing the total number of frames, the motion image file may be divided into eight equal time intervals by referencing the playback time of the motion image, for example.
The extraction size data storage area 67 stores data sizes of the frame image data (in a compressed format) for the extracted nine frame images and also has nine storage areas like the extraction position data storage area 66 . Each of these storage areas serves to store a numerical value (a value in units of bytes, for example) indicating the data size of the corresponding frame image.
The nine areas of the extraction position data storage area 66 are correlated with the nine areas of the extraction size data storage area 67 . Thus storage areas with the same layout position hold data related to the same frame image.
The output image data storage area 33 serves to temporarily store output image data for a motion image file by sequentially laying out nine frame images extracted from the motion image file as shown in FIG. 13A , and to temporarily store output image data for a still image file by laying out one still image represented by the still image file as shown in FIG. 13B .
The enlarged/reduced image data storage area 34 serves to store enlarged/reduced image data generated by converting (expanding or reducing) the output image data to a predetermined thumbnail image size.
The frame image data storage area 35 serves to store frame image data extracted from a motion image file. The frame image data stored in this region is in a compressed state (the JPEG format, for example) and has not yet been expanded (decoded).
The print data storage area 36 serves to temporarily store print data for actual printing that has been produced by converting the output image data.
The temporary variable storage area 37 serves to temporarily store variables and counters, such as a page no. counter, cursor position counter, processing page no. variable, generated image counter, process frame image counter, output image pixel counter, and line counter. These variables and counters are used during various processes executed by the CPU 14 , as will be described later.
The LCD position data storage area 38 serves to store data indicating a display page (described later) of the selection screen 81 , and a display position at which each thumbnail image is to be positioned. As shown in FIG. 7 , the LCD position data storage area 38 is provided with an input image ID storage area 71 , a display page no. storage area 72 , a display image position number storage area 73 , a horizontal display coordinate storage area 74 and a vertical display coordinate storage area 75 .
The input image ID storage area 71 stores input image IDs for the image files, which correspond to the input image IDs stored in the input image ID storage area 51 of the input image data storage area 31 .
The display page no. storage area 72 stores, for each input image ID, a page number of the selection screen 81 on which the thumbnail image for the corresponding image file should be displayed. Since there is a limit to the number of thumbnail images that can be displayed simultaneously on the LCD unit 11 (three in the present embodiment), the user must switch among a plurality of pages of the selection screen 81 when the number of selectable image files exceeds this limit.
The display image position number storage area 73 stores one of the numbers 0, 1, and 2 to indicate the position at which each thumbnail image should be displayed on the selection screen 81 (0 th , or 2 nd position from the left). Now assume that four image files are stored on the media card and are assigned input image IDs of 0, 1, 2 and 3. In this case, thumbnail images 91 a , 91 b and 91 c for the image files having IDs of 0-2 are displayed on a first page of the selection screen 81 respectively at left, center and right positions, as shown in FIG. 8A , and the remaining thumbnail image 91 d for the image file having ID of 3 is displayed at the left position on a second page, as shown in FIG. 8B .
The horizontal display coordinate storage area 74 stores data for a horizontal image layout starting point indicating a horizontal starting point at which each thumbnail image is to be displayed on the LCD unit 11 .
The vertical display coordinate storage area 75 stores data for a vertical image layout starting point indicating a vertical starting point at which each thumbnail image is to be displayed on the LCD unit 11 . Each circle in FIG. 9 shows positions corresponding to each combination of coordinates stored in the horizontal display coordinate storage area 74 and the vertical display coordinate storage area 75 .
The LCD image storage area 39 serves to store thumbnail images to be displayed simultaneously on the LCD unit 11 . Specifically, as shown in FIG. 10 , the LCD image storage area 39 has a plurality of sub-regions for storing thumbnail images, each sub-region being assigned one of the position numbers 0 th , 1 st and 2 nd that correspond to the numbers (0, 1 and 2) stored in the display image position number storage area 73 . The thumbnail images 91 a , 91 b , 91 c are respectively stored in the sub-regions of the position numbers 0 th , 1 st , and 2 nd , to display the first page of the selection screen 81 . The thumbnail image 91 d is stored in the sub-region of the position number 0 th to display the second page of the selection screen 81 .
Next, processes executed by the CPU 14 will be described in detail with reference to FIGS. 11 through 15 .
The CPU 14 of the MFP 10 performs the following processes (1)-(4):
(1) a media image printing process;
(2) an output image generating process;
(3) an LCD image generating process; and
(4) a printing process.
The CPU 14 executes the media image printing process (process (1) described above) when the user performs an operation on the input unit 12 to select a ‘media image printing mode’ while a media card storing image files is inserted in the media card slot 13 . The other processes (2)-(4) are executed as subroutines called during the media image printing process.
First, the media image printing process executed by the CPU 14 of the MFP 10 will be described while referring to a flowchart in FIG. 11 .
In S 101 at the beginning of this media image printing process, the CPU 14 reads data (a filename and file size) for one image file stored in the media card.
In S 102 the CPU 14 stores the data read in S 101 in the input image data storage area 31 in association with one input image ID. The CPU 14 further stores the input image ID and display page and position data for the subject image file (data of a display page and position at which a thumbnail image for the subject image file should be displayed) in the input image ID storage area 71 , the display page no. storage area 72 , the display image position number storage area 73 , the horizontal display coordinate storage area 74 and the vertical display coordinate storage area 75 in the LCD position data storage area 38 .
In S 103 the CPU 14 determines whether data for all image files stored in the media card has been re-ad.
If the CPU 14 determines that data for all image files has not been read (S 103 : NO), the CPU 14 returns to S 101 and reads data for one of the remaining image files.
However, if data has been read for all image files (S 103 : YES), in S 104 the CPU 14 initializes both of the page no. counter and the cursor position counter (prestored in the temporary variable storage area 37 ) to 0. The page no. counter represents on which page a cursor image 82 (see FIG. 8 AB) is currently being located among all the pages available in the selection screen 81 . The cursor position counter represents the position at which the cursor image 82 is currently being located, among the three thumbnail images simultaneously displayed on one page of the selection screen 81 . The page no. counter and the cursor position counter are interlocked with the user's operations of the Up, Down, Left and Right keys in the input unit 12 .
In S 105 the CPU 14 determines whether the page no. of the selection screen 81 has been updated. Specifically, the processing page no. variable is prestored in the temporary variable storage area 37 for representing a page no. on which an image file currently being processed is located among all the pages available in the selection screen 81 . The processing page no. variable is given an initial value of −1. The CPU 14 determines whether the page no. of the selection screen 81 has been updated by the user by comparing the value of the processing page no. variable with the value of the page no. counter, and judges that the page no. has been updated by the user when the two values are different. The processing page no. variable has been set to an initial value of −1 to ensure that the CPU 14 makes a YES determination the first time S 105 is performed. After reaching a YES determination in S 105 , before executing the process of S 106 , the processing page no. variable is updated to match the value of the page no. counter.
When the CPU 14 determines that the values of the processing page no. variable and the page no. counter are different from each other, i.e., the CPU 14 determines that the page no. was updated by the user (S 105 : YES), in S 106 the CPU 14 sets the input image ID of an image file to be processed (target image file). Here, specifically, the generated image counter has been stored in the temporary variable storage area 37 for counting how many output images have been generated for being displayed on one page of the selection screen 81 . The CPU 14 assigns the input image ID for the target image file with an input image ID that is stored in the input image ID storage area 71 in association with a combination of the value in the display page no. storage area 72 that is equal to the value of the page no. counter and the value in the display image position number storage area 73 that is equal to the value of the generated image counter. The value stored in the generated image counter is always reset to 0 when the CPU 14 advances from S 105 to S 106 .
In S 107 the CPU 14 executes the output image generating process (process (2) described above) on a targeted image file whose input ID has been set in S 106 . In S 107 , the CPU 14 generates output image data for the targeted image file (image data representing an image to be printed) in the output image data storage area 33 . Details of the output image generating process will be described later with reference to FIG. 12 .
In S 108 the CPU 14 executes the LCD image generating process (process (3) described above) on the output image data stored in the output image data storage area 33 (as a result of the output image generating process executed in S 107 ) to generate a thumbnail image for the targeted image file and stores the thumbnail image in the LCD image storage area 39 at a position having the position number indicated by the generated image counter. Details of the LCD image generating process will also be described later.
In S 109 the CPU 14 determines whether one screenful of thumbnail images has been generated. The CPU 14 increments the generated image counter by 1 in S 109 upon determining that one screenful of thumbnail images has not been generated (S 109 : No) and returns to S 106 to generate another thumbnail image.
Specifically, in S 109 the CPU 14 determines whether one screenful of thumbnail images has been generated based on whether the value of the generated image counter has reached the maximum number of images that can be displayed in one screen (since three images can be displayed simultaneously in the selection screen 81 in the present embodiment, the maximum image number is set to two because the initial value of the generated image counter is 0).
Further, if there are less than three thumbnail images in the last page to be displayed on the selection screen 81 , the CPU 14 determines that one screenful of thumbnail images has been generated by referring to the input image ID in addition to the value of the generated image counter. If the input image ID indicates the target image file is the last file, even though the value of the generated image counter does not reach the maximum number (i.e., the current value of the generated image counter remains either 0 or 1 in this example), the CPU 14 does not endlessly repeat the process S 106 -S 109 but determines that one screenful of thumbnail images has been generated in S 109 .
When one screenful of thumbnail images is determined to have been generated (S 109 : YES), in S 110 the CPU 14 displays the image data stored in the LCD image storage area 39 on the LCD unit 11 , and subsequently advances to S 111 .
The CPU 14 also jumps to S 111 after determining in S 105 that the page no. was not updated by the user.
In S 111 the CPU 14 displays a cursor image 82 on the selection screen 81 at a position associated with the cursor position counter. As shown in FIGS. 8A and 8B , the cursor image 82 in the present embodiment is a yellow border surrounding a thumbnail image displayed on the selection screen 81 in the LCD unit 11 .
In S 112 the CPU 14 receives data inputted from the input unit 12 when the user presses an operating key in the input unit 12 .
In S 113 the CPU 14 determines based on the data inputted in S 112 whether the pressed key was the OK key or another key, such as the Up key, Down key, Left key, or Right key.
If the CPU 14 determines in S 113 that the pressed key was a key other than the OK key, in S 114 the CPU 14 updates the page no. counter and/or the cursor position counter.
For example, when the pressed key was the Down key or Right key, the CPU 14 increments the cursor position counter by 1 in order to move the position of the cursor image 82 rightward one place. However, if the value of the cursor position counter exceeds the maximum value (2 in the present embodiment since the counter was initially set to 0) as a result of this increment, such as when the Down key or Right key was pressed when the cursor image 82 is in the rightmost position, the CPU 14 resets the cursor position counter to 0 and increments the page no. counter by 1. In this case, if the value of the page no. counter would exceed the maximum value (the page number of the last page −1, since the counter is initially set to 0) as a result of this increment, i.e., when there is no next page, the CPU 14 maintains the page no. counter at the maximum value without incrementing the counter.
On the other hand, if either the Up key or Left key was pressed in S 113 , the CPU 14 decrements the cursor position counter by 1 in order to move the position of the cursor image 82 leftward one place. In this case, if the value of the cursor position counter would be less than 0 following this decrementing operation, such as when the Up key or Left key was pressed when the cursor image 82 was already in the leftmost position, the CPU 14 resets the cursor position counter to 0 and decrements the page no. counter by 1. In this case, if the value of the page no. counter would be less than 0 as a result of the decrementing operation, i.e., when no previous page exists, the CPU 14 maintains the value of the page no. counter at 0 without decrementing the counter.
The CPU 14 returns to S 105 after finishing S 114 .
However, if the CPU 14 determines in S 113 that the pressed key was the OK key, in S 115 the CPU 14 assigns the input image ID for an image file to be printed with an input image ID that is stored in the input image ID storage area 71 in association with a combination of the value of the display page no. storage area 72 that is equal to the current value of the page no. counter and the value of the display image position number storage area 73 that is equal to the current value of the cursor position counter.
In S 116 the CPU 14 executes the output image generating process on the image file having the input image ID set as the printing target in S 115 . As a result of this process, output image data for the targeted image file (image data representing the print image) is generated in the output image data storage area 33 .
In S 117 the CPU 14 executes the printing process (process (4) described above) on the output image data stored in the output image data storage area 33 as a result of the output image generating process executed in S 116 and subsequently ends the current media image printing process. Details of the printing process will also be described later.
Next, the output image generating process (process (2) described above) executed in S 107 and S 116 of the media image printing process will be described with reference to a flowchart in FIG. 12 . The output image generating process is configured to be executed in S 107 on the image file whose ID has been set in S 106 to be displayed on the selection screen 81 , while to be performed in S 116 on the image file whose ID has been set in S 115 as a target to be printed.
In S 201 at the beginning of the output image generating process, the CPU 14 determines the type of the targeted image file by referencing the header data therein. Specifically, the CPU 14 refers to the filename stored in the input image filename storage area 52 in association with the ID of the targeted image file in the input image data storage area 31 . By using the filename, the CPU 14 directly accesses the target image file stored on the media card and refers to the header data therein.
In S 202 the CPU 14 determines whether the type of image file determined in S 201 is classified as a still image file or a motion image file.
If the CPU 14 determines in S 202 that the image file is a motion image file, then in S 203 the CPU 14 executes a process to analyze the motion image file. Through this analytical process, the CPU 14 acquires format type data and codec type data for the motion image file. The CPU 14 stores these data respectively in the format type storage area 61 and codec type storage area 62 of the motion image data storage area 32 (See FIG. 5 ).
In S 204 the CPU 14 executes a process to extract motion image parameters from the motion image file. Through this extraction process, the CPU 14 acquires horizontal size data, vertical size data, and total frame number data for the motion image file; and the extraction position data and extraction size data for each of the nine frames to be extracted. The CPU 14 stores these data respectively in the horizontal size storage area 63 , vertical size storage area 64 , total frame number storage area 65 , extraction position data storage area 66 , and extraction size data storage area 67 of the motion image data storage area 32 , as shown in FIG. 5 . If data for a different motion image file has already been stored in the motion image data storage area 32 at this time, the CPU 14 first deletes the existing data before storing the data for the motion image file currently being processed (overwrites the existing data).
In S 205 the CPU 14 performs a process to read, from the motion image file, data of a frame image to be processed from among the nine frame images (0 th through 8 th frames) based on the extraction position data and extraction size data stored in the extraction position data storage area 66 and extraction size data storage area 67 , respectively. Here, the process frame image counter prestored in the temporary variable storage area 37 is given an initial value of 0, and the CPU 14 targets data for the frame image corresponding to the value of the process frame image counter. As will be described later, the value of the process frame image counter is incremented after processing data for each frame image.
In S 206 the CPU 14 stores the frame image data read in S 205 in the frame image data storage area 35 .
In S 207 the CPU 14 performs an expansion (decoding) process on the frame image data stored in the frame image data storage area 35 and converts this data to a format in which pixel calculations are possible (such as image data expressing RGB values for each pixel as numerical values from 0 to 255).
In S 208 the CPU 14 stores or lays out the pixel data expanded in S 207 at a position in the output image data storage area 33 corresponding to the frame image being processed. When executing S 208 , if output image data for another image file has already been stored in the output image data storage area 33 , the CPU 14 first deletes the existing output image data before storing the new output image data for the currently targeted image file (i.e., overwrites the existing data).
In S 209 the CPU 14 determines whether the expansion process and layout process have been performed for all frame images. Specifically, the CPU 14 increments the process frame image counter by 1 each time processing of S 207 -S 208 for one frame image is completed. The CPU 14 determines that the expansion process and layout process have been performed on all frame images when the value of the process frame image counter reaches the value (the number of frame images to be laid out −1), i.e., eight in the present embodiment.
If the CPU 14 determines that the expansion process and layout process have not been completed for all frame images (S 209 : NO), the CPU 14 returns to S 205 and repeats the above process on data for an unprocessed frame image By repeatedly executing the processes of S 205 -S 209 , the CPU 14 lays out the nine frame images in their order of extraction (i.e., based on their positional order in the motion image), as illustrated in FIG. 13A . In the present embodiment, a margin is provided around each frame image when the frame images are laid out, but this margin is not necessarily required.
However, if the CPU 14 determines that the expansion process and layout process have been completed for all frame images (S 209 : YES), the CPU 14 ends the current output image generating process. At this time, the image data stored in the output image data storage area 33 (pixel data representing an image in which nine frame images are laid out) is the output image data for the motion image file.
On the other hand, if the CPU 14 determines in S 202 described above that the image file is a still image file, then in S 210 the CPU 14 performs an expansion process on the still image file to convert the image data in the still image file to a format in which pixel calculations are possible.
In S 211 the CPU 14 stores the image data expanded in S 210 in the output image data storage area 33 , and subsequently ends the current output image generating process. In other words, for still image files, unlike motion image files, a single still image is laid out in the output image data storage area 33 , as illustrated in FIG. 13B . At this time, the image data stored in the output image data storage area 33 (pixel data representing a still image) is the output image data for the still image file.
Next, the LCD image generating process (process (3) described above) executed in S 108 of the media image printing process will be described with reference to a flowchart in FIG. 14 . The LCD image generating process is configured to be executed on the output image data that has been generated in S 107 for the targeted image file whose ID has been set in S 106 .
In S 301 at the beginning of the LCD image generating process, the CPU 14 executes a process to enlarge or reduce the targeted image data (the output image data stored in the output image data storage area 33 ). Here, through this enlargement/reduction process, the CPU 14 generates an enlarged/reduced image (thumbnail image) by converting (enlarging or reducing) the targeted image data to a predetermined size for thumbnail images. The CPU 14 determines whether to execute an enlargement process or a reduction process by comparing the pixel size of the targeted image data with the pixel size of thumbnail images to be displayed on the LCD unit 11 .
Usually the reduction process is performed on the targeted image data since the pixel size of the targeted image data is normally greater than that of the thumbnail images. However, conceivably, the pixel size of the output image data could be smaller than that of the thumbnail images, in which case the enlargement process would be executed on the targeted image data. It is also conceivable that the pixel size of the targeted image data could be the same as that of the thumbnail images, in which case it is not necessary to perform an enlargement or reduction process on the image data. The enlargement and reduction processes are performed using well known algorithms, such as the nearest neighbor algorithm, bilinear algorithm, or bicubic algorithm, to generate an enlarged/reduced image one pixel at a time.
In S 302 the CPU 14 stores the image data resulting from the enlargement/reduction process of S 301 in the enlarged/reduced image data storage area 34 .
In S 303 the CPU 14 determines whether the enlargement/reduction process has been executed on all pixels in the targeted image data. In the present embodiment, the output image pixel counter has been prestored in the temporary variable storage area 37 for counting the number of pixels on which the enlargement/reduction process has already been completed. The output image pixel counter is given an initial value of 0. The CPU 14 increments this output image pixel counter by one each time the process in S 301 is performed. The CPU 14 determines that the enlargement/reduction process has been executed for all pixels in the targeted image when the value of the output image pixel counter reaches the number of pixels in the targeted image data.
The CPU 14 returns to S 301 upon determining in S 303 that the enlargement/reduction process has not been executed for all pixels in the targeted image (S 303 : No).
However, if the CPU 14 determines that the enlargement/reduction process has been completed for all pixels (S 303 : YES), in S 304 the CPU 14 copies the data stored in the enlarged/reduced image data storage area 34 to a region of the LCD image storage area 39 that is associated with a display position number for the targeted image file (see FIG. 10 ) which is indicated by the current value of the generated image counter. Subsequently, the CPU 14 ends the LCD image generating process.
Next, the printing process (process (4) described above) executed in S 117 of the media image printing process will be described with reference to a flowchart in FIG. 15 , The printing process is executed on the output image data generated and stored in the output image data storage area 33 in S 116 .
In S 401 at the beginning of the printing process, the CPU 14 copies one line worth of the output image data stored in the output image data storage area 33 to the print data storage area 36 . If the size of the output image is 1600 pixels horizontally×1200 pixels vertically, for example, one line would be 1600×1 pixels.
In S 402 the CPU 14 performs color space conversion for converting pixel data in the print data storage area 36 from RGB values to CMYK values. More specifically, the CPU 14 performs an RGB→CMY conversion on the pixel data using a color conversion method well known in the art, and performs CMY→CMYK conversion on the resulting data using a GCR process well known in the art.
In S 403 the CPU 14 converts the pixel data in the print data storage area 36 to binary data for printing in each of the CMYK colors. This binary conversion is performed using processes well known in the art, such as the error diffusion method and dither matrix method.
In S 404 the CPU 14 outputs the binary data produced in S 403 to the printing unit 18 , whereby the printing unit 18 performs a printing operation based on this binary data.
In S 405 the CPU 14 determines whether the above process has been completed for all lines of the output image data. In the present embodiment, the line counter having an initial value of 0 has been prestored in the temporary variable storage area 37 . The CPU 14 increments this line counter by one each time the process described above has been completed for one line. The CPU 14 determines whether the process has been completed for all lines of the output image data when the value of the line counter reaches the number of lines of the output image data stored in the output image data storage area 33 .
The CPU 14 returns to S 401 when determining in S 405 that there remain lines to be processed (S 405 : No).
When the process has been completed for all lines (S 405 : YES), the CPU 14 ends the current printing process.
As described above, the MFP 10 according to the present embodiment displays the selection screen 81 with which a user can select an image file to print. The MFP 10 displays images in the selection screen 81 for selecting image files that are candidates for printing. The displayed images give the user a good idea of what the actual printed image will look like if the image file is selected. Accordingly, the user of the MFP 10 can more effectively select image files to obtain desired printed images.
In other words, if only a thumbnail image of one frame image from the motion image file were displayed, this frame image may differ from the images that the user will actually be printing. Hence, the user must select an image file without knowing exactly what images are available for printing in the motion image file. Thus, in some cases the user will not find a desired printed image in the selected image file and must search through several image files in an effort to find the desired image. The MFP 1 according to the present embodiment solves this problem by displaying images the same as print images in the selection screen 81 for selection.
Further, since the MFP 10 of the present embodiment can print an image in which a plurality of frame images has been laid out on the same page, the MFP 10 is configured to display an image having a combination of frame images as a thumbnail image for selection. Arranging a plurality of frame images on a single page also enables the user to more easily identify the content of a motion image than when only one frame image of the motion image is displayed as a selectable image. Printing a plurality of images on a single page is more suited to motion images than still images, particularly when the frame images of the motion image are smaller in size than the still images, since frame images of a motion image may appear grainy and poorer in quality when printed at an enlarged size.
The MFP 10 of the present embodiment can also allow the user to select an image file to be printed from among a combination of motion image files and still image files. This eliminates the inconvenience of having to select motion image files and still image files using different modes when both file types are stored on the same media card.
Further, since the MFP 10 of the present embodiment displays a row of thumbnail images for a plurality of image files in the selection screen 81 as selectable images, the user can compare output images of different image files when selecting an image file to print.
While the present invention has been described in detail with reference to the embodiment thereof, it would be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention.
For example, the MFP 10 according to the present embodiment described above automatically identifies nine frame images to be extracted from a motion image file, but the present invention is not limited to this configuration. For example, the MFP 10 may prompt the user to select which frame images are to be extracted. Further, the number of frame images to be extracted from a motion image file is not limited to nine and need not be fixed to any specific number. The user may be prompted to specify the number of frame images to be extracted.
Further, the present invention has been applied to a multifunctional peripheral as an example of printing devices according to the present embodiment, but the present invention may also be applied to a printing device other than a multifunctional device, such as a printer without scanning function.
Further, the present invention may also be applied to a computer connectable with a printing device. In this case, a driver program for controlling operations of the connected printing device is installed on a ROM, an HDD or the like in the computer. By executing the driver program, the computer performs the above-described processes (1) to (4), just like the MFP 10 . That is, the computer reads image files (motion image files and still image files) from a media card inserted in the computer, generates output images for each image file, displays thumbnail images corresponding to the output images on a display unit of the computer for selection, and controls the printing device to print an output image corresponding to the thumbnail image selected by a user. The driver program may be originally stored on a recording medium, such as a CD-ROM, and installed on the computer.
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An image processing apparatus comprising an retrieving unit configured to retrieve a first image file representing a motion image and a second image file representing a still image, a display image file generating unit configured to generate, from the first image file, a first single display image file comprising a plurality of frame images extracted from the first image file; a display control unit configured to display the first single display image file and a second single display image file adjacent to each other, the second single display image file comprising the still image represented by the second image file; a selection accepting unit configured to accept a selection of one from among the first single display image file and the second single display image; and a printing data generation unit configured to generate print data to be used for printing based upon the selection.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for closing one end of a core barrel installed in equipment used for drilling for minerals or oil.
2. Description of the Prior Art
It is known that a core barrel can be installed at the end of a line of rotating hollow drill-rods used for test drilling, in particular in geological layers containing minerals and oil, said core barrel allowing samples to be taken from these layers, for example for analysis.
This core barrel which may be, for example, of the type described in Belgian Pat. No. 875016 comprises, on the one hand, an external rotating tube which is constituted by drill-rods and of which the lower end bears a welding ring and, on the other hand, an internal, non-rotating tube, the lower end of which is provided with an extracting cone.
In a core barrel of this type, a drilling liquid is injected inside the drill-rods from the surface.
At the beginning of the drilling operation, it is essential to guide the drilling liquid through the core barrel in order to clear and clean the debris which has accumulated at the bottom of the shaft during the rise and fall of the drill-rods.
A core sample which is representative of the ground cannot in fact be taken until the clearing operation is completed.
While cutting out a core sample, the flow of drilling liquid is generally diverted toward the exterior of the core barrel into an annular space surrounding it. This annular space is defined by the internal wall of the lower rod of the set of hollow drill-rods and the external surface of the internal tube of the core barrel.
In known boring or drilling equipment, the flow of drilling liquid is diverted by freely throwing, from the end of the line of drill-rods remote from the core barrel, a ball intended to close a seat provided at the upper end of the core barrel. It is known that the flow of drilling liquid can be increased in order to accelerate the descent of the ball.
In practice, even though the flow of drilling liquid can be as high as 1,500 liters per minute, the descent of the ball in line of hollow drill-rods having a length of approximately 3,000 meters can take about 20 minutes, with a device according to British Pat. No. 2,048,996 which corresponds to U.S. Pat. No. 4,452,322.
In addition, it has been found that, at the end of its drop, the ball abruptly strikes the above-mentioned seat and causes in the descending column of drilling liquid a surge which damages the core barrel and possibly the boring shaft.
This British patent proposes to divert the flow of drill flushing fluid by means of a valve body releasing a ball in the vicinity of the core barrel and closing a seat provided at the upper end of the core barrel.
The valve body is restrained in a releasable storage cavity arranged in the core drill device, in the vicinity of the core barrel by means of a latch consisting of an annular body formed as a piston housing under a preload. The core barrel is connected to the steam path of the drill flushing fluid by an inlet comprising a seat at the upper end of the core barrel. The piston is movable downwards against the preload when the pressure of the drill flushing fluid is increased to a maximal value by the operators of the drilling equipment at the surface.
The piston, provided with a lateral opening, liberates the ball which reaches and closes immediately, but violently, the seat at the inlet of the core sleeve, stops the flow of drill flushing fluid through the core sleeve, and diverts the flow into the annular space between the outer sleeve and the core sleeve.
This boring or drilling apparatus thus has the drawback that the ball, at the end of its drop, under excessive flow velocities abruptly strikes the above-mentioned seat and causes a surge which damages the core barrel and possibly the boring shaft.
BRIEF SUMMARY OF THE INVENTION
The present invention aims to overcome these disadvantages and relates to a device for rapidly closing the seat provided at the upstream end of the core barrel, without causing a surge in the column of drilling liquid.
The device according to the invention for closing the upstream end of a core barrel, is essentially characterised in that it comprises a tube element similar to those forming the line of drill-rods and in whose bore there is guided a sliding member providing a passage for drilling liquid under pressure, this sliding member being caused to make a first movement under the influence of an increase in the flow of drilling liquid between an initial rest position and a remote stable position in which it holds a closing element remote from a seat provided at the end of the core barrel and being brought back, under the influence of a subsequent reduction in the flow, to its starting position in which it allows this closing element to place itself on the above mentioned seat.
It is preferable, according to a feature of the invention, that this closing element be formed by a solid metal ball separate from the sliding member.
According to a further feature of the invention, the sliding member is provided at one end with an attachment directed towards the above-mentioned end of the core barrel, this attachment being provided with a protuberance having a shape which is such that, in the initial rest position of the sliding member, the attachment holds the ball in a first section of the bore of the tubular element, while, in the remote stable position, the protuberance holds the ball in a second section of the bore of the tubular element and allows the ball to be released towards the seat of the core barrel when the sliding member re-occupies its starting position.
In an embodiment of the device according to the invention, the above-mentioned attachment of the sliding member has a cylindrical free end which is coaxial with the bore of the tubular element. This bore is formed by successive coaxial cylindrical sections, a first one of these sections having a diameter substantially equal to that of the attachment increased by twice the diameter of the ball, the second of these sections having a diameter greater than that of the free end of the protuberance increased by at least twice the diameter of the ball, whereas a third section of the bore, adjacent to the second section thereof and located on the side of the above-mentioned end of the core barrel, has a diameter smaller than the diameter of the above-mentioned free end of the attachment increased by twice the diameter of the ball, in such a way that the sliding member occupies a stable upper initial rest position in which the cylindrical end of the attachment, when engaged in the second section of the bore, allows the ball to be held in the first section of this bore and that the sliding member occupies a stable lower position in which it allows the ball to pass from the first section of the bore into the second section thereof and to place itself on the seat of the core barrel when the sliding member returns to its starting position.
The sliding member provided in the device according to the present invention is preferably formed by a sleeve comprising, on the one hand, an orifice for throttling the flow of drilling liquid in the vicinity of its end remote from the end bearing the attachment and, on the other hand, a series of divergent holes for the delivery of the hydraulic liquid, situated in the vicinity of its end bearing the attachment.
A spring permanently causes the sliding member to travel in the direction opposed to the direction of the drilling liquid.
According to a further feature of the invention, the free end of the attachment holds the ball in a first section of the above-mentioned bore which is situated upstream of the second section thereof, at least until the moment when the free end of the attachment engages in the third section of the bore.
Further features and details of the invention will appear from the following detailed description in which reference is made to the accompanying drawings which show, by way of a non-limiting example, an embodiment of a device according to the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross section through a device according to the invention in which a sliding member occupies an initial rest position in which it holds a ball.
FIGS. 2 and 3 also show a cross section through the device according to the invention shown in FIG. 1, in which the sliding member and the ball occupy different positions.
FIG. 4 is a cross sectional view similar to FIGS. 1 and 3, showing the device according to the invention in which the ball closes the upstream end of the core barrel.
In these various Figures, the same reference numerals designate identical elements.
DETAILED DESCRIPTION
FIG. 1 is a cross sectional view of a device according to the invention designated in its entirety by the reference numeral 1 in which a ball 2 which is intended to close the upstream end 3 of a core barrel 4 by applying itself to the seat 5 provided for the ball 2 at said end 3.
The device 1 comprises a tubular element 6 in whose bore there is guided a sliding member 7 which provides a passage for a drilling liquid under pressure (direction of the arrow X). The tubular element 6 comprises, at its upstream end 8, tapping 9 in which there is screwed a hollow drill-rod 10 advantageously equipped a turbine 11 or with a hole base motor and, at its downstream end 12, a screw thread 13 on which the core barrel 4 is screwed. The turbine 11 which is rotated during the passage of the drilling liquid in the direction of the arrow X, sets the device 1 as well as the core barrel 4 into rotation.
The sliding member is constituted by a sleeve 14 comprising, on the one hand, a throttling orifice 15 for throttling the flow of drilling liquid in the vicinity of its upstream end 16 and, on the other hand, a series of divergent holes 17 for the delivery of the drilling liquid located in the vicinity of its downstream end 18 bearing an attachment 19. The sleeve 14 ends, upstream of the orifice 15 for throttling the flow of drilling liquid, with a funnel-shaped member 20, intended to guide the flow of liquid towards the throttling orifice 15. The sleeve 14 comprises an annular stop 21 on its external face 22 in the vicinity of its upstream end 16, this stop 21 holding a collar 23 of a bushing 24 in position.
The attachment 19 provided in the vicinity of the downstream end 18 of the sleeve 14 is formed by a cylindrical rod 25 bearing at its free end 26 adjacent to the core barrel 4, a head-shaped protuberance 27, said head-shaped protuberance 27 having the form of a cylinder 28 provided at each of its ends with a truncated cone shaped outlet 29, 30.
The sleeve 14 forming the sliding member comprises, in the vicinity of the funnel-shaped member 20, a cylindrical external surface 31 adjacent to the internal surface 32 of the tubular element 6, this surface 31 comprising an annular groove 33 in which there is placed a gasket 34.
The tubular element 6 comprises a passage 35 formed, from the upstream end to the downstream end, by a cylindrical section 36, which is in contact with the cylindrical external surface 31 having a diameter smaller than that of this section 36, so as to form an annular flange 38, on which there rests a collar 39 provided with a flange 40, a bore 41 and finally, at its downstream end, a last cylindrical section 42 having a diameter greater than the diameter of the ball 2.
The protuberance or head 27 of the sliding member 7 moves in the bore 41, this sliding member 7 moving under the influence of a loss of charge due to a variation in the flow of drilling liquid. When the flow of drilling liquid is great, the loss of charge due to the passage of the fluid through the throttle 15 of the sliding member 7 is great and the sliding member 7 moves in the direction of the flow (direction X) of the drilling liquid against the action of a coil spring 43 located between the collar 23 of the bushing 24 resting on the stop 21 of the sliding member 7 and the flange 40 of the collar 39 resting on the annular flange 38 of the tubular element 6.
The bore 41 is constituted by coaxial cylindrical sections 44, 45, 46, connected to one another and to the cylindrical sections 42 and 37, by truncated cone-shaped sections 47, 48, 49, 50.
The central cylindrical section 45 of the bore 41 has a diameter greater than that of the protuberance or head 27 of the attachment 19 increased by twice the diameter of the ball 2, whereas the cylindrical portion 46, of this bore 41 has a diameter smaller than the diameter of the protuberance or head 27 increased by twice the diameter of the ball 2, in such a way that the head 27, when engaged in the cylindrical section 46, allows the ball 2 to be held in the central cylindrical section 45 whereas, when it is extracted from this cylindrical section 46, it allows the ball 2 to pass from the central cylindrical section 45, into the cylindrical section 46 and to apply itself to the seat 5 of the core barrel 4 (see FIGS. 3 and 4).
The cylindrical section 44 located upstream of the central cylindrical section 45 of the bore 41 has a diameter smaller than the diameter of the protuberance or the head 27 increased by twice the diameter of the ball 2 but greater than the diameter of the rod 25 increased by twice the diameter of the ball 2, such that a ball 2 introduced into the upstream cylindrical section 44 through a hole 51 provided with a removable stopper 52, remains in this section 44 at least until the moment when the head 27 engages in the cylindrical section 46 of the bore 41 (see FIGS. 2 and 3). The downstream end 53 of the turbine 11 acts as a stop for the sliding member 7.
The core barrel 4 may be constituted by an external tube 54 equipped with a drilling ring 55 in which there is accommodated a hollow drill-rod 56 comprising the seat 5 for the ball 2 at its upstream section 55.
When the ball 2 closes the end 3 of the hollow rod 56, the flow of drilling liquid is guided in divergent orifices 57 toward the annular space 58 located between the external tube 54 and the hollow rod 56, and the core sampling operation can take place.
A sequential description of the core sampling process using the device described above is illustrated in FIGS. 1 to 4.
As shown in FIG. 1, a ball is introduced through the hole 51 into the upstream cylindrical section 44 of the bore 41 before the boring operation is commenced, that is to say before the line of drill-rods and the core barrel are introduced into the drilling shaft.
The descent of the line of drill-rods causes earth to fall into the drilling shaft.
Before taking a test bore sample, it is convenient to pass the drilling liquid (direction of the arrow X) through the core barrel in order to clear and remove the debris which has accumulated at the bottom of the boring shaft during the descent and the rise of the line of hollow drill-rods. In fact, a core sample which is representative of the geological layer to be analysed cannot be removed until the debris clearing operation has taken place.
For this clearing operation, the flow of drilling liquid is advantageously adjusted to 1,900 liters per minute. Rinsing is thus carried out effectively and the loss of charge created in the throttling orifice 15 and which attains about 1 bar is just too weak to repel the sliding member subjected to the opposing action of the coil spring 43.
During the rinsing operation, the force applied to the sliding member due to the loss of charge in the throttle is in equilibrium with the force of compression of the spring. The rinsing flow creates a loss of charge which does not cause any significant movement of the sliding member. Any interruption, for example accidental, in the rinsing of the core barrel does not cause significant movement of the sliding member either.
When the operator considers that the rinsing operation is completed, he increases the flow of drilling liquid to 2,900 liters per minute for a short period, creating a loss of charge of about 3 bars in the throttling orifice 15 of the sliding member 7.
This loss of charge causes the sliding member 7 to travel in the direction of the flow of drilling liquid (arrow X) against the action of the coil spring 43. Thus, the head 27 of the attachment 19 of the sliding member 7 travels in the direction (X) of the flow of liquid and, when it has engaged in the third section 46 of the bore 41, it allows the ball 2 which has been introduced beforehand into the first section 44 arranged upstream of the bore 41 through the orifice 51 equipped with the stopper 52 to pass from the first upstream section 44 into the second section 45 of the bore 41 (see FIGS. 2 and 3).
When the operation of clearing the bottom of the shaft is completed and when the ball 2 is located in the second section 45 of the bore 41, the flow of drilling liquid is reduced or optionally stopped so that, due to the action of the spring 43 on the sliding member 7 and due to the slight or zero loss of charge in the throttling orifice 15 of the sliding member 7, this sliding member travels in the direction of the arrow Y. Thus, the head 27 of the sliding member 7 is extracted from the third cylindrical section 46 so as to allow the ball 2 to pass from the second section 45 into the third section 46. The ball 2 can thus apply itself, by gravity, to the seat 5 of the core barrel 4 (see FIGS. 3 and 4).
This minimal or zero flow makes it possible to avoid a surge which might have caused an abrupt stoppage of the flow of liquid from the flow of drilling liquid inside the core barrel.
Such a surge is particularly harmful in a boring core barrel because a sudden deviation in the flow of drilling liquid is manifested by the simultaneous creation of a reduced pressure inside the core barrel and an excess pressure outside the core barrel.
The simultaneous reduction in pressure inside the core barrel and increase in pressure outside the core barrel could cause radial buckling and crushing of the core barrel which, as known, necessarily comprises thin walls.
Once the ball has been placed on the seat of the core barrel 4, as shown in FIG. 4, the core sampling operation can take place.
For this purpose, a flow of drilling liquid of about 1,100 liters per minute may be necessary to set the core barrel 4 as shaft as the device according to the invention 1 into rotation by means of the turbine 11. The drilling fluid is guided through the divergent orifices 57 towards the annular space 58 of the core barrel 4 so as not to damage the sampled core. Such a flow of 1,100 liters per minute creates a loss of charge of about 0.5 bar in the throttling orifice 15 of the sliding member 7.
It is obvious that core barrels other than the one shown and described in this specification can be used. Thus, a double core barrel of the type described in Belgian Pat. No. 875 016 can be used.
The device according to the invention, the core barrel, the turbine and the hollow drill-rods are advantageously composed of steel, whereas the drilling ring advantageously contains particles of abrasive materials such as diamond, corundum, tungsten or silicon carbide, optionally agglomerated in the form of thin slabs.
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The invention relates to a device for closing, without a surge, one end of a core barrel installed in a mining or oil drilling rig, optionally equipped with a turbine.
This device comprises a tubular element in whose bore there is guided a sliding member which provides a passage for the drilling liquid under pressure, this sliding member being movable in the above-mentioned bore under the influence of a variation in the flow of drilling liquid between a first position in which it keeps a closing member such as a ball remote from a seat provided at the above-mentioned end of the core barrel and, when it has engaged in the second section of the bore allows the closing element to be held in the first section of the bore, and a second position in which it allows the closing element to pass from the first section of the bore into the second section thereof and to place itself on the seat of the core barrel when the sliding member returns to its starting position.
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RELATED APPLICATIONS
This application claims priority and benefit to U.S. Provisional Application No. 61/891,885, filed Oct. 16, 2013, entitled “Robust Sensing System for Verifying Engagement of a Deadbolt Bolt into a Deadbolt Strike Plate,” and to U.S. Provisional Application No. 61/897,768, filed Oct. 30, 2013, entitled “Robust Sensing System for Verifying Deadbolt Engagement Including Door Angle Sensing Subsystem.” All of these applications are incorporated by referenced herein in their entireties.
TECHNICAL FIELD
This relates generally to door locks, including but not limited to sensing systems for verifying deadbolt engagement.
BACKGROUND
As discussed in U.S. Pat. No. 6,950,033 to Guyre, entitled “Door Bolt Alarm,” which is incorporated by reference herein, it is desirable for purposes of home security and homeowner reassurance for a user to be able to know for certain whether a door to their home, such as a front door, is properly closed and that the deadbolt is properly engaged. Security systems, building automation systems, and HVAC systems all benefit from knowing the state of doors, such as whether they are open or closed, locked or unlocked, and the like. Several known deadbolt systems are able to verify that a bolt of the deadbolt system is either extended or retracted and are able to communicate this status in various ways to a user. However, the status of the bolt as being extended or retracted is not necessarily indicative of the true security state of the door. For example, it may be the case that the bolt is extended, but that the door is still partially open. Moreover, many existing systems require wiring to be installed in door frames and/or door jambs, which can be expensive and complicated to install and maintain.
Thus, existing systems cannot reliably verify that a door has indeed been shut and that the deadbolt has indeed been properly engaged. Moreover, existing systems are complex and often include a multitude of sensors and require significant wiring.
SUMMARY
Accordingly, it would be desirable to provide a system that can reliably verify that a door has indeed been shut and that the deadbolt has indeed been properly engaged. It would be further desirable to provide such a system in a manner that does not require a high degree of complexity, does not require an inordinate number of sensors, and does not require an inordinate number of wires.
In accordance with some embodiments, a door lock detection system includes a magnet flexibly attached to a strike plate (e.g., by spring, hinge, or combination thereof). The strike plate includes an opening. The magnet extends across the opening of the strike plate in a first orientation when a bolt does not extend into the opening of the strike plate. The magnet is configured to be deflected from the first orientation to a second orientation, distinct from the first orientation, in response to the bolt being extended into the opening of the strike plate. The door lock detection system also includes a magnetometer configured to detect one or more magnetic fields of the magnet that is flexibly attached to the strike plate in the first orientation and in the second orientation.
In accordance with some embodiments, a method is performed by a door lock detection system that has a magnet flexibly attached to a strike plate. The strike plate includes an opening. The magnet extends across the opening of the strike plate in a first orientation when a bolt does not extend into the opening of the strike plate. The magnet is configured to be deflected from the first orientation to a second orientation, distinct from the first orientation, in response to the bolt being extended into the opening of the strike plate. The door lock detection system also has a magnetometer configured to detect one or more magnetic fields of the magnet that is flexibly attached to the strike plate in the first orientation and in the second orientation; and a controller. The method includes detecting, with the magnetometer, one or more magnetic fields of the magnet that is flexibly attached to the strike plate; determining whether the detected one or more magnetic fields correspond to the magnet being in the second orientation; and based at least in part on determining that the detected one or more magnetic fields correspond to the magnet being in the second orientation, relaying, with the controller, to at least one other system information that indicates that the bolt is engaged in the strike plate.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the various described embodiments, reference should be made to the Description of Embodiments below, in conjunction with the following drawings in which like reference numerals refer to corresponding parts throughout the figures.
FIG. 1A is a front view of a deadbolt assembly in accordance with some embodiments.
FIG. 1B is a side view of a deadbolt assembly in accordance with some embodiments.
FIG. 2A is a front view of a deadbolt assembly in accordance with some embodiments.
FIG. 2B is a side view of a deadbolt assembly in accordance with some embodiments.
FIGS. 3A-3B are perspective views of a deadbolt assembly in accordance with some embodiments.
FIGS. 4A-4D are front views of a deadbolt assembly in accordance with some embodiments.
FIGS. 5A-5D are side views of a deadbolt assembly in accordance with some embodiments.
DESCRIPTION OF EMBODIMENTS
FIGS. 1A, 1B, 2A, and 2B illustrate a sensing system for verifying that a door is properly shut and that a deadbolt is properly engaged. More particularly, FIGS. 1A and 1B illustrate front and side views, respectively, of a deadbolt assembly 102 mounted on a door 112 that has been shut into a door jamb 116 , wherein a bolt 104 of the deadbolt assembly 102 is in a retracted state. As with conventional systems, there is a deadbolt face plate 114 affixed to the door 112 , and a deadbolt strike plate 118 affixed to the door jamb 116 . In some embodiments, there is provided a magnet 108 that is flexibly and springably attached to the deadbolt strike plate 118 , such as by flex/spring member 109 , such that the magnet 108 extends across the opening of the deadbolt strike plate 118 . In some embodiments, the deadbolt assembly 102 is provided with a magnetometer 106 . The magnetometer 106 and the magnet 108 are mutually configured and dimensioned such that the magnetometer 106 can sense a change in orientation of the magnet 108 . In particular, when the magnet 108 is deflected, the magnetic field that is produced by the magnet is correspondingly deflected. In some embodiments, magnetic field readings from the magnetometer 106 are compared against previous readings to determine whether the readings correspond to a deflected magnetic field (e.g., resulting from the bolt 104 deflecting the magnet 108 ), or an undeflected magnetic field (e.g., resulting from the bolt 104 not deflecting the magnet 108 ).
FIGS. 2A and 2B illustrate corresponding front and side views, respectively, of the sensing system of FIGS. 1A and 1B in which the bolt 104 is in an extended state. FIGS. 3A and 3B illustrate perspective views, FIGS. 4A-4D illustrate front views, and FIGS. 5A-5D illustrate side views of the sensing system in accordance with some embodiments. As shown in FIGS. 2A and 2B , the magnet 108 has changed its orientation by 90 degrees by virtue of the mechanical insertion of the bolt 104 through the opening of the deadbolt strike plate 118 , an orientation change that is detected by magnetometer 106 . In some embodiments, this change in orientation is communicated from the magnetometer 106 to one or more user interfaces using a variety of different electronics and communications configurations, such as those described in Guyre, supra.
Advantageously, false engagement signals associated with the situation of an extended bolt but unclosed door are avoided, because the magnet 108 will not change orientation in that case. Conversely, false engagement signals associated with a situation of a rotated magnet 108 but non-extended bolt (such as by a person sticking their finger into the opening of the deadbolt strike plate) is also avoided, because if the door is not closed, then the magnetometer 106 will be too far from the magnet 108 to sense its orientation change. In some embodiments, false engagement signals are still further avoided by virtue of a separate sensing system (not shown) onboard the deadbolt assembly 102 for sensing whether the bolt has been extended (e.g., by optical sensing, electrical bumper switch, magnetic sensing, etc.). In such cases, the conclusion that the door has been closed and the deadbolt locked is reached when it is determined that both (a) the bolt has been extended (e.g., as determined by the separate sensing system), and (b) the magnet 108 has changed its orientation (e.g., as determined by the magnetometer 106 ).
One example of a commercially available magnetometer suitable for use with the present system is an ASAHIKASEI AKM AK8963 3-axis electronic compass. In a calibration step in the locked position, the X, Y, and Z magnetic fields reported by the magnetometer are measured. Within a tolerance, when this same combination of fields is seen again (and, optionally, the bolt is known to be extended), it is determined that the door is securely locked. One example of a magnet that can be used is a Neodymium rare earth magnet, such as a Neodymium disc magnet having dimensions of 0.5 inch diameter by 0.125 inch thickness.
The disclosed systems and methods use minimally invasive sensors to identify if a deadbolt is properly engaged in a doorframe, as opposed to merely detecting if the deadbolt is out but the door is not closed. Using a strike plate that mounts inside the doorframe, the bolt deflects a magnet when the bolt is properly engaged into the strike plate. Once the door is locked (i.e., the bolt is extended through an opening of the strike plate and into a door jamb), a magnetometer measures the magnetic field it senses. If the magnetometer senses a magnetic field substantially equivalent to the previously calibrated magnetic field (e.g., which corresponds to the magnetic field that is sensed when the bolt deflects the magnet in the latch in the doorframe), it is determined that the bolt is engaged properly in the doorframe and that the door is secured. A microcontroller relays this information to other systems such as a door mounted notification light or alarm, a security system, and/or a control panel. In some embodiments, the system is also connected to an electromechanical door locking/unlocking mechanism.
The disclosed embodiments provide numerous advantages over conventional deadbolts. For example, as noted above, conventional deadbolts (even electromechanical ones) do not know if the bolt (when extended) actually extends into the door jamb securing the door; they just know if the bolt is extended or retracted. In the disclosed embodiments, however, there is no need for an electrical switch inside the door jamb to sense that the bolt is engaged. Rather, the sensor that determines whether the bolt is engaged or not is external to the door jamb and strike plate (e.g., it is coupled to a deadbolt assembly mounted to the door). Also, because there is no electrical switch, there is no need to run electrical wires inside the doorjamb. Indeed, in some embodiments, the strike plate is retrofitted into existing door jambs without additional wiring. Furthermore, the disclosed embodiments do not require redesigning conventional bolts or locking mechanisms, as the magnet and magnetometer are agnostic to the particular locking mechanism being used. Indeed, the disclosed embodiments will work well with both manually operated and electromechanical door locks to provide feedback if the deadbolt is actually engaged.
In some embodiments, the deadbolt assembly 102 is further configured and adapted to sense the particular angle of the door (e.g., 0 degrees corresponding to a completely closed state, 10 degrees corresponding to a cracked or partially open state, 90 degrees corresponding to an open state, and so forth). For example, a microelectromechanical system (MEMs) magnetometer mounted to a door senses door orientation (i.e. closed, open, partially open) by measuring changes in orientation with respect to the earth's magnetic field or a reference magnetic field (e.g., a stationary a magnet or coil). In some embodiments, this MEMs magnetometer can be one and the same as the magnetometer 106 . For other embodiments, the door-angle-sensing MEMs magnetometer is a separate magnetometer than the magnetometer 106 provided with the deadbolt assembly 102 . In still other embodiments, the door-angle-sensing MEMs magnetometer is mounted in a separate device or structure on the door. In addition to or as an alternative to the door-angle-sensing MEMs magnetometer, a MEMs gyroscope (“gyro”) device is optionally included in the deadbolt assembly 102 or otherwise mounted to a door for measuring the angular rate of the door opening or closing. Knowing time, after integrating the gyro, the door's angular relative position from a known starting point is determined, thereby allowing determination of the door's absolute opening angle. By way of example and not by way of limitation, examples of suitable MEMs gyros include the BOSCH BMG160, the ST LPY410A, and the ST A3G4250D.
Information regarding the door angle is useful in a variety of different ways. In some embodiments, the door angle information is used to verify that the door is indeed properly closed (i.e., completely closed, as opposed to partially or fully open). Another use includes communicating the door angle to a user interface screen of a user, so that the user can determine, from a remote location, whether and to what extent the door is open. Another useful application arises for doorways equipped with a screen door, (i.e., a second door that allows air to pass in and out while also keeping out insects and other pests), or for other doors such as interior doors that affect air circulation in the house. In such embodiments, the detected door angle is communicated to an HVAC system for any of a variety of useful purposes relating to the monitoring or governing of air flow in the home. Additionally, applications further include doors equipped with associated motors and linkages for achieving automated opening and closing, where the door angle is used as part of a feedback control system.
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A door lock detection system is disclosed. The system includes a magnet flexibly attached to a strike plate. The strike plate includes an opening. The magnet extends across the opening of the strike plate in a first orientation when a bolt does not extend into the opening of the strike plate. The magnet is configured to be deflected from the first orientation to a second orientation, distinct from the first orientation, in response to the bolt being extended into the opening of the strike plate. The system includes a magnetometer configured to detect one or more magnetic fields of the magnet that is flexibly attached to the strike plate in the first orientation and in the second orientation.
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FIELD OF THE INVENTION
[0001] This invention relates generally to semiconductors and, more particularly, to trench memory devices and a method for manufacturing same.
DESCRIPTION OF THE RELATED ART
[0002] In trench memory, retention of an electric charge in a cell capacitor is greatly influenced by various leakage mechanisms. Trench memory devices or structures are subject to vertical parasitic leakage that degrades charge or data retention. As shown in FIG. 1 , a vertical parasitic transistor is formed in a contemporary trench memory structure where the N+ buried strap is the drain, the N+ buried plate is the source, the N+ trench poly is the gate and the collar oxide is the gate dielectric. Vertical parasitic leakage current is generated due to the sub-threshold current of the vertical parasitic transistor, degrading the charge retention.
[0003] The resulting vertical parasitic leakage current can be suppressed through increased p-well doping. However, increasing p-well doping leads to other problems, such as elevated junction leakage and depressed write-back current.
[0004] In U.S. Pat. No. 6,818,534, it is suggested to utilize a fully doped collar in trench DRAM to improve leakage performance. As shown in FIG. 2 , a fully boron-doped collar is utilized. However, the boron in the collar counter-dopes arsenic-doped N+ poly, causing high poly resistance. Additionally, the fully boron-doped collar is left exposed during subsequent high-temperature processes, such as, for example, the STI process. These high-temperature processes cause boron contamination and undesired auto-doping in the active area. The closeness of the heavily doped P-well also disturbs the characteristics of the array transistor.
[0005] Accordingly, there is a need for trench memory that reduces or suppresses vertical parasitic leakage. There is a further need for a process of manufacturing such trench memory structures or devices.
SUMMARY OF THE INVENTION
[0006] In one aspect, a trench memory cell is provided comprising a trench capacitor and a transistor. The trench capacitor is formed in a silicon substrate and has a collar comprising a doped insulator portion and an undoped insulator portion. The transistor comprises a gate, a source and a drain, wherein the drain is electrically coupled to the trench capacitor. The undoped insulator portion is above the doped insulator portion.
[0007] In another aspect, a deep trench capacitor is provided comprising a substrate; a trench in the substrate and having one or more walls; a buried plate of a first conductivity type positioned in the substrate near a lower portion of the trench; a node dielectric layer on the one or more walls of the lower portion of the trench; a well region of a second conductivity type in the substrate above the buried plate; a strap of the first conductivity type adjacent to the trench; a conducting material fill disposed in the trench; and a collar insulator formed upon the one or more walls of the trench above the buried plate. The collar insulator comprises a doped portion and an undoped portion.
[0008] In yet another aspect, a method of manufacturing a trench memory device is provided comprising: providing a substrate; forming a trench in the substrate, wherein the trench comprises sidewalls; forming a buried plate in the substrate in proximity to the bottom portion of the trench; layering a node dielectric along the sidewalls of the bottom portion of the trench; forming a first layer of conducting material in a bottom portion of the trench; forming a collar on the sidewalls of the trench above the first layer of conducting material, wherein said collar comprises a doped portion and an undoped portion; forming a second layer of conducting material in the trench above the first layer of conducting material; and forming a shallow isolation region in a top portion of the substrate, wherein the shallow isolation region caps the trench.
[0009] The undoped portion of the collar insulator can be positioned above the doped portion of the collar insulator. The capacitor may further comprise a shallow trench isolation adjacent to the trench and on a top portion of the silicon substrate. The first conductivity type can be N-type and the second conductivity type can be P-type. Alternatively, the first conductivity type can be P-type and the second conductivity type can be N-type. The doped portion of the collar insulator can be less than 50% of the undoped portion of the collar insulator.
[0010] The manufacturing method may further comprise planarizing a top surface of the substrate after forming the shallow isolation region, wherein the substrate comprises a nitride layer. The method can further comprise forming a buried-strap connected to a top portion of the trench. The method may further comprise: depositing a doped insulator layer along the substrate and into the trench; removing a portion of the doped insulator via etchback; depositing an undoped insulator layer along the substrate and into the trench; and removing a portion of the undoped insulator layer or the doped insulator layer to form the collar. The method can further comprise performing reactive ion etching. The method may further comprise performing high density plasma deposition.
[0011] The above-described and other features and advantages of the present disclosure will be appreciated and understood by those skilled in the art from the following detailed description, drawings, and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a schematic illustration of a prior art trench memory structure;
[0013] FIG. 2 is a schematic illustration of a prior art trench memory structure as described in U.S. Pat. No. 6,818,534;
[0014] FIG. 3 is a schematic illustration of a trench memory structure according to an exemplary embodiment of the present invention;
[0015] FIG. 4 is a method of manufacturing the trench memory structure of FIG. 3 ;
[0016] FIG. 5A is a first portion of a trench memory structure during manufacture by the method of FIG. 4 ;
[0017] FIG. 5B is a second portion of a trench memory structure during manufacture by the method of FIG. 4 ; and
[0018] FIG. 5C is a third portion of a trench memory structure during manufacture by the method of FIG. 4 .
[0019] FIG. 5D is a fourth portion of a trench memory structure during manufacture by the method of FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
[0020] Referring now to the drawings and in particular to FIG. 3 , an exemplary embodiment of a trench memory structure is shown and generally represented by reference numeral 5 . Trench memory structure 5 can be used in various devices and systems such as, for example, embedded DRAM, DRAM, SRAM, system-on-chip and application-specific integrated circuits. Trench memory structure 5 has one or more deep trench storage capacitors 10 and one or more transistors 15 , such as, for example, a MOSFET, in or on a substrate 20 . Trench memory structure 5 would typically comprise an array of deep trench capacitors 10 coupled with an array of transistors 15 to form an array of memory cells interconnected by rows and columns for reading data from, or writing data to, the memory cells. For simplicity, trench memory structure 5 is being described with respect to one of the deep trench capacitors 10 coupled with one of the transistors 15 , but of course any number could be used.
[0021] Deep trench capacitor 10 has a trench 25 in substrate 20 . The trench 25 is filled with conducting materials such as N+ polycrystalline silicon (poly) 30 , 32 , and 34 . Other conducting materials such as metals, metallic compounds, silicides, and any combination of these materials including polysilicon can also be used to fill the trench. Near a bottom portion of trench 26 , a buried plate 40 is positioned. The buried plate is a heavily doped region. For instance, the buried plate can be doped by arsenic or phosphorous. The poly 30 and buried plate 40 are isolated from each other by a node dielectric layer 50 formed along the walls of the bottom portion of the trench 25 . A P-well 60 is positioned in the substrate 20 above the buried plate 40 . A shallow trench isolation region (STI) 70 is formed into the substrate 20 from a top surface thereof.
[0022] Along the walls of trench 25 , a collar 80 is formed, which is adjacent to the walls of the P-well 60 . The collar 80 comprises a first portion 90 and a second portion 100 . The first portion 90 is a doped insulator, such as, for example, boron-doped oxide. The second portion 100 is an undoped insulator such as an oxide. The doped portion 90 is positioned along a lower portion of collar 80 , while the undoped portion 100 is positioned along an upper portion of the collar. A buried strap 110 is connected at the top of the trench 25 to the drain 16 of the transistor 15 , which also has a gate 17 and a source 18 as illustrated in FIG. 3 .
[0023] The trench memory structure 5 with the collar 80 comprising both doped and undoped portions 90 and 100 provides several advantages. First, a localized and heavily doped P+ region 95 is formed next to the doped portion of the collar 90 by driving the dopants in the doped collar to the substrate. This heavily doped P+ region 95 increases the threshold voltage of the vertical parasitic transistor and therefore suppresses the vertical parasitic leakage. Second, less counter-doping of the N+ poly 30 occurs due to the use of undoped portion 100 of the collar 80 , which reduces poly resistance. Third, the doped portion 90 of the collar 80 is no longer exposed (being sealed by the undoped portion 100 ) during subsequent high temperature processes, such as, for example, STI formation, so there is no contamination or undesired auto-doping in the active area. Fourth, the transistor 15 is not disturbed as the P+ region is far enough away from the transistor. Finally, the P+ region has minimal impact on substrate sensitivity as it is localized.
[0024] Referring to FIGS. 4 through 5 D, a method for manufacturing the trench memory structure 5 is illustrated and generally shown by reference numeral 400 . In step 400 , standard deep trench processing is used to form the deep trench capacitor 10 into the substrate 20 . This may include etching of the trench 25 to a predetermined depth, filling of the poly 30 into the trench and recessing the poly to a depth of about 700-1500 nm, positioning of the buried plate 40 into the substrate and layering of the node dielectric 50 along the wall of the trench. A pad layer 535 is positioned along the top surface of the substrate 20 adjacent the trench 25 . The pad layer, which may comprise a nitride layer with an optional underlying oxide layer, protects the substrate 20 in the subsequent process. The resulting first portion of trench memory 5 is shown in FIG. 5A .
[0025] In step 420 , a doped insulating material 590 is deposited along the substrate 20 , into trench 25 and above the poly 30 . The doped insulator 590 can be oxide, oxynitride, nitride, other dielectric materials such as “high-k” materials, or any suitable of combination of these materials. Preferably, the insulator 590 is an oxide that is doped with a P-type dopant such as boron or indium with a concentration of 0.1-6% in weight and more preferably 1-2% in weight. The process for depositing the insulator 590 , includes but is not limited to, chemical vapor deposition (CVD), atomic layer deposition (ALD), physical vapor deposition (PVD), sputtering, plating, or any suitable combination of these processes. Preferably, the insulator 590 is deposited by a high density plasma (HDP) CVD process. Due to the anisotropic nature of HDP process, i.e, the deposition rate of HDP process is higher in the vertical direction than in the lateral direction), the oxide thickness on top of the poly 30 and pad layer 535 is greater than on trench sidewall.
[0026] For example, the oxide thickness on trench sidewall is only one third of the oxide 1 thickness on top of the poly and pad layer by a typical HDP deposition process. Preferably, the oxide thickness ranges from 50-200 nm on top of the poly and pad layer and 15-70 nm on trench sidewall after HDP deposition. Optionally, an oxide liner (not shown) of approximately 2-6 nm may be formed by thermal oxidation before HDP deposition to protect the trench sidewall from the attack of plasma during HDP process. In one embodiment, the insulator 590 is in-situ doped during deposition. In another embodiment, the insulator 590 is doped after deposition. For example, ion implantation of boron after deposition can be used to form a P-type doped insulator 590 .
[0027] Portions of the doped insulator 590 are then removed from trench sidewall by an etchback in step 430 . When the doped insulator is oxide deposited by HDP process, a timed wet etch comprising buffered HF (BHF) or diluted HF (DHF) can be used. Approximately the same amount of HDP oxide is removed from the top of the poly and pad layer, resulting approximate 30-150 nm doped oxide on top of the poly and the pad nitride after etch. The optional oxide liner, if present, may be removed along with the HDP oxide by BHF or DHF. The resulting first portion of trench memory 5 is shown in FIG. 5B .
[0028] In step 440 , undoped insulator 600 is deposited into the trench 25 and above the doped insulator 590 . The undoped insulator 600 can be oxide, oxynitride, nitride, or any other suitable dielectric materials deposited by any suitable deposition techniques, such as chemical vapor deposition (CVD), thermal oxidation, atomic layer deposition (ALD), physical vapor deposition (PVD), sputtering, plating, and any combination of these techniques. The undoped layer may be oxide, oxynitride, nitride, other dielectric materials such as “high-k” materials, or any suitable of combination of these materials. Preferably, the undoped insulator 600 is an oxide deposited by a conformal process such low-pressure CVD process. In another embodiment, the undoped insulator 600 is an oxide formed by thermally oxidizing the exposed trench sidewall. When thermal oxidation is used, the undoped collar is formed only on trench sidewall, deposited by a conformal process such low-pressure CVD process. The thickness of the undoped insulator ranges from 10 nm to 50 nm, and more preferably 20-30 nm. The resulting second portion of trench memory structure 5 is shown in FIG. 5C .
[0029] In step 450 , the insulator 600 and 590 are removed from the top of the poly 30 and the pad layer 535 to form a collar 80 on trench sidewall. The collar 80 comprises an undoped portion 100 and doped portion 90 . A reactive ion etching (RIE) can be used to form the collar. The RIE etchback removes portions of the undoped insulator 600 so that the collar 80 is formed with a doped insulator lower portion 90 and an undoped insulator upper portion 100 . The doped insulator has a height of 30-150 nm and the undoped insulator has a height of 500-1200 nm. Dopant in the doped portion of the collar is driven into the substrate by the subsequent thermal process to form a localized doped region 95 . In one embodiment, the doped collar portion is doped with boron and thus the localized doped region 95 in the substrate is P-type. In another embodiment, the localized doped region in the substrate is self-aligned to the buried plate. The resulting third portion of trench memory structure 5 is shown in FIG. 5D .
[0030] In step 460 , standard trench memory processing is used to form the remaining components of the trench memory 5 shown in FIG. 3 . This may include filling the formed collar 80 with a conducting material 32 , recessing the conducting material 32 , removing the exposed collar, buried strap 110 formation by deposition and recess of strap material 34 , and isolating active areas by STI formation, such as, for example, by anisotropic etching, filling with an oxide, planarizing to the surface of the substrate 20 and capping the deep trench capacitor 10 . As needed by the trench capacitor 10 , well implants, gate oxidation, gate conductors, and source-drain diffusions are formed. Other structural features, such as gate conductors and wiring, are common in the field of trench memory, and, as such, are omitted for brevity. Hence, the remainder of the deep trench capacitor is formed so as to produce a trench memory structure 5 such as that shown in FIG. 3 , for example.
[0031] While the instant disclosure has been described with reference to one or more exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope thereof. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiment(s) disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
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A trench device and method for fabricating same are provided. The trench device has a collar with a first portion that is doped and a second portion that is undoped. Fabrication of the partially doped collar can be done by deposition of a doped insulator in the trench, removal of a portion of the doped deposition, deposition of an undoped insulator in the trench and removal of a portion of the doped and undoped insulators.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an inline skate provided with a shock absorber, and more particularly to an inline skate in which a plurality of air tubes for absorbing shocks transmitted to the respective wheels is installed at the inner upper end of a wheel bracket so as to allow the use of wheels having high hardness, to effectively increase the rolling speed of the wheels, to secure rider's safety, and to protect the knees and ankles from shock.
2. Description of the Related Prior Art
As is well-known, a conventional inline skate, not shown, includes a boot body for receiving and fixing a rider's foot, a wheel bracket attached to the lower side of the boot body, and a plurality of wheels fixed by bearings installed to the wheel bracket that allow the boot body to roll.
The conventional inline skate exhibits excellent skating performance but insufficient walking performance. Due to these drawbacks, riders feel inconvenienced since they must wear ordinary shoes instead of the inline skates when climbing stairs or due to the fact that traveling a long distance while wearing the inline skates is uncomfortable. If the rider attempts to avoid the inconvenience of having to change into ordinary shoes when climbing stairs by attempting to climb the stairs in the inline skates, it is very dangerous in that the rider may slip and fall.
Moreover, since the conventional inline skate is equipped with bearings installed between the wheels and the wheel bracket for reducing friction of the wheels, sand may be introduced into the bearings and the bearings may be damaged due to the sand as the sand wears down the bearing during the rotation of the bearing.
In addition, since the boots of the conventional inline skates are heavy, they are inconvenient to carry and store.
For the purpose of overcoming the above disadvantages, roller shoes have been developed. At the rear bottom surface of the roller shoe, a roller is positioned such that its surface is exposed below that of the tread of the shoe. To use the roller shoe the rider lifts the front end of the roller shoe so as to travel for a desired distance using the roller. To be sure, since the roller is detachable, the rider can wear the roller shoes like the ordinary shoes.
However, it is difficult for the user to maintain their balance when using the roller function of the roller shoe as they must delicately concentrate their weight over the rear end of the shoe. As such, it is difficult to travel at any substantial speed using the roller shoes. Moreover, it is impossible to propel oneself using the conventional side thrust technique used when inline skating, and, as such, users must build up speed by running on their toes and then arching the foot back onto the roller to glide for some distance.
In addition, since the conventional inline skate and the roller shoes have no structure for absorbing shock from the ground, the boot must be reinforced so as to prevent the user's ankles from damage, thus increasing the weight thereof. Since the boot must be sufficiently tall to completely cover the ankles, the boot becomes very heavy so that it is inconvenient to carry. Though the boot is sufficiently high, the user's ankles and knees may be damaged due to impacting the ground during use or if the user collides with an obstacle.
When the wheels travel over an obstacle, since the conventional inline skate has no structure for absorbing shock, excellent balance is required to adapt to the shape of obstacles, and the user may lose his/her balance when traveling over the obstacle. This principle can be compared to riding a motorcycle without a shock absorber or a spring, where even a small obstacle generates a large shock.
In addition, the wheels of conventional inline skates are made of urethane so that they may exhibit a slight shock-absorbing effect of their own. However, since friction between these soft wheels and the ground is increased, it is difficult to accelerate and the wheels of the conventional inline skate wear out rapidly.
SUMMARY OF THE INVENTION
Therefore, the present invention has been made in view of the above and other problems, and it is an object of the present invention to provide an inline skate in which a plurality of air tubes for absorbing shock transmitted to the wheels is installed at the inner upper end of a wheel bracket, thus allowing use of extremely rigid wheels, which effectively increases rolling speed of the wheels, and serving to enhance the rider's safety, and to protect the rider's knees and ankles from shock.
In accordance with the present invention, the above and other objects can be accomplished by the provision of an inline skate with a shock absorber including: a wheel bracket installed to the lower side of an outsole of an ordinary shoe, a plurality of wheels coupled to the inner lower sides of the wheel bracket and supported by shafts, a rotating support coupled to the rear upper side of the wheel bracket by a shaft and coupled to a connecting protrusion from the outsole of the ordinary shoe so as to prevent the wheel bracket from separating from the outsole, a frame constituting the wheel bracket, and having insertion compartment formed at the inner upper sides of the frame that receive a plurality of shock absorbers, a plurality of guide recesses oriented perpendicular to the insertion compartment, brackets, protruding between the guide recesses, for defining desired spaces, a wheel holder having supporting plates in which the wheels are coupled to and supported by the sides of the supporting plate, and inserted into the guide recesses so that the wheel holder can move vertically when an external force is applied so as to transmit the external force to the shock absorbers, and shock absorbers inserted into the insertion compartment and filled with air so as to dissipate the external force when the wheel holder moves upward and downward.
Preferably, each guide recess has a connecting protrusion extending from the inner upper side of the guide recess to a certain height, and a longitudinal guide slot formed at the lower side of the guide recess.
Each supporting plate has a guide slot formed at the upper side of the supporting plate, into which the connecting protrusion is inserted and guided vertically, and a connecting protrusion formed at the outer lower side of the supporting plate that is inserted into the guide slot of the guide recess.
Each shock absorber includes a housing made of soft synthetic resin, predetermined spaces formed at the sides of the housing, air tubes installed in the predetermined spaces, a cover sheet wrapped around the housing, and a connecting part made of the same material as the housing, disposed at the midsection of the housing, and integrated with the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view illustrating an inline skate with a shock absorber according to the preferred embodiment of the present invention;
FIG. 2 is a partial side view illustrating the mechanics of shock absorption by the inline skate with a shock absorber according to the preferred embodiment of the present invention;
FIG. 3 is a partially exploded perspective view illustrating the structure of the inline skate with a shock absorber according to the preferred embodiment of the present invention;
FIGS. 4 a and 4 b are cross-sectional views illustrating an air tube installed in the inline skate with a shock absorber according to the preferred embodiment of the present invention.
FIG. 5 is a side cutaway view illustrating the mechanics of shock absorption by the inline skate with a shock absorber according to the preferred embodiment of the present invention.
FIG. 5 is a side partial cross-sectional view illustrating the mechanics of shock absorption by the inline skate with a shock absorber according to the preferred embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, an inline skate with a shock absorber according to the preferred embodiment of the present invention will be described with reference to the accompanying drawings.
FIG. 1 is a side view illustrating the inline skate with a shock absorber according to the preferred embodiment of the present invention.
As shown in the drawing, the inline skate 2 with a shock absorber is an inline skate in which a plurality of air tubes for absorbing shock transmitted to respective wheels is installed at the inner upper end of a wheel bracket, thus allowing the use of extremely rigid wheels, which effectively increases the rolling speed of the wheels, serving to enhance the rider's safety, and protecting the rider's knees and ankles from shock.
The inline skate 2 with a shock absorber according to the preferred embodiment of the present invention includes a shoe part 3 having an ordinary shoe 4 , and a wheel bracket 100 installed on the lower side of the shoe part 3 and having a plurality of wheels 112 mounted at the inside of the wheel bracket 100 and exposed to the lower side of the wheel bracket 100 .
The shoe part 3 can use an ordinary shoe, but it is preferable to use a shoe 4 having an upper section, an insole, and an outsole 6 that are all relatively thicker than those of the ordinary shoe, and a relatively long ankle portion. Moreover, the rear side, (i.e., the heel portion) of the shoe 4 of the shoe part 3 has a connecting protrusion 8 .
The wheel bracket 100 includes a frame 102 having a shape similar to the lower frame of the ordinary inline skate, longitudinal guide slots 104 , formed at the lower side of the frame 102 , for guiding the connecting protrusions 110 of the wheel supports (See FIGS. 2 and 3 ) to be connected to the wheel bracket 100 and moved upward and downward within the guide slots 104 , and a supporting holder 106 provided at the rear upper side of the frame 102 and connected to the connecting protrusion 8 provided at the rear side of the shoe 4 .
The connecting protrusion 8 and the supporting holder 106 are connected to each other such that the wheel bracket 100 is separated from the shoe part 3 .
The wheel bracket 100 is divided into two parts in the longitudinal direction, and the frame 102 includes a plurality of screws 108 for fixing the two divided parts of the wheel bracket 100 .
FIG. 2 is a partial side view illustrating the mechanics of shock absorption by the inline skate with a shock absorber according to the preferred embodiment of the present invention, and FIG. 3 is a partially exploded perspective view illustrating the structure of the inline skate with a shock absorber according to the preferred embodiment of the present invention.
As shown in the drawings, in the inline skate 2 with a shock absorber according to the preferred embodiment of the present invention, only one of the two parts of the wheel bracket 100 is depicted in FIG. 3 . The frame 102 has longitudinal insertion compartment 130 formed at its inner upper side which accommodate a shock absorber 134 , and a lower wheel support 114 formed with a guide recess 126 for guiding a wheel holder 116 in the tilted direction. The wheel holder 116 is inserted into the guide recess 126 and moves upward and downward when receiving impact from the wheels 112 .
In addition, the frame 102 is formed with a plurality of screw holes 120 at the upper edge of the frame 102 , and is provided with a plurality of brackets 132 protruding between the wheel supports 114 and defining desired spaces having a width equal to the thickness of the wheel holder 116 .
The guide recess 126 includes a connecting protrusion 128 formed at the inner upper side thereof and protruding to a certain height, and a longitudinal guide slots 104 formed at the inner lower side thereof.
The wheel holder 116 accommodated in the guide recess 126 supports the wheel 112 . The wheel holder 116 includes supporting plates 116 a and 116 b coupled to the sides of the wheel 112 so as to support the wheel 112 , and the supporting plates 116 a and 116 b are connected to each other at their upper sides so as to accommodate part of the wheel 112 and to expose the rest of the wheel 112 to be in contact with the ground.
Guide slots 124 are formed in the upper sides of the supporting plates 116 a and 116 b and guide the connecting protrusion 128 of the guide recess 126 when being inserted thereinto, and the connecting protrusions 110 protrude from the outer lower sides of the supporting plates 116 a and 116 b and are inserted into the longitudinal guide slots 104 . Shaft holes 122 are formed in the inner lower sides of the supporting plates 116 a and 116 b to receive the shafts of the wheel 112 .
In other words, the guide slots 124 of the upper sides of the supporting plates 116 a and 116 b of the wheel holder 116 are connected to the connecting protrusions 128 at the upper sides of the guide recesses 126 , while the connecting protrusions 110 at the outer lower sides of the supporting plates 116 a and 116 b of the wheel holder 116 are inserted into the guide slots 104 at the lower sides of the guide recesses 126 . Since the guide slots 124 and 104 are equal in length to the connecting protrusions 128 and 110 and are coupled to parts of the guide slots 124 and 104 , the shock absorbers 134 absorb shock in correspondence to the freedom of movement of the connecting protrusions 128 and 110 within the guide slots 124 and 104 .
Therefore, according to the inline skate 2 with a shock absorber in accordance with the preferred embodiment of the present invention, since air tubes are provided at the inner upper side of the wheel support so as to absorb shock transmitted from the respective wheels, wheels having high hardness can be used to effectively increase the rolling speed of the wheels and to enhance the rider's safety.
FIGS. 4 a and 4 b are cross-sectional views illustrating an air tube installed in the inline skate with a shock absorber according to the preferred embodiment of the present invention.
As shown in the drawings, the inline skate 2 with a shock absorber according to the preferred embodiment of the present invention includes shock absorbers 134 so as to absorb shock transmitted from the wheels 112 . The shock absorbers 134 have vertical cross-sections as shown in FIG. 4 a . In other words, each shock absorber 134 includes a soft synthetic resin housing 136 which is formed with predetermined spaces at the sides, into which air tubes 140 are installed.
Moreover, since a cover sheet (not shown) is wrapped around the housing 136 , the air tubes 140 will not become separated from the housing 136 . A connecting part 138 of the same material as that of the housing 136 is disposed at the midsection of the housing 136 and is integrated with the housing 136 .
The shock absorbers 134 are inserted into the insertion compartments 130 horizontally formed at the upper side of the frame 102 . Four shock absorbers 134 are installed in a plurality of frames 102 constituting the wheel bracket 100 , while a single shock absorber 134 includes two air tubes 140 at the sides thereof.
FIG. 5 is a side cutaway view illustrating the mechanics of shock absorption by the inline skate with a shock absorber according to the preferred embodiment of the present invention.
As shown in FIG. 5 , in the inline skate 2 with a shock absorber according to the preferred embodiment of the present invention, the connecting protrusions 128 formed at the upper sides of the guide recesses 126 are inserted into the guide slots 124 formed in the upper sides of the supporting plates 116 a and 116 b of the wheel holder 116 , and the connecting protrusions 110 formed at the outer lower sides of the supporting plates 116 a and 116 b of the wheel holder 116 are inserted into the guide slots 104 formed in the lower sides of the guide recesses 126 .
Moreover, since the guide slots 124 and 104 are equal in length to the connecting protrusions 128 and 110 and are coupled to parts of the guide slots 124 and 104 , the shock absorbers 134 absorb shock in correspondence to the freedom of movement of the connecting protrusions 128 and 110 within the guide slots 124 and 104 .
Thus, as shown in FIG. 5 , since, if stones or other obstacles protruding from the ground impact the wheel holder 116 (disposed at the right side as seen in FIG. 5 ), the wheel holder 116 moves toward the shock absorber 134 and the guide slots 124 of the wheel holder 116 move upward in the direction of the connecting protrusions 128 of the guide recesses 126 , as is shown in FIG. 6 , and the connecting protrusions 110 formed at the lower sides of the wheel holder 116 move upward within the guide slots 104 formed at the lower sides of the guide recesses 126 .
Therefore, since the upper sides of the wheel holder 116 press one of the air tubes 140 of the shock absorbers 134 , the shock transmitted to the wheel holder 116 is absorbed via the distortion of the air tube 140 and thus is not transmitted to the outsole. Since the wheel 112 receiving the shock from the uneven ground moves to a higher position than that of an undisturbed wheel 112 , the rider can balance while rolling on the uneven ground.
Moreover, according to the inline skate 2 with a shock absorber in accordance with the preferred embodiment of the present invention, since the shock is absorbed by the wheel bracket 100 installed on the lower side of the outsole, urethane wheels are not required, and wheels 112 having high hardness can be used. Thus, due to the increased hardness of the wheels, riders are capable of skating much faster using the inline shoe 2 according to the present invention.
As described above, an inline skate with a shock absorber according to the present invention includes air tubes provided at the inner upper sides of the wheel bracket which absorb shocks transmitted from the wheels so that wheels having high hardness can be employed to increase the rolling speed of the wheels. Since the wheel holder moves vertically as the skate traverses the surface of the uneven ground, the rider can balance easily and the rider's safety can be secured.
Although the preferred embodiments of the present invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
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An inline skate mounting a pair of air tubes is invented for absorbing shock transmitted to its wheels so as to allow the use of rigid wheels, and to protect the rider's knees and ankles from shock. The inline skate comprises a frame having insertion compartments for mounting the shock absorbers, guide recesses, brackets for defining desired spaces, and a wheel holder having supporting plates. The wheels are coupled to and supported by the sides of the supporting plate and inserted into the guide recesses so that the wheel holder moves upward and downward when an external force is applied so as to transmit the external force to the shock absorbers. The shock absorbers are inserted into the insertion compartments and filled with air to absorb the external force when the wheel holder moves vertically. Since the wheel holder moves vertically as the skate traverses an uneven surface, the inline skater can balance stably and safely.
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CROSS REFERENCE OF RELATED APPLICATION
[0001] This is a divisional application of U.S. patent application Ser. No. 12/911,525, filed Oct. 25, 2010, which claims priority under 35 U.S.C. 119(a-d) to CN 201010511597.8, filed Oct. 19, 2010.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates to the field of firearm sights, more particularly, to a method of using a touch display screen to adjust and determine a reticle of an electronic firearm sight.
[0004] 2. Brief Description of Related Arts
[0005] Over times, people invented a variety of instruments and devices to help shooters to aim at a target. In general, the conventional sighting devices used in firearms can be categorized into telescopic sight, reflex sight and other sights based upon different principles.
[0006] To achieve the goal of aiming at a potential target accurately, rapidly and conveniently, a reticle is a very important factor to locate the target. Other auxiliary aides, such as measuring the range, can be also used. However, the design and usage of current reticles have many disadvantages. The existing firearm sight, including the two types described above and an electronic sight uses two devices to adjust the reticle. One is controlling the reticle to move vertically so as to make it superimposed on the bullet's impact point, namely up and down; the other is controlling the reticle to move horizontally, namely left or right. However, these adjusting methods have the following shortcomings:
[0007] On the one hand, the existing sight, either mechanically or electronically, all set two buttons or knobs to make the reticle move. With this design, not only the errors of the two parts themselves, but also their wearing out could cause inaccuracy to adjusting the reticle. On the other hand, these devices all preset a rated value as a moving scale. The moving unit is rated, which represents a fixed value of the movement of the reticle. However, a certain bullet impact point t does not have to be one of these fixed moving scales; as a result, the reticle can only be superimposed on the bullet's impact point approximately, but can not fulfill the full superimposition theoretically. In practice, the shooter could encounter a target at the range of more than one thousand yards, but usually the superimposition of the impact point and the reticle can only be done within a very short distance, such as one hundred yards. Therefore, once the distance is over one thousand yards, the error value of the approximate superimposition will be quite big, which brings a lot of inconvenience to firing if highly accuracy is required
[0008] A telescopic sight can only use one reticle shape, which causes big limitation to shooting, because the different types of firearms, bullets, and shooting environments in practical shooting have different ballistic trajectory. Usually, the reticle image used in a reflex sight is just one red or bright orange light spot. Sometimes, a cross line, a light ring or other shapes are even used. Their principles simply can not be adopted to set a reticle scale based on ballistic trajectory. In current electronic sights, the design of a reticle also follows the traditional one, at most presetting or downloading some reticles, but never mentioning about how to adjust a suitable reticle according to different ballistic trajectories of different bullets. One thing is needed to point out is that because the reticle in these electronic sights are either downloaded from internet or designed by the user through computers, if the user does not have correct knowledge about ballistics, he or she probably will choose or design an incorrect reticle, and directly lead to incorrect settings to the sight.
[0009] Another important factor of affecting aiming accuracy is a clear view even in an environment with low intensity illumination. However, current electronic sights have no any solution for the problems. As for telescopic sights and reflex sights, the limitation of optical theory does not allow the sight to capture good quality images in the circumstances of low intensity illumination.
SUMMARY OF THE PRESENT INVENTION
[0010] One objective of the present invention is to provide an electronic firearm sight, which has a touch display screen used for adjusting and determining an accurate and proper reticle, so as to overcome the shortcoming of current technology.
[0011] According to the present invention, the electronic firearm sight comprises a set of lens for capturing the optical image of an aimed object, an image sensor for converting the optical image into electronic signals, a processor for receiving the electronic signals from the image sensor and processing them and other data, a memory for storing different programs and data, and a touch display screen for the operation of adjusting and determining a reticle, once having received operation instructions from users, the touch display screen sending the corresponding information to the processor, and receiving and executing commands from the processor.
[0012] There are pre-saved data or information in the memory of a Cartesian coordinate system, ballistic trajectory data of different bullets, and different reticle scales based on the different trajectory data, and even different colors and shapes of the reticle scales. These data or information is presaved to determine a proper and accurate reticle.
[0013] Moreover, in order to overcome the problem of not being able to view clearly long distance objects of existing sights, a set of zoom lens are used. The creative combination of zoom lens and the image sensor allows the long distance object display very clearly on the screen, which not only gets the traditional telescopic sight out of turning the magnifying ratio ring to enlarge images, but also fills in the blank of existing electronic sights, which use the digital magnification with the most magnification ration of 4×.
[0014] In addition, the present invention further comprises a rangefinder, which is for detecting and measuring the distance between the aimed objects and the sight itself, and transmitting corresponding data to the processor. These data are used, as one of parameters, for the processor to analyze the location of a bullet impact point and the reticle.
[0015] Likewise, the present invention further comprises a wind speed & direction sensor connected with the processor for detecting the speed and direction of wind, to detect the crosswind and the wind speed, and transmitting corresponding data to the processor. These data are used, as one of parameters for the processor to analyze the location of the impact point and the reticle.
[0016] Another objective of the present invention is to provide a touch display screen used for adjusting the reticle of a firearm sight described above. The touch display screen comprises a touch screen, a display and a display driver. The touch screen comprises a touch detection part and a touch controller. The touch display screen is connected with a processor, which in turn is connected with a memory; the memory has presaved a Cartesian coordinate system, ballistic trajectory data based on different bullets, and reticle shapes based on the trajectory data of different bullets; once having received operation instructions from users about adjusting the reticle, the touch display screen sends corresponding information to the processor; once the processor finishing data analysis and forming commands, the touch display screen receives the commands and executes them.
[0017] Moreover, the touch display screen is connected with an operation panel. On the operation panel are set operation buttons for controlling the Cartesian coordinate system and reticle scales of the trajectories formed based on different bullets, locking the image of aimed objects, and zooming in or out the image.
[0018] Another objective of the present invention is to provide a method of using the touch display screen described above to adjust and determine the reticle of an electronic firearm sight, so as to overcome the shortcomings of current technologies, which preset a rated value as the basic value per unit movement of the reticle.
[0019] According to the present invention, the method comprises the following steps:
[0020] setting an object to fire;
[0021] calling up a Cartesian coordinate system saved in a memory to the touch display screen, superimposing the Cartesian coordinate over the image of the object, and setting the origin of the coordinate at the center of the touch display screen;
[0022] viewing the image of the object through the touch display screen, and aiming at the object with the origin of the coordinate;
[0023] firing the first bullet toward the object to get a bullet hole on it and viewing the corresponding scene through the touch display screen;
[0024] locking the scene;
[0025] finding the corresponding place of the first bullet hole appearing on the touch display screen;
[0026] obtaining the coordinate value of the corresponding place of the first bullet hole appearing on the touch display screen;
[0027] determining the opposite value, on the touch display screen, of the coordinate value of the corresponding place of the first bullet hole;
[0028] clicking on the place of the opposite value on the coordinate of the screen so as to move the origin of the coordinate to the place of the opposite value;
[0029] unlocking the scene;
[0030] aiming at the object with the new origin of the moved coordinate;
[0031] firing the second bullet, thereby the corresponding place of second bullet hole appearing on the touch display screen;
[0032] locking the scene again;
[0033] removing the coordinate from the touch display screen;
[0034] clicking on the corresponding place of the second bullet hole on the touch display screen, thereby a reticle appearing;
[0035] unlocking the scene.
[0036] Moreover, the method described above further comprise the steps, after determining the place of the reticle, that choosing a proper reticle shape based on the bullet type, the color and brightness of the reticle, and the requirement for lines. These steps can be operated through an operation panel.
[0037] The present invention has the following advantages.
[0038] By providing the firearm sight with a touch display screen and a new method of applying the touch display screen to adjusting and determining the reticle, the users can simply click the actual bullet's impact point displayed on the screen, instead of using the rated movement scale of the reticles of the existing technologies. Therefore, it can fulfill real accurate superimposition of a reticle and a bullet impact point, and eventually improve the aiming accuracy greatly;
[0039] By applying zoom lens to the electronic firearm sight, the optically amplified object can be displayed very clearly on the screen, thereby opening up a new time of big magnification sight. It is incredible to use a sight with the magnification rate of 36×, or even 100× in the practical shooting, compared to the at most 4× digital zoom of current electronic firearm sights and at most 8× of telescopic sights.
[0040] It is worth mentioning that by adding a rangefinder and a wind speed & direction sensor to the sight, plus the different trajectory data pre-saved in the memory, the real automatic aiming can become real, and even a shooter with poor skills can hit an object accurately.
BRIEF DESCRIPTION OF DRAWINGS
[0041] FIG. 1 is the structural block diagram of a firearm sight with a touch display screen of the present invention.
[0042] FIG. 2 is the structural block diagram of an embodiment of the firearm sight of the present invention.
[0043] FIG. 3 is a diagrammatic view of an operation panel, which is a component of the sight of FIG. 2 .
[0044] FIG. 4 is the schematic diagram of a touch display screen of the present invention.
[0045] FIG. 5 is the flow chart of the method of the present invention.
[0046] FIG. 6 - FIG. 11 are schematic diagrams of modifying the place of an impact point, which appears on the touch display screen, by way of a Cartesian coordinate system.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0047] As shown in FIG. 1 , an electronic firearm sight 1 comprises a set of optical lens 3 , which captures the image of an object 2 , an image sensor 4 connected with the set of optical lens 3 , which converts lights into charges, a processor 6 connected with the image sensor 4 , which processes the image from the image sensor 4 , a memory 7 connected with the processor 6 , which stores a variety of information ready to be processed or having processed by the processor, and a touch display screen 8 , which receives operation instructions given by a user 9 and sends corresponding information to the processor, the processor analyzing and processing the information, and then sending it back to and having it displayed on the touch display screen.
[0048] Referring to FIG. 2 , The lens 3 is a multiple of zoom lens, which can change the focus through changing the relative places of the lens, so that make the views at distance clearer. The lens 3 could be wide-angle lens, standard lens, telephoto lens, or fixed focal length lens (FFL), or other lens made according to specific requirements of the sight. The lens includes other components, such as an aperture motor 15 for adjusting the aperture, a focus motor 16 for adjusting the focus, and a day/night vision shifting motor 17 . Other lens components could be added. When an infrared led 18 is added to the lens, the day/night vision shifting motor 17 converts to the mode of might vision, so that the sight can be used at night.
[0049] According to different demands, the image sensor 4 can be charge-coupled device array (CCD array), complementary metal oxide semiconductor (CMOS), or other types.
[0050] Referring to FIG. 2 , the processor 6 is connected through ADC 14 with an image driver 5 and the image sensor 4 , so that ADC 14 converts the electrical signals of an image into digital signals. The processor 6 includes an image-processing chip to restore digital signals to an optical image, to superimpose an adjusted reticle on it, and to display the superimposed image on the touch display screen. The processor 6 is also connected with a Flash 13 , which stores program codes.
[0051] The memory 7 mentioned above is a RAM, in the present embodiment.
[0052] Referring to FIG. 2 and FIG. 4 , the touch display screen 8 comprises a touch screen 11 , a display 10 and a display driver 9 . The touch screen 11 is connected with the processor through the display 10 and a display driver 9 .
[0053] As shown in FIG. 2 , a rangefinder 20 and a wind speed & direction sensor 19 are connected with the processor 6 . The rangefinder 20 is used to measure the distance between the object 2 and the sight 1 when the user has locked the object, through laser, ultrasonic, red infrared ray or other chips of measuring distances, and then to send corresponding data to the processor 6 . The wind speed & direction sensor 19 has a chip for detecting the wind speed, delivering real-time wind speed to the processor. Therefore, after comparing the ballistic trajectory data, the processor 6 can calculate a new impact point and corresponding reticle place. For example, according to pre-saved data, a bullet drops 4 cm at the distance of 500 meters, and the real-time crosswind speed is 6 m/s which cause the bullet to move left by 3 cm. Thus, modify the deviation resulted from the drop of the bullet and wind speed, based on the pre-saved data. After getting the new impact point, show the new place with the modified reticle on the screen.
[0054] As shown in FIG. 2 and FIG. 3 , the sight has an operation panel 21 consisting of six function buttons, power switch 22 , main menu 23 lock 24 , reticle brightness 25 , screen brightness 26 , and magnification 27 . The power switch 22 is connected with a battery 28 , which provides electrical source and can be charged through a battery charging port 29 . The lock button 24 is for locking the image of an aimed object. When the user needs to view and measure the impact point after firing a bullet, the lock button needs to be pressed. The magnification function 27 is used to magnify or reduce the image of the object displayed on the display screen. The main menu 23 includes the following options, coordinate, reticle, rangefinder, wind speed & direction, and recorder. After clicking on the reticle option, its sub-interface is popped up, which includes settings of various parameters, such as reticle type, reticle line, reticle color, and reticle shape, and et.; For example, the reticle type includes general reticle, bullet drop compensation reticle, and specially made reticle.
[0055] The sigh is also provided with a USB connector 30 , a removable memory card 31 and a video connector 32 .
[0056] FIG. 5 is the flow chart of the method of the present invention. The following
[0057] Referring to FIG. 5 , and FIG. 6 - FIG. 11 , an embodiment of the method of using the touch display screen to determine a proper reticle is described as follows.
[0058] First, an object is set at a certain distance from the sight. As shown in FIG. 6 , when pressing the menu button on the operation panel of the sight, and further clicking the coordinate option, a coordinate 39 appears on the touch screen 11 . Set the origin 40 of the coordinate at the center of the screen, which is the intersection of the diagonal of the screen. The user can view the image 41 of the object through the screen, and aim at the image 41 with the origin 40 of the coordinate 39 .
[0059] Next, fire the first bullet, and accordingly get the first bullet hole 42 , which is displayed on the screen, as shown in FIG. 7 . Press the lock button on the panel to lock the instant scene.
[0060] Referring to FIG. 8 , read the value from the coordinate the first bullet hole 42 on the screen, and find the opposite value 43 at the coordinate. Click the opposite value 43 , so that the coordinate 39 is moved to the place where the opposite value 43 is. By doing so, the coordinate 39 has been moved from the center of the screen to the place 43 of the opposite value of the actual bullet impact point. Then, press the lock button on the operation panel to unlock the scene, and aim at the image 41 with the new origin of the moved coordinate again, which is the place of the opposite value 43 . Now the impact point, which was not at the center of the screen, appears at the center of the screen and the previous origin of the coordinate before being moved, which was at the center of the screen, has been moved out from the center.
[0061] Referring to FIG. 9 , now the user can fire the second bullet and get the second bullet hole 44 . The second bullet hole 44 appears at the center of the screen and, theoretically, it will be superimposed with the first bullet hole 42 . Lock the instant scene again.
[0062] Referring to FIG. 10 , remove the coordinate, and click on the second bullet hole 45 on the screen, the figure of a reticle 45 appears at the place. Then, unlock the instant scene.
[0063] Referring to FIG. 11 , based on the place of the reticle of last step, the user can modify the reticle with a certain shape, color, line, brightness of the reticle and the screen through the operation panel to get a suitable reticle. For example, the user can choose a suitable color for the reticle in order to make the reticle outstanding in the environment background.
[0064] The embodiment described above is to adjust the bullet impact point so as to be located at the center of the screen. If hoping the reticle to appear at any desired place, instead of the center of the screen, the user, after getting the first bullet impact point, simply just finds the opposite value of an adjusted amount the user desires and aims at the opposite value with the new origin of the moved coordinate. Then fire the second bullet to get the second bullet hole, which is at the ideal place of the screen. Finally, click on the second bullet hole on the screen and a reticle at the ideal place appears.
[0065] Therefore, within the range the screen can display, the user can adjust the reticle until the reticle appears at a desired point.
[0066] Because of the brand-new adjusting method, the user can make the impact point return to the origin at any distance and in any shooting circumstances, which makes the task of time consuming, bullet consuming, and rarely being done with accuracy be easier.
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A method for adjusting the reticule includes the following steps: displaying a coordinate on the touch display screen, setting the origin of the coordinate at the center of the touch display screen, aiming at an object with the origin, firing the first bullet to get the first bullet hole on the touch display screen, obtaining the coordinate value of the first bullet hole, determining the opposite value, clicking on the place of the opposite value, moving the origin of the coordinate to the place of the opposite value, and aiming at the object with the new origin, firing the second bullet to get the second bullet hole, removing the coordinate; clicking the second bullet hole, an adjusted reticle appearing.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to reinforced resin-derived carbon foams useful for high temperature and/or high strength applications, such as composite tooling; electrodes; thermal insulation; core material used in sandwich structures; impact and sound absorption; and high-temperature furnace insulation and construction. More particularly, the present invention relates to carbon fiber reinforced carbon foams exhibiting superior graphitic strength, weight and density characteristics. The invention also includes methods for the production of such carbon foams.
2. Background Art
Carbon foams have attracted considerable recent activity because of their properties of low density, coupled with either very high or low thermal conductivity. Conventionally, carbon foams are prepared via two general routes. Highly graphitizable foams have been produced by thermal treatment of mesophase pitches under high pressure. These foams tend to have high thermal and electrical conductivities. For example, in Klett, U.S. Pat. No. 6,033,506, mesophase pitch is heated while subjected to a pressure of 1000 psi to produce an open-cell foam containing interconnected cells with a size range of 90-200 microns. According to Klett, after heat treatment to 2800° C., the solid portion of the foam develops into a highly crystalline graphitic structure with an interlayer spacing of 0.366 nm. The foam is asserted to have compressive strengths greater than previous foams (3.4 MPa or 500 psi for a density of 0.53 g/cm 3 ).
In Hardcastle et al. (U.S. Pat. No. 6,776,936), carbon foams with densities ranging from 0.68-1.5 g/cm 3 are produced by heating a pitch in a mold at pressures up to 800 psi. The foam is alleged to be highly graphitizable and provide high thermal conductivity (250 W/m° K.).
According to H. J. Anderson et al. in Proceedings of the 43rd International SAMPE Meeting, p. 756 (1998), carbon foam is produced from mesophase pitch followed by oxidative thermosetting and carbonization to 900° C. The foam has an open-cell structure of interconnected cells with varying shapes and with cell sizes ranging from 39 to greater than 480 microns.
Rogers et al., in Proceedings of the 45 th SAMPE Conference, p. 293 (2000), describe the preparation of carbon foams from coal-based precursors by heat treatment under high pressure to produce materials with densities of 0.35-0.45 g/cm 3 with compressive strengths of 2000-3000 psi (thus a strength/density ratio of about 6000 psi/(g/cm 3 )). These foams have an open-cell structure of interconnected cells with cell sizes up to 1000 microns. Unlike the mesophase pitch foams described above, the coal-based foams are not highly graphitizable. In a recent publication, the properties of this type of foam are described (High Performance Composites, September 2004, p. 25). The foam has a compressive strength of 800 psi at a density of 0.27 g/cm 3 or a strength-to-density ratio of 3000 psi/(g/cm 3 ).
Stiller et al. (U.S. Pat. No. 5,888,469) describe production of carbon foam by pressure heat treatment of a hydrotreated coal extract. These materials are claimed to have high compressive strengths of 600 psi for densities of 0.2-0.4 g/cm 3 (strength/density ratio of 1500-3000 psi/(g/cm 3 )). It is suggested that these foams are stronger than those having a glassy carbon or vitreous nature that are not graphitizable.
Carbon foams can also be produced by direct carbonization of polymers or polymer precursor blends. Mitchell, in U.S. Pat. No. 3,302,999, discusses preparing carbon foams by heating a polyurethane foam at 200-255° C. in air followed by carbonization in an inert atmosphere at 900° C. These foams have densities of 0.085-0.387 g/cm 3 and compressive strengths of 130 to 2040 psi (ratio of strength/density of 1529-5271 psi/(g/cm 3 )).
In U.S. Pat. No. 5,945,084, Droege describes the preparation of open-celled carbon foams by heat treating organic gels derived from hydroxylated benzenes and aldehydes (phenolic resin precursors). The foams have densities of 0.3-0.9 g/cm 3 and are composed of small mesopores with a size range of 2 to 50 nm.
Mercuri et al. (Proceedings of the 9 th Carbon Conference, p. 206 (1969)) prepare carbon foams by pyrolysis of phenolic resins. For foams with a density range of 0.1-0.4 gm/cm 3 , the compressive strength-to-density ratios are from 2380-6611 psi/(g/cm 3 ). The cells are ellipsoidal in shape with cell sizes of 25-75 microns for a carbon foam with a density of 0.25 g/cm 3 .
Stankiewicz (U.S. Pat. No. 6,103,149) prepares carbon foams with a controlled aspect ratio range of 0.6-1.2. The patentee points out that users often require a completely isotropic foam for superior properties with an aspect ratio of 1.0 being ideal. An open-cell carbon foam is produced by impregnation of a polyurethane foam with a carbonizable resin followed by thermal curing and carbonization. The cell aspect ratio of the original polyurethane foam is thus changed from 1.3-1.4 to 0.6-1.2.
Unfortunately, carbon foams produced by the prior art processes are not effective certain applications where high thermal and electrical conductivities as well as a high compressive strength are required to maintain the structural integrity of the carbon foam. Generally, the most economical and convenient method of producing carbon foam is to directly carbonize a precursor foam derived from either phenolic or polyurethane resin. These resins are known to produce a non-graphitizable, glassy carbon, which have much lower thermal and electrical conductivities. Thus, these carbon foam structures are suitable for applications such as thermal insulation and composite tooling but not for commercial applications where higher conductivities and compressive strength are desirable.
What is desired, therefore, is a reinforced resin-derived carbon foam which is monolithic and has a controllable cell structure, where the cell structure, strength and strength-to-density ratio make the foam suitable for use in composite tooling, heat and electrical conductors, batteries and fuel cell components, aerospace components, satellite structures, cores used in sandwich structures, and also in high-temperature insulation and construction as well as in other high temperature and/or high strength applications. Indeed, a combination of characteristics, including improved conductivities and strength-to-density ratios higher than those contemplated in the prior art, have been found to be necessary for use of a carbon foam in high temperature and strength applications. Also desired is a process for preparing such foams.
SUMMARY OF THE INVENTION
The present invention provides a carbon foam which exhibits improved conductivities, thermal and electrical conductivity, density, compressive strength and compressive strength-to-density ratio to provide a combination of strength, conductivity and relatively light weight characteristics not heretofore seen. In addition, the monolithic nature and bimodal cell structure of the foam, with a combination of larger and smaller cells, which are relatively spherical, provide a carbon foam which can be produced in a desired block size and configuration and which can be readily machined.
More particularly, the inventive carbon foam has a density of about 0.03 to about 0.6 gram per cubic centimeter (g/cm 3 ), with a compressive strength of at least about 2000 pounds per square inch (psi) (measured by, for instance, the ASTM C695 method). An important characteristic for the foam when intended for use in a high temperature application is the ratio of strength to density. For such applications, a ratio of compressive strength to density of at least about 7000 psi/(g/cm 3 ) is required, more preferably at least about 8000 psi/(g/cm 3 ).
The inventive carbon foam should have a relatively uniform distribution of cells in order to provide the required high compressive strength. In addition, the cells should be relatively isotropic, by which is meant that the cells are relatively spherical, meaning that the cells have, on average, an aspect ratio of between about 1.0 (which represents a perfect spherical geometry) and about 1.5. The aspect ratio is determined by dividing the longer dimension of any cell with its shorter dimension.
The foam should have a total porosity of about 50% to about 95%, more preferably about 60% to about 95%. In addition, it has been found highly advantageous to have a bimodal cell size distribution, that is, a combination of two average cell sizes, with the primary fraction being the larger size cells and a minor fraction of smaller size cells. Preferably, of the cells, at least about 90% of the cell volume, more preferably at least about 95% of the cell volume should be the larger size fraction, and at least about 1% of the cell volume, more preferably from about 2% to about 10% of the cell volume, should be the smaller size fraction.
The larger cell fraction of the bimodal cell size distribution in the inventive carbon foam should be about 10 to about 150 microns in diameter, more preferably about 15 to about 95 microns in diameter, most preferably about 25 to about 95 microns in diameter. The smaller fraction of cells should comprise cells that have a diameter of about 0.8 to about 3.5 microns, more preferably about 1 to about 2 microns. The bimodal cell-structure nature of the inventive foams provide an intermediate structure between open-cell foams and closed-cell foams, thus limiting the fluid permeability of the foam while maintaining a foam structure. Indeed, advantageously, the inventive carbon foams should exhibit a nitrogen gas permeability of no greater than about 3.0 darcys, more preferably no greater than about 2.0 darcys (as measured, for instance, by the ASTM C577 method).
Advantageously, to produce the inventive foams, a polymeric foam block, particularly a phenolic foam block, is carbonized in an inert or air-excluded atmosphere, at temperatures which can range from about 500° C., more preferably at least about 800° C., up to about 3200° C. to prepare carbon foams useful in high temperature applications.
An object of the invention is to provide a reinforced carbon foam having improved conductivities and strength characteristics which enable it to be employed for commercial applications where a higher thermal conductivity and electrical conductivity are desired as well as a greater compressive strength.
Another object of the invention, therefore, is a monolithic carbon foam having characteristics which enable it to be employed in high temperature applications such as composite tooling, core materials for sandwich panels and high-temperature furnace construction.
Yet another object of the invention is a carbon foam having improved graphitizability, density, compressive strength and ratio of compressive strength to density sufficient for high temperature applications.
Still another object of the invention is a carbon foam having a porosity and cell structure and size distribution to provide utility in applications where highly connected porosity is undesirable.
Yet another object of the invention is a carbon foam which can be produced in a desired block size and configuration, and which can be readily machined or joined to provide larger carbon foam structures.
Another object of the invention is to provide a method of producing the inventive carbon foam.
These aspects and others that will become apparent to the artisan upon review of the following description can be accomplished by providing a carbon foam article produced using a resin-derived foam, such as a phenolic resol, formed by polymerization in the presence of carbon fibers, single and multi-walled and phenolic micro-balloons, selected to improve the conductivity and/or the strength of the finished carbon foam. The precursor polymeric foam can also include graphitization promoting additives to increase the thermal and electrical conductivities of the final carbon foam product as well as oxidation-protective additives to reduce the foam's rate of oxidation.
The inventive carbon foam has a ratio of compressive strength to density of at least about 7000 psi/(g/cm 3 ), especially a ratio of compressive strength to density of at least about 8000 psi/(g/cm 3 ). The inventive foam product advantageously has a density of from about 0.03 to about 0.6 g/cm 3 and a compressive strength of at least about 2000 psi, and a porosity of between about 50% and about 95%. The cells of the carbon foam have, on average, an aspect ratio of between about 1.0 and about 1.5.
Preferably, at least about 90% of the cell volume is composed of the cells having a diameter of between about 10 and about 150 microns; indeed, most preferably, at least about 95% of the cell volume is composed of the cells having a diameter of between about 25 and about 95 microns. Advantageously, at least about 1% of the cell volume is composed of the cells having a diameter of between about 0.8 and about 3.5 microns, more preferably, from about 2% to about 10% of the cell volume is composed of the cells having a diameter of about 1 to about 2 microns.
The inventive foam can be produced by carbonizing a polymeric foam article, especially a phenolic foam, in an inert or air-excluded atmosphere. The phenolic foam should preferably have a compressive strength of at least about 100 psi.
It is to be understood that both the foregoing general description and the following detailed description provide embodiments of the invention and are intended to provide an overview or framework of understanding to nature and character of the invention as it is claimed.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Carbon foams in accordance with the present invention are prepared from polymeric foams, such as polyurethane foams or phenolic foams, with phenolic foams being preferred. Phenolic resins are a large family of polymers and oligomers, composed of a wide variety of structures based on the reaction products of phenols with aldehydes. Phenolic resins are prepared by the reaction of phenol or substituted phenol with an aldehyde, especially formaldehyde, in the presence of an acidic or basic catalyst. Phenolic resin foam is a cured system composed of open and closed cells. The resins are generally aqueous resol catalyzed by sodium hydroxide at a formaldehyde-to-phenol ratio which can vary, but is preferably about 2:1. Free phenol and formaldehyde contents should be low, although urea may be used as a formaldehyde scavenger.
The foam is prepared by adjusting the water content of the resin and by adding a surfactant (e.g., an ethoxylated nonionic), a blowing agent (e.g., pentane, methylene chloride, or chlorofluorocarbon), and a catalyst (e.g., toluenesulfonic acid or phenolsulfonic acid). The sulfonic acid catalyzes the reaction, while the exotherm causes the blowing agent, emulsified in the resin, to evaporate and hence expand the foam. The surfactant controls the cell size as well as the ratio of open-to-closed cell units. Both batch and continuous processes are employed. In the continuous process, the machinery is similar to that used for continuous polyurethane foam. The properties of the foam depend mainly on density and the cell structure.
The preferred phenol is resorcinol; however, other phenols of similar kind that are able to form condensation products with aldehydes can also be used. Such phenols include monohydric and polyhydric phenols, pyrocatechol, hydroquinone, alkyl-substituted phenols, such as, for example, cresols or xylenols, polynuclear monohydric or polyhydric phenols, such as, for example, naphthols, p.p′-dihydroxydiphenyl dimethyl methane or hydroxyanthracenes.
The phenols used to make the foam starting material can also be used in admixture with non-phenolic precursors that are able to react with aldehydes in the same way as phenol.
The preferred aldehyde for use in the solution is formaldehyde. Other suitable aldehydes include those that will react with phenols in the same manner. These include, for example, acetaldehyde and benzaldehyde.
In general, the phenols and aldehydes that can be used in the process of the invention are those described in U.S. Pat. Nos. 3,960,761 and 5,047,225, the disclosures of which are incorporated herein by reference.
In order to create a reinforced resin-derived carbon foam with improved strength and/or graphitic properties, the carbon foam should be prepared with carbon fibers, carbon nanotubes and carbonized phenolic micro-balloons, incorporated throughout the foam's structure. The particular type of carbon fibers determines the resulting improvement of the carbon foam as carbon fibers derived from PAN, isotropic pitch, and mesophase pitch improve the strength characteristics of the carbon foam while fibers derived solely from mesophase pitch increase the foam's electrical and thermal conductivities. When carbon nanotubes are the selected type of carbon fiber for incorporation into the foam, both the strength and conductive properties of the foam are improved. Additionally, the graphitic properties of reinforced carbon foam are increased because of the physical incorporation of the carbon fibers. The individual carbon fiber filaments physically enhance the graphitizability of the precursor phenolic resins through stress-induced graphitization resulting in a more graphitic carbon foam end product.
The preferred method for creating reinforced phenolic-derived carbon foam is by incorporating carbon fibers into the initial liquid resol resin. Optimally, the liquid resol resin will have a water content of about 10% to about 30% by weight and the carbon fibers will have a length of about 0.1 inch to about 1.0 inch. Typically, the carbon fibers are added to the liquid resol resin in carbon fiber bundles under room temperature conditions. Each bundle consists of approximately 2,000 to 30,000 individual carbon fiber filaments held together in the tow form with a polymer resin or a sizing agent. The carbon fiber filaments are typically, either mesophase pitch carbon fibers, isotropic pitch carbon fibers, carbonized rayon fibers, cotton fibers, polyacrylonitrile (PAN) carbon fibers, cellulose fibers, carbon nanofibers, carbon nanotubes, or a combination of the aforementioned fibers. Phenolic microballoons either in the natural or carbonized state can also be employed as a reinforcing additive. For the most effective reinforcement and the greatest uniformity in properties of the carbon foam, the carbon fiber bundles need to be separated into individual filaments and dispersed throughout the carbon foam's structure. Optimally, the resin used in holding the carbon fiber bundles is water soluble and will readily dissolve upon addition to the liquid resol resin, allowing for the dispersion of individual carbon fiber filaments.
The carbon fiber bundles adhered with a water-soluble resin, can be added from about 0.5% to about 10% by weight to the liquid resol phenolic resin. This percentage range will optimally increase the strength and graphitic properties of the foam while not substantially reducing the inherent desirable properties of phenolic resin-derived carbon foam. Upon addition of the carbon fiber bundles to the liquid resol resin, the individual carbon fiber filaments will disperse throughout the resin and provide an ideal carbon fiber-resin mixture for the subsequent foaming process. Through foaming the phenolic resin, the carbon fiber will become uniformly dispersed and fixed in a specific spatial orientation within the phenolic foam product. During the carbonization of the phenolic foam, the carbon fiber filaments will aid in the stress orientation of the carbon foam ligaments, leading to an improved graphitizability and ultimately higher thermal and electrical conductivities. Also, the carbon fiber filaments will act as reinforcing agents to the solid carbon fraction of the foam and act as a conductive filler within the carbon foam.
In another embodiment, various additives can be added with the carbon fiber bundles to the initial liquid resol resin to achieve supplementary improvements. Additional additives for improving electrical and thermal conductivities include natural graphite flakes, graphitized powders and metal powders. Furthermore, oxidation-protective additives can also be added along with the carbon fiber bundles into the initial resol resin. The oxidation-protective additives include both polycarbosilane and silicon-nitrogen-containing polymers that will decompose at elevated temperatures into silicon carbide and silicon nitride. The above additives impart oxidation resistance to carbon foam, improving the performance of the carbon foam while minimally affecting the carbon foam's desired characteristics.
The polymeric foam precursor prepared as described above, that is used as the starting material in the production of the inventive carbon foam, should have an initial density that mirrors the desired final density for the carbon foam to be formed. In other words, the polymeric foam should have a density of about 0.03 to about 0.8 g/cm 3 , more preferably about 0.03 to about 0.6 g/cm 3 . The cell structure of the polymeric foam should be closed with a porosity of between about 50% and about 95% and a relatively high compressive strength, i.e., on the order of at least about 100 psi, and as high as about 300 psi or higher.
In order to convert the polymeric foam to carbon foam, the foam is carbonized by heating to a temperature of from about 500° C., more preferably at least about 800° C., up to about 3200° C., in an inert or air-excluded atmosphere, such as in the presence of nitrogen. The heating rate should be controlled such that the polymeric foam is brought to the desired temperature over a period of several days, since the polymeric foam can shrink by as much as about 50% or more during carbonization. Care should be taken to ensure uniform heating of the polymeric foam piece for effective carbonization.
By the use of a polymeric foam heated in an inert or air-excluded environment, a non-graphitizable carbon foam is obtained, which has the approximate density of the starting polymeric foam, but a compressive strength of at least about 2000 psi and, significantly, a ratio of strength to density of at least about 7000 psi/(g/cm 3 ), more preferably at least about 8000 psi/(g/cm 3 ). The carbon foam has a relatively uniform distribution of isotropic cells having, on average, an aspect ratio of between about 1.0 and about 1.5.
The resulting carbon foam has a total porosity of about 50% to about 95%, more preferably about 60% to about 95% with a bimodal cell size distribution; at least about 90%, more preferably at least about 95%, of the cell volume is composed of the cells of about 10 to about 150 microns in diameter, more preferably about 15 to about 95 microns in diameter, most preferably about 25 to about 95 microns in diameter, while at least about 1%, more preferably about 2% to about 10%, of the cell volume is composed of the cells of about 0.8 to about 3.5 microns, more preferably about 1 to about 2 microns, in diameter. The bimodal cell-structure nature of the inventive foam provides an intermediate structure between open-cell foams and closed-cell foams, limiting the fluid permeability of the foam while maintaining a foam structure. Nitrogen gas permeabilities less than 3.0 darcys, even less than 2.0 darcys, are preferred.
Typically, characteristics such as porosity and individual cell size and shape are measured optically, such as by the use of an optical microscopy using bright field illumination, and are determined using commercially available software, such as Image-Pro Software available from MediaCybernetic of Silver Springs, Md.
The cell structure of the foam is unique as compared to other foams in that it is intermediate to a closed cell and open cell configuration. The large cells appear to be only weakly connected to each other and connected by the fine porosity so that the foam exhibits permeability in the presence of water but does not readily absorb more viscous liquids.
Accordingly, by the practice of the present invention, carbon foams having heretofore unrecognized characteristics are prepared. These foams exhibit graphitizability as well as high compressive strength to density ratios and have a distinctive bimodal cell structure, making them uniquely effective at applications, such as composite tooling applications, core materials for sandwich panels and high-temperature furnace construction.
The disclosures of all cited patents and publications referred to in this application are incorporated herein by reference.
The above description is intended to enable the person skilled in the art to practice the invention. It is not intended to detail all of the possible variations and modifications that will become apparent to the skilled worker upon reading the description. It is intended, however, that all such modifications and variations be included within the scope of the invention that is defined by the following claims. The claims are intended to cover the indicated elements and steps in any arrangement or sequence that is effective to meet the objectives intended for the invention, unless the context specifically indicates the contrary.
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A reinforced carbon foam material is formed from carbon fibers incorporated within a carbon foam's structure. First, carbon fiber bundles are combined with a liquid resol resin. The carbon fiber bundles separate into individual carbon fiber filaments and disperse throughout the liquid resol resin. Second, the carbon fiber resin mixture is foamed thus fixing the carbon fibers in a permanent spatial arrangement within the phenolic foam. The foam is then carbonized to create a carbon fiber reinforced foam with improved graphitic characteristics as well as increased strength. Optionally, various additives can be introduced simultaneously with the addition of the carbon fiber bundles into the liquid resol, which can improve the graphitic nature of the final carbon foam material and/or increase the foam's resistance to oxidation.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application 60/328,065, filed Oct. 9, 2001.
TECHNICAL FIELD OF THE INVENTION
The invention relates to novel diazoketone derivatives. The invention also relates to processes for homologation of these diazoketone derivatives. The processes are useful for preparing compounds that are caspase inhibitors.
BACKGROUND OF THE INVENTION
Apoptosis, or programmed cell death, is a principal mechanism by which organisms eliminate unwanted cells. The deregulation of apoptosis, either excessive apoptosis or the failure to undergo it, has been implicated in a number of diseases such as cancer, acute inflammatory and autoimmune disorders, ischemic diseases and certain neurodegenerative disorders [see generally Science, 281, pp. 1283-1312 (1998); Ellis et al., Ann. Rev. Cell. Biol., 7, p. 663 (1991)].
Caspases are a family of cysteine protease enzymes that are key mediators in the signaling pathways for apoptosis and cell disassembly [N. A. Thornberry, Chem. Biol., 5, pp. R97-R103 (1998)]. These signaling pathways vary depending on cell type and stimulus, but all apoptosis pathways appear to converge at a common effector pathway leading to proteolysis of key proteins. Caspases are involved in both the effector phase of the signaling pathway and further upstream at its initiation. The upstream caspases involved in initiation events become activated and in turn activate other caspases that are involved in the later phases of apoptosis.
The utility of caspase inhibitors to treat a variety of mammalian disease states associated with an increase in cellular apoptosis has been demonstrated using peptidic caspase inhibitors. For example, in rodent models, caspase inhibitors have been shown to reduce infarct size and inhibit cardiomyocyte apoptosis after myocardial infarction, to reduce lesion volume and neurological deficit resulting from stroke, to reduce post-traumatic apoptosis and neurological deficit in traumatic brain injury, to be effective in treating fulminant liver destruction, and to improve survival after endotoxic shock [H. Yaoita et al., Circulation, 97, pp. 276-281 (1998); M. Endres et al., J. Cerebral Blood Flow and Metabolism, 18, pp. 238-247, (1998); Y. Cheng et al., J. Clin. Invest., 101, pp. 1992-1999 (1998); A. G. Yakovlev et al., J. Neurosci., 17, pp 7415-7424 (1997); I. Rodriquez et al., J. Exp. Med., 184, pp. 2067-2072 (1996); Grobmyer et al., Mol. Med., 5, p. 585 (1999)]. However, due to their peptidic nature, such inhibitors are typically characterized by undesirable pharmacological properties, such as poor cellular penetration and cellular activity, poor oral absorption, poor stability and rapid metabolism [J. J. Plattner and D. W. Norbeck, in Drug Discovery Technologies , C. R. Clark and W. H. Moos, Eds. (Ellis Horwood, Chichester, England, 1990), pp. 92-126]. This has hampered their development into effective drugs. These and other studies with peptidic caspase inhibitors have demonstrated that an aspartic acid residue is involved in a key interaction with the caspase enzyme [K. P. Wilson et al., Nature, 370, pp. 270-275 (1994); Lazebnik et al., Nature, 371, p. 346 (1994)].
Accordingly, non-peptidyl aspartic acid mimics are useful in the synthesis of caspase inhibitors. WO96/03982 reports azaaspartic acid analogs effective as interleukin-1β converting enzyme (“ICE”) inhibitors. Fluoromethylketone analogs have also been reported as components of ICE inhibitors [WO99/47154; WO99/18781; WO93/05071].
It is well known that enzyme active sites are chiral and catalyze reactions stereospecifically. A substrate must fit precisely within this active site in order to interact with the enzyme. In accordance with this principle, a chiral compound could in many cases show improved inhibitory activity over its corresponding enantiomeric or diastereomeric mixtures.
Existing processes for synthesizing aspartic and glutamic acid derivatives and their analogues as caspase inhibitors or as intermediates for caspase inhibitors suffer from limited success and offer little control over stereochemistry [L. Revesz et al., Tetrahedron Lett., 35, pp. 9693-9696 (1994); WO91/15577; D. Rasnick, Anal. Biochem., 149, p.461 (1985)]. These transformations result in the formation of enantiomeric mixtures, which would require tedious separation steps to obtain an enantiomerically pure aspartic or glutamic acid mimic. Consequently, studies of the inhibitory activity of compounds with an aspartic or glutamic acid component generally refer to enantiomeric or diastereomeric mixtures, which may limit their effectiveness as enzyme inhibitors. Accordingly, the need exists for a process of synthesizing aspartic and glutamic acid analogues, and derivatives thereof, that are useful as intermediates for caspase inhibitors, to obtain chirally enriched derivatives in a reasonable yield.
Syntheses involving chiral diazoketones have been reported in the literature for the formation of β-amino-α-keto esters [Darkins et al., Tetrahedron Assym., 5, pp. 195-198 (1994)], N-protected allylamine derivatives [Nishi et al., Heterocycles, 29, pp. 1835-1842 (1989)], and β-homoamino acids [Ondetti et al., J. Med. Chem., 18, pp. 761-763 (1975)]. These procedures report little to no detectable racemization of the chiral center in the diazoketone transformation step.
SUMMARY OF THE INVENTION
The present invention solves the difficulties and shortcomings of the prior art for the synthesis of caspase inhibitors and provides chirally enriched aspartic and glutamic acid derivatives and processes for producing chirally enriched aspartic and glutamic acid derivatives. Applicants' approach to these aspartic and glutamic acid derivatives overcomes the problem of racemization of the chiral center adjacent to the amine, a problem sometimes encountered in existing methods of synthesizing aspartic and glutamic acid derivatives.
This invention solves the above problems by providing compounds of formula 1:
wherein R x , R y , R 1 , R 5 , n, and p are as described below. Compounds of formula 1 are useful as intermediates in the synthesis of aspartic and glutamic acid derivatives.
A process of this invention comprises the step of subjecting a diazoketone derivative of formula 1 to conditions that effect the rearrangement of 1 to form the corresponding homologation product 2:
Homologation may be accomplished, for example, by reacting a compound of formula 1 in the presence of a base and a silver salt. Advantageously, this method preserves the chirality of the starting compound in the homologation product.
This process is particularly useful for producing caspase inhibitors and/or intermediates that may be subsequently converted into caspase inhibitors, through additional steps known in the art.
DETAILED DESCRIPTION OF THE INVENTION
Some of the abbreviations used through the specification (including the chemical formulae) are:
Bn=benzyl Boc=t-butoxycarbonyl Cbz=benzyloxycarbonyl Alloc=allyloxycarbonyl Ac=acetyl TBDMS=t-butyldimethylsilyl TBDPS=t-butyldiphenylsilyl DMF=N,N-dimethylformamide THF=tetrahydrofuran DMSO=dimethylsulfoxide PCC=pyridinium chlorochromate PDC=pyridinium dichromate TPAP=tetrapropylammonium perruthenate THP=tetrahydropyranyl
The present invention provides a process for homologating an α-amino acid derivative to the corresponding β-amino acid derivative whereby the asymmetry of the chiral center (*) is substantially preserved. This is shown in EQ. 1 where G represents the side chain of an α-amino acid:
The process is particularly useful for providing aspartic and glutamic acid derivatives wherein the carboxylic acid on the amino-bearing carbon is replaced by a substituted α-methyl ketone and R 1 is the P2-P4 portion of a caspase inhibitor. This is shown in EQ. 2 where R 5 is the substituent on the methyl ketone:
Many α-amino acid derivatives of high optical purity are known in the literature and are useful starting materials for the current process. Since there is little or no racemization of the alpha carbon during the process of this invention, one may thereby obtain β-amino acid derivatives having an optical purity similar to that of the starting material.
The process is exemplified in the preparation of useful synthetic intermediates of caspase inhibitors:
wherein R 1 is a P2-P4 portion of a caspase inhibitor; R x is H; R y is OR 2 ; R 2 is H or an alcohol protecting group; or R x and R y are taken together to form —O(CH 2 ) y O— or ═O; y is 2-3; p is 0-6; and n is 0-6;
provided that when R x and R y are taken together to form ═O, R 1 is other than H.
The symbol “*” denotes an asymmetric carbon. In a preferred embodiment of the present invention, the process provides compounds wherein one of the stereochemical forms of the asymmetric carbon is present in greater than about 50% excess over the other stereochemical form.
According to one embodiment, the invention provides a compound represented by formula 1:
wherein:
R 1 is hydrogen; an amine protecting group; or a P2-P4 moiety of a caspase inhibitor, or portion thereof; R x is H; R y is OR 2 ; or R x and R y are taken together to form —O(CH 2 ) y O— or ═O; y is 2-3; provided that when R x and R y are taken together to form ═O, R 1 is other than H; each R 2 is independently hydrogen or an alcohol protecting group; R 5 is an electronegative leaving group, halo, OR, or SR; each R is independently hydrogen; C1-C6 aliphatic; or Ar; wherein said aliphatic is optionally substituted with one or more substituents halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ), Ar, Ar 1 , O—Ar, or O—Ar 1 ; Ar is a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N and S; wherein Ar is optionally substituted at one or more ring atoms with one or more substituents independently selected from halo; C1-C6 alkoxy; cyano; nitro; oxo; OR 2 ; OR 7 ; SR 7 ; N(R 6 ) 2 ; N(R 7 ) 2 ; N(R 6 )(R 7 ); C(O)R 7 ; C(O)OR 7 ; C(O)N(R 7 ) 2 ; NR 7 C(O)R 7 ; NR 7 C(O)N(R 7 ) 2 ; NR 7 SO 2 R 7 ; SO 2 N(R 7 ) 2 ; NR 7 SO 2 N(R 7 ) 2 ; Ar 1 ; O—Ar 1 ; C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ); or O—C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ); Ar 1 is a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N, and S; each R 6 is independently hydrogen or an amine protecting group; each R 7 is independently hydrogen; C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, amino, oxo or hydroxy; or a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N, and S, and wherein each ring atom is optionally substituted with 1 to 3 substituents independently selected from halo, C1-C6 alkyl, C1-C6 alkoxy, cyano, nitro, amino, and hydroxy; n is 0-6; and p is 0-6.
According to a preferred embodiment, the compound of formula 1 is in greater than about 50% diastereomeric excess and greater than about 50% enantiomeric excess.
According to a more preferred embodiment, the compound of formula 1 is in greater than about 95% enantiomeric excess.
According to an even more preferred embodiment, the compound of formula 1 is in greater than about 98% enantiomeric excess.
According to a preferred embodiment, a compound of formula 1a or 1b:
is provided.
According to one preferred embodiment, R 1 is a carbamate protecting group. More preferably, R 1 is Boc, Cbz, methyl carbamate, ethyl carbamate, 2,2,2-trichloroethyl carbamate, adamantyl carbamate, or Alloc.
In a more preferred embodiment, R 1 is Boc, Alloc, or Cbz.
Most preferably, R 1 is Boc or Cbz.
According to another preferred embodiment, R 1 is a P2-P4 moiety of a caspase inhibitor, or portion thereof.
According to a preferred embodiment, R x is H and R y is OR 2 .
In another preferred embodiment, R 2 is an ester or ether protecting group. More preferably, R 2 is formate, acetate, trichloroacetate, trifluoroacetate, phenylacetate, propionate, pivaloate, benzoate, substituted benzoate, benzyl, allyl, or tetrahydropyranyl.
In a most preferred embodiment, R 2 is acetate.
According to another preferred embodiment, R 2 is a silyl protecting group. More preferably, R 2 is trimethylsilyl, triethylsilyl, triisopropylsilyl, TBDMS, or TBDPS.
In a most preferred embodiment, R 2 is TBDMS.
According to another preferred embodiment, R 5 is F.
According to a preferred embodiment, R 6 is Boc, Cbz, alloc, trifluoroacetamide, or phthaloyl.
According to a preferred embodiment, n is 0 or 1. More preferably, n is 0.
According to a preferred embodiment, p is 0.
According to a more preferred embodiment, compound 1 is selected from the group consisting of:
wherein R 1 and R 2 are as defined in any of the above embodiments.
According to a most preferred embodiment, compound 1 is selected from the group consisting of:
wherein R 1 is Boc, Cbz, or a P2-P4 moiety of a caspase inhibitor, or portion thereof; and R 2 is acetate or a silyl protecting group.
This invention also provides a process for converting compound 1 to compound 2:
wherein:
R 1 is hydrogen; an amine protecting group; or a P2-P4 moiety of a caspase inhibitor, or portion thereof; R x is H; R y is OR 2 ; or R x and R y are taken together to form —O(CH 2 ) y O— or ═O; y is 2-3; provided that when R x and R y are taken together to form ═O, R 1 is other than H; each R 2 is independently hydrogen or an alcohol protecting group; R 4 is OR, OR 2 , N(R) 2 , N(R 6 ) 2 , N(R 6 )(R 7 ), or N(R 7 ) 2 ; R 5 is an electronegative leaving group, halo, OR, or SR; each R is independently hydrogen; C1-C6 aliphatic; or Ar; wherein said aliphatic is optionally substituted with one or more substituents halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ), Ar, Ar 1 , O—Ar, or O—Ar 1 ; Ar is a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N and S; wherein Ar is optionally substituted at one or more ring atoms with one or more substituents independently selected from halo; C1-C6 alkoxy; cyano; nitro; oxo; OR 2 ; OR 7 ; SR 7 ; N(R 6 ) 2 ; N(R 7 ) 2 ; N(R 6 )(R 7 ); C(O)R 7 ; C(O)OR 7 ; C(O)N(R 7 ) 2 ; NR 7 C(O)R 7 ; NR 7 C(O)N(R 7 ) 2 ; NR 7 SO 2 R 7 ; SO 2 N(R 7 ) 2 ; NR 7 SO 2 N(R 7 ) 2 ; Ar 1 ; O—Ar 1 ; C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ); or O—C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ); Ar 1 is a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N, and S; each R 6 is independently hydrogen or an amine protecting group; each R 7 is independently hydrogen; C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, amino, oxo or hydroxy; or a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N, and S, and wherein each ring atom is optionally substituted with 1 to 3 substituents independently selected from halo, C1-C6 alkyl, C1-C6 alkoxy, cyano, nitro, amino, hydroxy; n is 0-6; and p is 0-6;
said process comprising the steps of:
providing a mixture of compound 1 and an organic solvent and subjecting the mixture to conditions that effect the rearrangement of compound 1 to compound 2.
In a preferred embodiment, said process comprises the steps of:
a) providing a mixture of compound 1 and an organic solvent; b) adding to the mixture produced in step a):
i) a base; and ii) a silver salt selected from Ag 2 O or AgO 2 CPh; and
c) allowing the mixture produced in step b) to react at a temperature in the range of −50° C. and 150° C. for 1 minute to 48 hours to provide compound 2.
In another embodiment, a compound R 4 H is optionally added to the step a) mixture before step b).
Preferably, any of the processes according to this invention comprise the further step of purifying compound 2.
According to a preferred embodiment, R x is H and R y is OR 2 .
Generally, the conversion of 1 to 2 will be performed under conditions in which R 1 is an amine protecting group or a P2-P4 moiety of a caspase inhibitor, or portion thereof, and R 2 is an alcohol protecting group.
According to a preferred embodiment, the compound of formula 2 is produced in greater than about 50% diastereomeric excess and greater than about 50% enantiomeric excess.
According to a more preferred embodiment, the compound of formula 2 is produced in greater than about 95% enantiomeric excess.
According to an even more preferred embodiment, the compound of formula 2 is produced in greater than about 98% enantiomeric excess.
According to a preferred embodiment, the compound of formula 1 is in greater than about 50% diastereomeric excess and greater than about 50% enantiomeric excess.
According to a more preferred embodiment, the compound of formula 1 is in greater than about 95% enantiomeric excess.
According to an even more preferred embodiment, the compound of formula 1 is in greater than about 98% enantiomeric excess.
According to a preferred embodiment, the process provides a compound of formula 2a or 2b:
wherein R x , R y , R 1 , R 4 , R 5 , n, and p are as above.
According to a preferred embodiment, R 1 is a P2-P4 moiety of a caspase inhibitor, or portion thereof.
According to a preferred embodiment, R 1 is a carbamate protecting group. More preferably, R 1 is Boc, Cbz, methyl carbamate, ethyl carbamate, 2,2,2-trichloroethyl carbamate, adamantyl carbamate, or Alloc.
In a more preferred embodiment, R 1 is Boc, Alloc, or Cbz.
Most preferably, R 1 is Boc or Cbz.
According to a preferred embodiment, R x is H and R y is OR 2 .
In a more preferred embodiment, R 2 is an ester or ether protecting group. More preferably, R 2 is formate, acetate, trichloroacetate, trifluoroacetate, phenylacetate, propionate, pivaloate, benzoate, substituted benzoate, benzyl, allyl, or THP.
In a most preferred embodiment, R 2 is acetate.
According to another preferred embodiment, R 2 is a silyl protecting group. More preferably, R 2 is trimethylsilyl, triethylsilyl, triisopropylsilyl, TBDMS, or TBDPS.
In another most preferred embodiment, R 2 is TBDMS.
According to a preferred embodiment, R 4 is OR.
In a more preferred embodiment, R is CH 3 , Bn, or t-butyl.
According to another preferred embodiment, R 5 is F.
According to a preferred embodiment, R 6 is Boc, Cbz, alloc, trifluoroacetamide, or phthaloyl.
According to a preferred embodiment, n is 0 or 1. In a more preferred embodiment, n is 0.
According to a preferred embodiment, p is 0.
According to a preferred embodiment, the organic solvent is a protic solvent.
In a more preferred embodiment, the organic solvent is methanol, t-butanol, isopropanol, benzyl alcohol or water.
Most preferably, the organic solvent is methanol, t-butanol, or benzyl alcohol.
When the process takes place in the presence of R 4 H wherein R 4 H is an alcohol, functionalized esters may be provided.
When the process takes place in the presence of ammonia or primary or secondary amines, primary, secondary, or tertiary amides, respectively, may be provided.
According to a preferred embodiment, the base is an aromatic or tertiary aliphatic amine. More preferably, the base is triethylamine, di-isopropylethylamine, N-methylmorpholine, pyrrolidine, pyridine or collidine.
According to a most preferred embodiment, the base is triethylamine.
According to another preferred embodiment, the silver salt is AgO 2 CPh.
In another preferred embodiment, the mixture is allowed to react at a temperature in the range of 0° C. to room temperature.
In yet another preferred embodiment, the mixture is allowed to react for 1 to 24 hours.
Alternatively, according to another embodiment, compound 1 is converted to compound 2 by heating the mixture produced in step a), without the use of chemical reagents other than the organic solvent or R 4 H.
According to yet another embodiment, compound 1 can be converted to compound 2 by exposing the mixture produced in step a) to UV light. Chemical reagents other than the organic solvent or R 4 H may optionally be present but are not required.
According to another embodiment, the invention provides a method for producing a compound of formula 3 from a compound of formula 1:
wherein:
R 1 is hydrogen; an amine protecting group; or a P2-P4 moiety of a caspase inhibitor, or portion thereof; R x is H; R y is OR 2 ; or R x and R y are taken together to form —O(CH 2 ) y O— or ═O; y is 2-3; provided that when R x and R y are taken together to form ═O, R 1 is other than H; each R 2 is independently hydrogen or an alcohol protecting group; R 4 is OR, OR 2 , N(R) 2 , N(R 6 ) 2 , N(R 6 )(R 7 ), or N(R 7 ) 2 ; R 5 is an electronegative leaving group, halo, OR, or SR; each R is independently hydrogen; C1-C6 aliphatic; or Ar; wherein said aliphatic is optionally substituted with one or more substituents halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ), Ar, Ar 1 , O—Ar, or O—Ar 1 ; Ar is a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N and S; wherein Ar is optionally substituted at one or more ring atoms with one or more substituents independently selected from halo; C1-C6 alkoxy; cyano; nitro; oxo; OR 2 ; OR 7 ; SR 7 ; N(R 6 ) 2 ; N(R 7 ) 2 ; N(R 6 )(R 7 ); C(O)R 7 ; C(O)OR 7 ; C(O)N(R 7 ) 2 ; NR 7 C(O)R 7 ; NR 7 C(O)N(R 7 ) 2 ; NR 7 SO 2 R 7 ; SO 2 N(R 7 ) 2 ; NR 7 SO 2 N(R 7 ) 2 ; Ar 1 ; O—Ar 1 ; C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ); or O—C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ); Ar 1 is a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N, and S; each R 6 is independently hydrogen or an amine protecting group; each R 7 is independently hydrogen; C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, amino, oxo or hydroxy; or a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N, and S, and wherein each ring atom is optionally substituted with 1 to 3 substituents independently selected from halo, C1-C6 alkyl, C1-C6 alkoxy, cyano, nitro, amino or hydroxy; n is 0-6; and p is 0-6; said process comprising the steps of: a) converting compound 1 to compound 2; b) wherein R x is H and R y is OR 2 , and wherein R 2 is an alcohol protecting group, converting R 2 to hydrogen; c) wherein R x and R y are taken together, optionally converting —C(R x )(R y )— to —CH(OH)—; and d) wherein R 1 is an amine protecting group, converting R 1 to hydrogen.
One of skill in the art of will recognize that steps b) and d) or steps c) and d) can be performed in any order.
One of skill in the art will recognize that step c) may involve reducing the compound of formula 2, wherein R x and R y are taken together, to produce the free alcohol. This may involve, for example, subjecting the compound of formula 2 to a reducing agent.
In a preferred embodiment, the process further comprises the step of purifying compound 3.
According to a preferred embodiment, R x is H and R y is OR 2 .
Generally, the conversion of 1 to 2 will be performed under conditions in which the amine and alcohol are protected, i.e., where R 1 is an amine protecting group or a P2-P4 moiety of a caspase inhibitor, or portion thereof and R 2 is an alcohol protecting group.
According to a preferred embodiment, the compound of formula 3 is produced in greater than about 50% diastereomeric excess and greater than about 50% enantiomeric excess.
According to a more preferred embodiment, the compound of formula 3 is produced in greater than about 95% enantiomeric excess.
According to an even more preferred embodiment, the compound of formula 3 is produced in greater than about 98% enantiomeric excess.
According to a preferred embodiment, the compound of formula 1 is in greater than about 50% diastereomeric excess and greater than about 50% enantiomeric excess.
According to a more preferred embodiment, the compound of formula 1 is in greater than about 95% enantiomeric excess.
According to an even more preferred embodiment, the compound of formula 1 is in greater than about 98% enantiomeric excess.
According to a preferred embodiment, the process provides a compound of formula 3a or 3b:
wherein R 1 , R 4 , R 5 , n, and p are as above.
According to a preferred embodiment, R 4 is OR.
In a more preferred embodiment, R is H, CH 3 , Bn, or t-butyl.
According to another preferred embodiment, R 5 is F.
According to a preferred embodiment, R 6 is Boc, Cbz, alloc, trifluoroacetamide, or phthaloyl.
According to a preferred embodiment, n is 0 or 1. In a more preferred embodiment, n is 0.
According to a preferred embodiment, p is 0.
According to another embodiment, the invention provides a method for producing a compound of formula 4 from a compound of formula 1:
wherein:
R 1 is hydrogen; an amine protecting group; or a P2-P4 moiety of a caspase inhibitor, or portion thereof; R x is H; R y is OR 2 ; or R x and R y are taken together to form —O(CH 2 ) y O— or ═O; y is 2-3; provided that when R x and R y are taken together to form ═O, R 1 is other than H; each R 2 is independently hydrogen or an alcohol protecting group; R 4 is OR, OR 2 , N(R) 2 , N(R 6 ) 2 , N(R 6 )(R 7 ), or N(R 7 ) 2 ; R 5 is an electronegative leaving group, halo, OR, or SR; each R is independently hydrogen; C1-C6 aliphatic; or Ar; wherein said aliphatic is optionally substituted with one or more substituents halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ), Ar, Ar 1 , O—Ar, or O—Ar 1 ; Ar is a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N and S; wherein Ar is optionally substituted at one or more ring atoms with one or more substituents independently selected from halo; C1-C6 alkoxy; cyano; nitro; oxo; OR 2 ; OR 7 ; SR 7 ; N(R 6 ) 2 ; N(R 7 ) 2 ; N(R 6 )(R 7 ); C(O)R 7 ; C(O)OR 7 ; C(O)N(R 7 ) 2 ; NR 7 C(O)R 7 ; NR 7 C(O)N(R 7 ) 2 ; NR 7 SO 2 R 7 ; SO 2 N(R 7 ) 2 ; NR 7 SO 2 N(R 7 ) 2 ; Ar 1 ; O—Ar 1 ; C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ); or O—C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ); Ar 1 is a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N, and S; each R 6 is independently hydrogen or an amine protecting group; each R 7 is independently hydrogen; C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, amino, oxo or hydroxy; or a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N, and S, and wherein each ring atom is optionally substituted with 1 to 3 substituents independently selected from halo, C1-C6 alkyl, C1-C6 alkoxy, cyano, nitro, amino or hydroxy; n is 0-6; and p is 0-6; said process comprising the step of oxidizing compound 3 to provide compound 4.
In a preferred embodiment, said process comprises the steps of:
a) converting compound 1 to compound 2;
b) wherein R x is H and R y is OR 2 , and wherein R 2 is an alcohol protecting group, converting R 2 to hydrogen;
c) adding to the step b) mixture an oxidizing agent; and
d) allowing the mixture produced in step c) to react at a temperature in the range of −78° C. and 150° C. for 1 minute to 48 hours.
In a preferred embodiment, the process further comprises the step of purifying compound 4.
According to a preferred embodiment, R x is H and R y is OR 2 .
Generally, the conversion of 1 to 2 will be performed under conditions in which the amine and alcohol are protected, i.e., where R 1 is an amine protecting group or a P2-P4 moiety of a caspase inhibitor, or portion thereof and R 2 is an alcohol protecting group.
According to a preferred embodiment, the compound of formula 4 is produced in greater than about 50% diastereomeric excess and greater than about 50% enantiomeric excess.
According to a more preferred embodiment, the compound of formula 4 is produced in greater than about 95% enantiomeric excess.
According to an even more preferred embodiment, the compound of formula 4 is produced in greater than about 98% enantiomeric excess.
According to a preferred embodiment, the compound of formula 1 is in greater than about 50% diastereomeric excess and greater than about 50% enantiomeric excess.
According to a more preferred embodiment, the compound of formula 1 is in greater than about 95% enantiomeric excess.
According to an even more preferred embodiment, the compound of formula 1 is in greater than about 98% enantiomeric excess.
According to a preferred embodiment, the process provides a compound of formula 4a or 4b:
wherein R 1 , R 4 , R 5 , n, and p are as above.
According to a preferred embodiment, R 4 is OR.
In a more preferred embodiment, R is H, CH 3 , Bn, or t-butyl.
According to another preferred embodiment, R 5 is F.
According to a preferred embodiment, R 6 is Boc, Cbz, alloc, trifluoroacetamide, or phthaloyl.
According to a preferred embodiment, n is 0 or 1. In a more preferred embodiment, n is 0.
According to a preferred embodiment, p is 0.
According to a preferred embodiment, the oxidizing agent is Dess-Martin reagent, TPAP, DMSO/oxalyl chloride, or pyridine/SO 3 .
In another preferred embodiment, the mixture produced in step c) is allowed to react at a temperature in the range of −78° C. and room temperature.
In yet another preferred embodiment, the mixture is allowed to react for 1 to 24 hours.
The synthesis of a compound of formula 1 is also within the scope of this invention. Accordingly, another embodiment of this invention provides a method for producing compound 1 from compound 11:
wherein:
R 1 is hydrogen; an amine protecting group; or a P2-P4 moiety of a caspase inhibitor, or portion thereof; R x is H; R y is OR 2 ; or R x and R y are taken together to form —O(CH 2 ) y O— or ═O; y is 2-3; provided that when R x and R y are taken together to form ═O, R 1 is other than H; each R 2 is independently hydrogen or an alcohol protecting group; R 3 is an acid activating group; R 5 is an electronegative leaving group, halo, OR, or SR; each R is independently hydrogen; C1-C6 aliphatic; and Ar; wherein said aliphatic is optionally substituted with one or more substituents halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ), Ar, Ar 1 , O—Ar, or O—Ar 1 ; Ar is a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N and S; wherein Ar is optionally substituted at one or more ring atoms with one or more substituents independently selected from halo; C1-C6 alkoxy; cyano; nitro; oxo; OR 2 ; OR 7 ; SR 7 ; N(R 6 ) 2 ; N(R 7 ) 2 ; N(R 6 )(R 7 ); C(O)R 7 ; C(O)OR 7 ; C(O)N(R 7 ) 2 ; NR 7 C(O)R 7 ; NR 7 C(O)N(R 7 ) 2 ; NR 7 SO 2 R 7 ; SO 2 N(R 7 ) 2 ; NR 7 SO 2 N(R 7 ) 2 ; Ar 1 ; O—Ar 1 ; C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ); or O—C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ); Ar 1 is a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N, and S; each R 6 is independently hydrogen or an amine protecting group; each R 7 is independently hydrogen; C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, amino, oxo or hydroxy; or a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N, and S, and wherein each ring atom is optionally substituted with 1 to 3 substituents independently selected from halo, C1-C6 alkyl, C1-C6 alkoxy, cyano, nitro, amino or hydroxy; n is 0-6; and p is 0-6;
said process comprising the step of converting compound 11 to compound 1.
One of skill in the art will recognize that converting compound 11 to compound 1 may involve subjecting compound 11 to conditions that will result in formation of the diazo derivative.
In a preferred embodiment, a method for producing compound 1 from compound 9 is provided:
wherein:
R 1 is hydrogen; an amine protecting group; or a P2-P4 moiety of a caspase inhibitor, or portion thereof; R x is H; R y is OR 2 ; or R x and R y are taken together to form —O(CH 2 ) y O— or ═O; y is 2-3; provided that when R x and R y are taken together to form ═O, R 1 is other than H; each R 2 is independently hydrogen or an alcohol protecting group; R 3 is an acid activating group; R 5 is an electronegative leaving group, halo, OR, or SR; each R is independently hydrogen; C1-C6 aliphatic; or Ar; wherein said aliphatic is optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ), Ar, Ar 1 , O—Ar, or O—Ar 1 ; Ar is a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N and S; wherein Ar is optionally substituted at one or more ring atoms with one or more substituents independently selected from halo; C1-C6 alkoxy; cyano; nitro; oxo; OR 2 ; OR 7 ; SR 7 ; N(R 6 ) 2 ; N(R 7 ) 2 ; N(R 6 )(R 7 ); C(O)R 7 ; C(O)OR 7 ; C(O)N(R 7 ) 2 ; NR 7 C(O)R 7 ; NR 7 C(O)N(R 7 ) 2 ; NR 7 SO 2 R 7 ; SO 2 N(R 7 ) 2 ; NR 7 SO 2 N(R 7 ) 2 ; Ar 1 ; O—Ar 1 ; C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ); or O—C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, oxo, OR 2 , OR 7 , SR 7 , N(R 6 ) 2 , N(R 7 ) 2 , N(R 6 )(R 7 ); Ar 1 is a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N, and S; each R 6 is independently hydrogen or an amine protecting group; each R 7 is independently hydrogen; C1-C6 aliphatic optionally substituted with halo, C1-C6 alkoxy, cyano, nitro, amino, oxo or hydroxy; or a saturated, partially saturated or unsaturated monocyclic or bicyclic ring structure, wherein each ring contains 5 to 7 ring atoms and each ring optionally contains from 1 to 4 heteroatoms selected from O, N, and S, and wherein each ring atom is optionally substituted with 1 to 3 substituents independently selected from halo, C1-C6 alkyl, C1-C6 alkoxy, cyano, nitro, amino or hydroxy; n is 0-6; and p is 0-6; said process comprising the steps of: a) wherein R 1 is H, converting H to an amine protecting group; b) converting the free alcohol to —C(R x )(R y )—; c) activating the carboxylic acid; d) converting the activated carboxylic acid formed in step c) to the corresponding diazoketone.
One of skill in the art will recognize that steps a) and b) can be performed in any sequence.
According to a preferred embodiment, R x is H and R y is OR 2 . According to another preferred embodiment, R 2 is an alcohol protecting group.
Generally, the manipulative steps involved in the production of 1 will be performed under conditions in which the amine and alcohol are protected, i.e., where R 1 is an amine protecting group or a P2-P4 moiety of a caspase inhibitor, or portion thereof and R 2 is an alcohol protecting group.
Compounds of formula 9 may contain one or more chiral centers. These compounds may be obtained from commercial sources, or may be obtained by literature methods or modifications thereof that would be known to one of skill in the art. For example, in a preferred embodiment, the compound 9 may be the fluorothreonine 101:
or another optically enriched amino acid derivative obtained through procedures known in the art. The high optical purity of these compounds may be achieved via the use of lipases [Shimizu et al., Tet. Asymm., 4, pp. 835-838 (1993)] or an enantioselective synthesis that takes advantage of a configurationally stable cyclic intermediate [Amin et al., Chem. Commun., 15, pp. 1471-1472 (1997); Scholastico et al., Synthesis, 9, pp. 850-855 (1985)]. Optical purity of the compound of formula 9 may be determined by analyzing the optical rotation, 1 H NMR, 19 F NMR, GC, HPLC, or other relevant property of the compound.
According to a preferred embodiment, the compound of formula 1 is produced in greater than about 50% diastereomeric excess and greater than about 50% enantiomeric excess.
According to a more preferred embodiment, the compound of formula 1 is produced in greater than about 95% enantiomeric excess.
According to an even more preferred embodiment, the compound of formula 1 is produced in greater than about 98% enantiomeric excess.
According to a preferred embodiment, the compound of formula 11 is in greater than about 50% diastereomeric excess and greater than about 50% enantiomeric excess.
According to a more preferred embodiment, the compound of formula 11 is in greater than about 95% enantiomeric excess.
According to an even more preferred embodiment, the compound of formula 11 is in greater than about 98% enantiomeric excess.
According to a preferred embodiment, the process provides a compound of formula 1a or 1b:
wherein R x , R y , R 1 , R 5 , n, and p are as above.
According to a preferred embodiment, R 1 is a P2-P4 moiety of a caspase inhibitor, or portion thereof.
According to a preferred embodiment, R 1 is a carbamate protecting group. More preferably, R 1 is Boc, Cbz, methyl carbamate, ethyl carbamate, 2,2,2-trichloroethyl carbamate, adamantyl carbamate, or Alloc.
In a more preferred embodiment, R 1 is Boc, Alloc, or Cbz.
Most preferably, R 1 is Boc or Cbz.
According to a preferred embodiment, R x is H and R y is OR 2 .
In a more preferred embodiment, R 2 is an ester or ether protecting group. More preferably, R 2 is formate, acetate, trichloroacetate, trifluoroacetate, phenylacetate, propionate, pivaloate, benzoate, substituted benzoate, benzyl, allyl, or THP.
In a most preferred embodiment, R 2 is acetate.
According to another preferred embodiment, R 2 is a silyl protecting group. More preferably, R 2 is trimethylsilyl, triethylsilyl, triisopropylsilyl, TBDMS, or TBDPS.
In another most preferred embodiment, R 2 is TBDMS.
According to another preferred embodiment, R 3 is Br, Cl, OC(O)OCH 2 CH(CH 3 ) 2 , OC(O)OCH 2 CH 3 , OC(O)OCH 3 or Cbz.
According to another preferred embodiment, R 5 is F.
According to a preferred embodiment, R 6 is Boc, Cbz, alloc, trifluoroacetamide, or phthaloyl.
According to a preferred embodiment, n is 0 or 1. In a more preferred embodiment, n is 0.
According to a preferred embodiment, p is 0.
According to a preferred embodiment, compound 11 is reacted with diazomethane or trimethylsilyldiazomethane to form the diazoketone 1.
As used herein, the following definitions shall apply unless otherwise indicated. Also, combinations of substituents are permissible only if such combinations result in stable compounds.
The term “aliphatic” as used herein means straight-chain, branched or cyclic hydrocarbons which are completely saturated or which contain one or more units of unsaturation. Preferred aliphatic groups have 1-12 carbon atoms. For example, suitable aliphatic groups include substituted or unsubstituted linear, branched, or cyclic alkyl, alkenyl, alkynyl groups and hybrids thereof such as (cycloalkyl)alkyl, (cycloaklenyl)alkyl or (cycloalkyl)alkenyl. The terms “alkyl” and “alkoxy” used alone or as part of a larger moiety refers to both straight and branched chains containing one to twelve carbon atoms. The terms “alkenyl” and “alkynyl” used alone or as part of a larger moiety shall include both straight and branched chains. Preferred alkenyl and alkynyl groups contain two to twelve carbon atoms. The term “halogen” or “halo” means F, Cl, Br, or I. The term “heteroatom” means N, O, or S and shall include any oxidized form of nitrogen and sulfur, and the quaternized form of any basic nitrogen.
In one embodiment of this invention is provided a process that may be used to prepare α-substituted methyl ketone aspartic acid and glutamic acid derivatives. Examples of such compounds include caspase inhibitors. Caspase inhibitors have been described in, for example, PCT patent publications WO 99/47545, WO 99/46248, WO 98/24805, WO 98/24804, WO 97/22619, WO 95/35308, WO 91/15577, WO 93/05071, WO 95/33751, WO 96/03982, WO 95/26958, and WO 95/29672, and European patent publications EP 623606, EP 644197, EP 628550, EP 644198, EP 623592, which are hereby incorporated by reference. Examples of caspase inhibitors include, without limitation:
The term “P2-P4 moiety of a caspase inhibitor, or portion thereof” as used herein, refers to a portion of a caspase inhibitor that is bound to an aspartic acid or aspartic acid derivative residue. For example, in the following caspase inhibitor:
the P2-P4 moiety is:
A portion of a P2-P4 moiety of a caspase inhibitor is a derivative or precursor thereof.
A derivative of a P2-P4 moiety of a caspase inhibitor is a P2-P4 moiety that has been modified in some way. As an example, for the above P2-P4 moiety, a structure such as:
may be a derivative of a P2-P4 moiety of a caspase inhibitor. A precursor of a P2-P4 moiety is a compound useful as an intermediate in the synthesis of a caspase inhibitor or P2-P4 moiety of a caspase inhibitor. Again considering the above-listed WO 97/22619 example, a compound such as:
may be a precursor of the P2-P4 moiety of the caspase inhibitor.
Portions of a P2-P4 moiety of a caspase inhibitor are specifically referred to in the art as a P2, P3, or P4 moiety or site. These Px terms are references to the amino acid sequence next to the aspartyl cleavage site of a particular caspase substrate. P1 refers to the aspartyl residue of the substrate where caspase-induced cleavage occurs in the natural substrate. In the design of new, nonpeptidic caspase inhibitors, the Px designation is often retained to show which portion of the amino acid sequence has been replaced by the non-peptidic moiety. As used herein, the term “P2-P4” moiety refers to either the amino acid sequence described above or a chemical moiety known to replace such a sequence described above or a chemical moiety known to replace such a sequence for the purpose of being a caspase substrate, and in particular an ICE substrate.
Examples of P2-P4 moieties that are non-peptidic are described in U.S. Pat. No. 5,919,790 (Allen et al.); U.S. Pat. No. 5,874,424 (Batchelor et al.); U.S. Pat. No. 5,847,135 (Bemis et al.); U.S. Pat. No. 5,843,904 (Bemis et al.); U.S. Pat. No. 5,756,466 (Bemis et al.); U.S. Pat. No. 5,716,929 (Bemis et al.); U.S. Pat. No. 5,656,627 (Bemis et al.); WO 99/36426 (Warner-Lambert); Dolle et al., J. Med. Chem., 40, 1941 (1997); WO 98/10778 (Idun); WO 98/11109 (Idun); WO 98/11129 (Idun) and WO 98/16502 (Warner Lambert), all of which are incorporated by reference.
The term “acid activating group”, as used herein, has the definition known to those skilled in the art (see, March, Advanced Organic Chemistry, 4 th Edition, John Wiley & Sons, 1992). Examples of acid activating groups include, without limitation, halogens such as F, Cl, Br, and I, mixed anhydrides, and imidazole.
The term “electronegative leaving group”, as used herein, has the definition known to those skilled in the art (see, March, Advanced Organic Chemistry, 4 th Edition, John Wiley & Sons, 1992). Examples of electronegative leaving groups include, without limitation, halogens such as F, Cl, Br, and I, aryl- and alkyl-sulfonyloxy groups, and trifluoromethanesulfonyloxy.
The term “organic solvent”, as used herein, means any suitable solvent which may be readily selected by one of skill in the art. An organic solvent may be present in any quantity needed to facilitate the desired reaction, and does not necessarily have to dissolve the substrates and/or reagents of the desired reaction. Suitable organic solvents include, without limitation, halogenated solvents, hydrocarbon solvents, ether solvents, protic solvents, and aprotic solvents. Examples of suitable solvents include, without limitation, diethyl ether, THF, 1,4-dioxane, CH 2 Cl 2 , toluene, benzene, and DMF. Examples of protic solvents include, without limitation, methanol, t-butanol, isopropanol, benzyl alcohol and water. Mixtures of solvents are also included within the scope of this invention.
The term “base”, as used herein, means any organic or inorganic base. Suitable bases may be readily selected by one of skill in the art of organic synthesis.
The term “amine protecting group”, as used herein, means a moiety that temporarily blocks an amine reactive site in a compound. Generally, this is done so that a chemical reaction can be carried out selectively at another reactive site in a multifunctional compound or to otherwise stabilize the amine. An amine protecting group is preferably selectively removable by a chemical reaction. An amine protecting groups may be a carbamate protecting group. Carbamate protecting groups include, without limitation, Boc, Cbz, methyl carbamate, ethyl carbamate, 2,2,2-trichloroethyl carbamate, adamantyl carbamate, and Alloc.
The term “alcohol protecting group”, as used herein, means a moiety that temporarily blocks an alcohol reactive site in a compound. Generally, this is done so that a chemical reaction can be carried out selectively at another reactive site in a multifunctional compound or to otherwise stabilize the alcohol. An alcohol protecting group is preferably selectively removable by a chemical reaction. An alcohol protecting group may be an ester protecting group. Ester alcohol protecting groups include, without limitation, formate, acetate, trichloroacetate, trifluoroacetate, phenylacetate, propionate, pivaloate, benzoate and substituted benzoate. An alcohol protecting group may also be a silyl protecting group. Silyl alcohol protecting groups include, without limitation, trimethylsilyl, triethylsilyl, triisopropylsilyl, t-butyldimethylsilyl, and t-butyldiphenylsilyl.
The term “oxidizing agent”, as used herein, means any reagent or set of reagents capable of bringing about an oxidation reaction. These reagents are commonly known to one of skill in the art and include, without limitation, Dess-Martin reagent, DMSO/oxalyl chloride, TPAP, SO 3 /pyridine, CrO 3 /pyridine, Jones reagent, sodium dichromate, potassium dichromate, PCC, PDC, and sodium hypochlorite.
The term “reducing agent”, as used herein, means any reagent or set of reagents capable of bringing about a reduction reaction. These reagents are commonly known to one of skill in the art and include, for example, NaBH 4 , and may be selected with consideration of other functional groups present in the compound.
Unless otherwise stated, structures that are depicted without specifying a particular chirality are meant to include all stereochemical forms of the structure; i.e., the R and S configurations for each asymmetric center. Therefore, single stereochemical isomers as well as enantiomeric and diastereomeric mixtures of such compounds are within the scope of the invention.
Unless otherwise stated, structures depicted herein are also meant to include compounds which differ only in the presence of one or more isotopically enriched atoms. For example, compounds having the present structures except for the replacement of a hydrogen by a deuterium or tritium or the replacement of a carbon by a 13 C- or 14 C-enriched carbon are within the scope of this invention.
In order that this invention be more fully understood, the following examples are set forth. These examples are for the purpose of illustration only and are not to be construed as limiting the scope of the invention in any way.
EXAMPLE 1
N-Carboxybenzyloxy-(2S,3S)-4-fluorothreonine (102)
To a stirred solution of (2S,3S)-4-fluorothreonine 101 (0.100 g, 0.82 mmol) in THF/H 2 O (1:1, 5 ml) adjusted to pH 9 using sodium carbonate was added N-carboxybenzyloxysuccinimide (0.308 g, 1.24 mmol). After stirring the solution for 18 hours at room temperature, the solvent was removed in vacuo to give a white residue. The residue was partitioned between ethyl acetate (5 ml) and water (10 ml). The organic layer was separated and aqueous layer further extracted with ethyl acetate (2×5 ml), this organic phase was discarded. The pH of the aqueous layer was adjusted to 3 using 1N HCl. The aqueous layer was extracted with ethyl acetate (4×10 ml), the combined organic layers were dried (MgSO 4 ) and the solvent removed in vacuo to afford N-carboxybenzyloxy-(2S,3S)-4-fluorothreonine 102 as a pale yellow oil (110 mg, 70% yield); 1 H (400 MHz, CDCl 3 ) 8.20 (1H, bs, OH, exchange with CH 3 OD), 6.46, 6.45 and 6.07 (1H, 3×d, J 8.9), 5.10-4.85 (2H, m, CH 2 Ph), 4.65-4.25 (4H, H-2, H-3 and 4-CH 2 ); 19 F (376 MHz, CDCl 3 ) −228.59 and −228.51 (2×dtJ 46,14 due to rotamers).
N-Carboxybenzyloxy-O-tert-butyldimethylsilyl-(2S,3S)-4-fluorothreonine (103)
To a stirred solution of N-carboxybenzyloxy-(2S,3S)-4-fluorothreonine 102 (0.060 g, 0.22 mmol) in DMF (3 ml) was added tert-butyldimethylsilyl chloride (0.073 g, 0.49 mmol) and imidazole (0.033 g, 0.49 mmol). The solution was gently heated at 80° C. for 18 hours. After allowing the solution to cool to room temperature, the solution was diluted with dichloromethane (15 ml) and washed with 1N HCl solution (3×10 ml). The organic layer was dried (MgSO 4 ) and the solvent was removed in vacuo to give a yellow oil. The residue was redissolved in a 1:1 THF/methanol solution (4 ml) and upon stirring 50% aqueous acetic acid (2 ml) was added. After stirring the solution vigorously for 4 hours the solvent was removed in vacuo to give a yellow oil. Trace amounts of acetic acid were removed by treatment of the residue in ethyl acetate (5 ml) with saturated sodium hydrogen carbonate solution (10 ml). The organic layer was dried (MgSO 4 ) and the solvent removed in vacuo to afford N-carboxybenzyloxy-O-tert-butyldimethylsilyl-(2S,3S)-4-fluorothreonine 103 as a pale yellow oil (0.073 g, 86% yield); 1 H (400 MHz, CDCl 3 ) 9.50 (1H, bs, OH, exchange with CH 3 OD), 7.60-7.20 (5H, m, Ph), 6.25, 5.75 and 5.45 (1H, 3×d, J 9.1, NH, exchange with CH 3 OD), 5.20-5.10 (2H, m, CH 2 Ph), 4.75-4.20 (4H, H-2, H-3, 4-CH 2 ), 1.00-0.80 (9H, 2×s, SiC(CH 3 ) 3 ), 0.15-0.00 (6H, m, Si(CH 3 ) 2 ); 19 F (376 MHz, CDCl 3 ) −224.82 and −225.39 (2×dtJ 47, 4 due to rotamers).
N-Carboxybenzyloxy-O-tert-butyldimethylsilyl-(2S,3S)-4-fluorothreonine diazoketone (104)
To a stirred solution of N-carboxybenzyloxy-O-tert-butyldimethylsilyl-(2S,3S)-4-fluorothreonine 103 (0.450 g, 1.17 mmol) in THF (12 ml) at 0° C. was added N-methylmorpholine (0.192 ml, 1.75 mmol) and isobutyl chloroformate (0.212 ml, 1.63 mmol). After stirring the suspension for 15 minutes, diethyl ether (20 ml) was added. The suspension was filtered and the filtrate reacted with diazomethane (4.90 mmol, prepared from Diazald) at 0° C. After allowing the solution to stand overnight, the solvent was removed in vacuo to give a pale yellow residue. Purification by column chromatograpy (3:1 petroleum ether 60-80° C./ethyl acetate) afforded N-carboxybenzyloxy-O-tert-butyldimethylsilyl-(2S,3S)-4-fluorothreonine diazoketone 104 as a pale yellow solid (0.277 g, 58% yield); Rf 0.48 (3:1 petroleum ether 60-80° C./ethyl acetate, UV light); 1 H (400 MHz, CDCl 3 ) 7.60-7.30 (5H, m, Ph), 5.85-5.65 (2H, m, CHN 2 , NH exchangeable with CH 3 OD), 5.20-5.10 (2H, m, CH 2 Ph), 4.70-4.20 (4H, H-2, H-3, 4-CH2), 0.87 (9H, s, SiC(CH 3 ) 3 ), 0.15-0.00 (6H, m, Si(CH 3 ) 2 ); 19 F (376 MHz, CDCl 3 ) −225.28 and −226.02 (2×dtJ 47,14, due to rotamers).
tert-Butyl N-(3S)-carboxybenzyloxy-O-(4S)-tert-butyldimethylsilyl-5-fluoropentanoate (105)
To a stirred solution of N-carboxybenzyloxy-O-tert-butyldimethylsilyl-(2S,3S)-4-fluorothreonine diazoketone 104 (0.277 g, 0.68 mmol) in tert-butanol (10 ml) was added a solution of silver benzoate (15 mg, 0.068 mmol) in triethylamine (0.094 ml, 0.68 mmol). After stirring for 18 hours at room temperature the suspension was filtered through Celite. The solvent of the filtrate was removed in vacuo to give a brown residue. The residue was redissolved in diethyl ether (15 ml) and washed with saturated sodium hydrogen carbonate solution (2×15 ml). The organic layer was dried (MgSO 4 ) and the solvent removed in vacuo to give a yellow oil. Purification by column chromatograpy (6:1 petroleum ether 60-80° C./ethyl acetate) gave tert-butyl N-(3S)-carboxybenzyloxy-O-(4S)-tert-butyldimethylsilyl-5-fluoropentanoate 105 as a pale yellow oil (0.166 g, 54% yield); Rf 0.59 (6:1 petroleum ether 60-80° C./ethyl acetate, ninhydrin stain); 1 H (400 MHz, CDCl 3 ) 7.50-7.30 (5H, m, Ph), 5.40-5.05 (3H, CH 2 Ph, NH), 4.55-3.95 (4H, CH 2 F, H-3, H-4), 2.50 (2H, d, J 7.2, 2-CH 2 ), 1.43 (9H, s, CO 2 (CH 3 ) 3 ), 0.91 (9H, s, SiC(CH 3 ) 3 ), 0.10 (6H, m, Si(CH 3 ) 2 ); 19 F (376 MHz, CDCl 3 ) −225.67 (dt, J 46, 16); 19 F (376 MHz, CDCl 3 , decoupled) −225.58 and −225.67 (2×s due to rotamers).
tert-Butyl O-(4S)-tert-butyldimethylsilyl-5-fluoropentanoate (106)
To a stirred suspension of 10% palladium on carbon (2 mg, 10% w/w) in ethyl acetate (2 ml) was added tert-butyl N-(3S)-carboxybenzyloxy-O-(4S)-tert-butyldimethylsilyl-5-fluoropentanoate 105 (10 mg, 0.022 mmol) in ethyl acetate (2 ml). The flask was evacuated and put under an atmosphere of hydrogen. After stirring for four hours at room temperature the suspension was filtered through Celite. The solvent of the filtrate was removed in vacuo to give tert-butyl O-(4S)-tert-butyldimethylsilyl-5-fluoropentanoate 106 as a colourless oil (7 mg, 100% yield); 1 H (400 MHz, CDCl 3 ) 4.75-4.35 (2H, m, CH 2 F), 4.32-3.85 (2H, H-3, H-4), 2.80-2.30 (2H, m, 2-CH 2 ), 1.46 (9H, s, CO 2 (CH 3 ) 3 ), 0.91 (9H, s, SiC(CH 3 ) 3 ), 0.08 (6H, m, Si(CH 3 ) 2 ); 19 F (376 MHz, CDCl 3 ) −225.84 (dt, J 48, 14); 19 F (376 MHz, CDCl 3 , decoupled) −225.84 (s).
While we have hereinbefore presented a number of embodiments of this invention, it is apparent that the basic construction can be altered to provide other embodiments which utilize the methods of this invention. Therefore, it will be appreciated that the scope of this invention is to be defined by the claims appended hereto rather than the specific embodiments which have been presented hereinbefore by way of example.
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The invention relates to novel diazoketone derivatives. The invention also relates to processes for homologation of these diazoketone derivatives. The processes are useful for preparing compounds that are caspase inhibitors.
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FIELD OF THE INVENTION
The invention relates to the field of client/server (also known as “distributed”) computing, where one computing device (“the client”) requests another computing device (“the server”) to perform part of the client's work.
BACKGROUND OF THE INVENTION
Client/server computing has become more and more important over the past few years in the information technology world. This type of distributed computing allows one machine to delegate some of its work to another machine that might be, for example, better suited to perform that work.
The benefits of client/server computing have been even further enhanced by the use of a well-known computer programming technology called object-oriented programming (OOP), which allows the client and server to be located on different (heterogeneous) “platforms”. A platform is a combination of the specific hardware/software/operating system/communication protocol which a machine uses to do its work. OOP allows the client application program and server application program to operate on their own platforms without worrying how the client application's work requests will be communicated and accepted by the server application. Likewise, the server application does not have to worry about how the OOP system will receive, translate and send the server application's processing results back to the requesting client application.
Details of how OOP techniques have been integrated with heterogeneous client/server systems are explained in U.S. Pat. No. 5,440,744 and European Patent Published Application No. EP 0 677,943 A 2. These latter two publications are hereby incorporated by reference. However, an example, of the basic architecture will be given below for contextual understanding of the invention's environment.
As shown in FIG. 1, the client computer 10 (which could, for example, be a personal computer having the IBM OS/2 operating system installed thereon) has an application program 40 running on its operating system (“IBM” and “OS/2” are trademarks of the International Business Machines corporation). The application program 40 will periodically require work to be performed on the server computer 20 and/or data to be returned from the server 20 for subsequent use by the application program 40 . The server computer 20 can be, for example, a high-powered mainframe computer running on IBM's MVS operating system (“MVS” is also a trademark of the IBM corp.). For the purposes of the present invention it is irrelevant whether the requests for communications services to be carried out by the server are instigated by user interaction with the first application program 40 , or whether the application program 40 operates independently of user interaction and makes the requests automatically during the running of the program.
When the client computer 10 wishes to make a request for the server computer 20 's services, the first application program 40 informs the first logic means 50 of the service required. It may for example do this by sending the first logic means the name of a remote procedure along with a list of input and output parameters. The first logic means 50 then handles the task of establishing the necessary communications with the second computer 20 with reference to definitions of the available communications services stored in the storage device 60 . All the possible services are defined as a cohesive framework of object classes 70 , these classes being derived from a single object class. Defining the services in this way gives rise to a great number of advantages in terms of performance and reusability.
To establish the necessary communication with the server 20 , the first logic means 50 determines which object class in the framework needs to be used, and then creates an instance of that object, a message being sent to that object so as to cause that object to invoke one of its methods. This gives rise to the establishment of the connection with the server computer 20 via the connection means 80 , and the subsequent sending of a request to the second logic means 90 .
The second logic means 90 then passes the request on to the second application program 100 (hereafter called the service application) running on the server computer 20 so that the service application 100 can perform the specific task required by that request, such as running a data retrieval procedure. Once this task has been completed the service application may need to send results back to the first computer 10 . The server application 100 interacts with the second logic means 90 during the performance of the requested tasks and when results are to be sent back to the first computer 10 . The second logic means 90 establishes instances of objects, and invokes appropriate methods of those objects, as and when required by the server application 100 , the object instances being created from the cohesive framework of object classes stored in the storage device 110 .
Using the above technique, the client application program 40 is not exposed to the communications architecture. Further the service application 100 is invoked through the standard mechanism for its environment; it does not know that it is being invoked remotely.
The Object Management Group (OMG) is an international consortium of organizations involved in various aspects of client/server computing on heterogeneous platforms as is shown in FIG. 1 . The OMG has set forth published standards by which client computers (e.g. 10 ) communicate (in OOP form) with server machines (e.g. 20 ). As part of these standards, an Object Request Broker has been defined, which provides the object-oriented bridge between the client and the server machines. The ORB decouples the client and server applications from the object oriented implementation details, performing at least part of the work of the first and second logic means 50 and 90 as well as the connection means 80 .
FIG. 2 shows a conventional architecture for such a system. Once client requests find their way through the ORB 21 and into the server, the ORB finds a particular server object capable of executing the request and sends the request to that server object's object adapter 22 (also defined by OMG standard) where it is stored in the object adapter's buffer to await processing by the server object. The server object has a plurality of parallel execution threads ( 23 a, 23 b, 23 c ) upon any of which it can run an instance of itself. In this way, the server object is able to process plural requests at the same time. The object adapter 22 looks to see which of the parallel execution threads is ready to process another request and then assigns one of the requests to the next available execution thread. This is explained in the above-mentioned U.S. Pat. as a “dispatching” mechanism whereby the server dispatches requests to execution threads.
The OMG-standard server architecture of FIG. 2 finds particular utility in the field of transaction processing. Computer implemented transaction processing systems are used for critical business tasks in a number of industries. A transaction defines a single unit of work that must either be fully completed or fully purged without action. For example, in the case of a bank automated teller machine from which a customer seeks to withdraw money, the actions of issuing the money, reducing the balance of money on hand in the machine and reducing the customer's bank balance must all occur or none of them must occur. Failure of one of the subordinate actions would lead to inconsistency between the records and the actual occurrences.
Distributed transaction processing involves a transaction that affects resources at more than one physical or logical location. In the above example, a transaction affects resources managed at the local automated teller device as well as bank balances managed by a bank's main computer. Such transactions involve one particular client computer (e.g, 10 in FIG. 1) communicating with one particular server computer (e.g., 20 ) over a series of client requests which are processed by the server.
In typical client/server systems, client and server systems are each contributing to the overall processing of such transactions. Further, many different clients may be concurrently attempting to use the same server to engage in separate transactions. For example, many different banking ATM machines (client systems) may be trying to concurrently begin transactions so as to access data from a popular database program running on the bank's large central server. In some of these situations, the server must be able to isolate these concurrent transactions so that they do not affect each other. That is, until one transaction is finished (either all parts are committed or all parts are aborted) other transactions trying to access the same server objects must be made to wait.
For example, if a husband is trying to transfer $2000 from a family's checking account into the family's higher interest paying savings account at an ATM machine at one bank on one side of town and his wife is attempting to perform the same transaction at another ATM (owned by a different bank) on the other side of town, the server must be able to deal with this situation effectively so that the two concurrent transactions do not create a problem for the bank owning the database server.
The way this problem is typically solved is for the server database program to perform transactional locking on concurrent accesses. That is, the database management system (DBMS) of the server would lock access to the family's account data stored in the database once a first client (e.g. the husband's ATM) requests access. Then, the husband's transaction would continue in isolation despite the fact that the wife's transaction has been requested concurrently. The wife's client ATM would not be granted access to the data because the husband's client ATM would already have a lock on the data.
Placing the concurrency control responsibility in the server application (i.e. in the DBMS) has worked fine for database servers as discussed above which already have the complex locking techniques integrated into their management system software. However, if other types of applications are to be used, the above system requires that the server application programmer include the complex locking schemes into his/her program while writing the object-oriented program. Also, the programmer must have an in-depth knowledge of transaction theory in order to be able to create the appropriate transaction context into the concurrency control aspects of the program.
To overcome this problem, the International Business Machines Corporation (IBM) has filed a patent application (UK Patent Application No. 9701566.3) on Jan. 25 1997, which discloses a method whereby transactional locking is performed within the ORB ( 21 of FIG. 2 ). That is, as each client request comes through the ORB 21 on the way to the object adapter 22 , the method determines whether a lock on server resources is necessary and obtains such a lock if the locks will not conflict with currently held locks. If a conflict exists, the incoming request must wait until the currently held conflicting lock (from a previous request) is released.
In both of these prior approaches, however, it is necessary to obtain locks on server resources in order to carry out concurrency control. The processing steps involved in obtaining such locks are as follows. First, an incoming request is dispatched to an available thread and thus an instance of the server object is instantiated. Second, local storage for this particular instance of the server object is obtained for this thread. Third, the program and data associated with the server object is loaded into the storage. Fourth, the relevant file is accessed for execution. Finally, after all of the above four steps are carried out, a lock is obtained on the server object to ensure that subsequent requests will not be allowed to conflict with this request's access to the server object's resources. For the next dispatched request, the first four steps are carried out and if this request requires access to a locked resource, the request must wait until the lock on the server object from the first request has been released.
The use of locks to perform concurrency control often results in an inefficient use of central processor unit (cpu) resources, especially as the number of concurrent requests increases. For example, assume that 2000 users are all sharing the same exchange rate object and that 1999 of them are clients that would like to obtain the most recent value of a popular exchange rate (e.g., from United States dollars to United Kingdom pounds sterling) and one user is requesting to update the value of the exchange rate. The use of locks results in 2000 threads being used and 2000 local storage areas being allocated. A very large number of cpu processing cycles is required in dispatching this many requests onto threads, obtaining this many storage areas, loading the large number of programs and accessing the large number of files. Thus, a great need exists in this art for a more efficient way to dispatch client requests.
SUMMARY OF THE INVENTION
According to one aspect, the present invention provides an apparatus for dispatching client requests for execution by a server object in a heterogeneous object-oriented client/server computing environment, the apparatus has: a request-holding buffer having an input connected to a communications channel which channels the client requests to the apparatus, and an output; a plurality of parallel execution threads connected to the output of the buffer; and a semantic concurrency control means for examining the semantics of a request in the buffer and the semantics of each request presently being executed on any of the plurality of parallel execution threads, and for delaying the request from being dispatched from the buffer to an execution thread if the examined semantics of the requests indicate that such dispatch would cause conflicting access to the server object's resources.
Preferably, the buffer is included within an object adapter. Further preferably, the communications channel includes an object request broker. Further preferably, the semantic concurrency control means also takes into account the state of the server object in making a determination as to whether the dispatch of a request in the buffer would conflict with a request that has already been dispatched to a thread.
According to a second aspect, the present invention provides a method of dispatching client requests for execution by a server object in a heterogeneous object-oriented client/server computing environment, having the steps of: examining the semantics of a request in a request-holding buffer having an input connected to a communications channel which channels the client requests to the apparatus, and an output; examining the semantics of each request presently being executed on any of a plurality of parallel execution threads connected to the output of the buffer; and delaying the request from being dispatched from the buffer to an execution thread if the examined semantics of the requests indicate that such dispatch would cause conflicting access to the server object's resources.
According to a third aspect, the present invention provides a computer program product for, when run on a computer, carrying out the method of the second aspect of the invention.
Thus, with the present invention, as there is no need to obtain locks on the server object resources, concurrency control of a server object with respect to client requests received at the server can be carried out in a highly efficient manner, with a very large savings in cpu processing cycles. Specifically, when locks are obtained, all requests in the buffer are dispatched to threads, storage is allocated for each dispatched request and other associated processing takes place for each dispatched request. However, with the present invention, a request is not dispatched from the buffer (and no storage is allocated for the request) until it is determined that the request will not involve a conflicting access to the server object resource with respect to other requests that are presently executing on a thread.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-described invention will be better understood by reference to the detailed description of a preferred embodiment presented below, in conjunction with the following drawing figures:
FIG. 1 is a block diagram of a well-known heterogeneous client/server architecture using object technology, in the context of which the present invention can be applied;
FIG. 2 is a block diagram of a server architecture according to a conventional design;
FIG. 3 is a block diagram of a server architecture according to a preferred embodiment of the present invention; and
FIG. 4 is a flow chart showing the processing steps involved according to a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the preferred embodiment of FIG. 3, requests received at the server process from client processes are first received by the server's ORB 31 . ORB 31 then passes on requests destined to a particular server object to that server object's object adapter 32 . This server object has a number of parallel execution threads 33 a, 33 b and 33 c where different instances of the server object can be running in parallel, in order to execute a large number of client requests. This is all analogous to the prior art of FIG. 2 that was described above.
An extra software unit is added to the prior art of FIG. 2, according to the present invention's preferred embodiment of FIG. 3 . This extra unit is a concurrency control unit 34 which receives an input from the object adapter 32 and from each of the execution threads 33 a to 33 c and provides an output to the object adapter 32 . The concurrency control unit 34 performs the function of making sure that a client request in the object adapter 32 is not dispatched to an execution thread if doing so would result in conflicting access to the server object's resources.
In the example that will be described hereinbelow to illustrate the operation of this preferred embodiment, the server object will represent a bank account. Thus, the various requests that will be discussed are requests to access a particular bank account. One request is from a client ATM (automated teller machine) to withdraw funds from this account. This request is from the person owning the account who wishes to withdraw some funds. A second request is from an official of the bank who is requesting to find out the amount of overdraft that is associated with the bank account (perhaps the account balance is getting close to zero and the bank official is concerned that the account will go into the red). A third request is from another client ATM to check the balance of the account. This request is from the account owner's wife, who is on the other side of town from the owner at another client ATM machine.
The concurrency control unit 34 takes an input from the request at the top of the buffer in object adapter 32 (the request that is next in line to be dispatched to an execution thread 33 a, 33 b or 33 c ) in order to determine the semantics of this request. That is, the concurrency control unit 34 determines whether this request is requesting read access to the bank account object, write access to the bank account object, or neither read nor write access to the bank account object.
The concurrency control unit 34 also takes inputs from each of the execution threads 33 a, 33 b and 33 c in order to determine the semantics of the requests that are currently being executed on the threads. That is, the concurrency control unit 34 determines whether each request being executed on a thread involves read access to the bank account object, write access to the bank account object, or neither read nor write access to the bank account object.
The concurrency control unit 34 then compares the semantics of the request at the top of the object adapter ( 32 ) buffer to the semantics of each of the requests being presently executed on each of the execution threads ( 33 a, 33 b, 33 c ). The concurrency control unit 34 only allows the top request to be dispatched from the buffer to an available thread if the dispatching of this request would not result in a conflicting access to the server object resource.
For example, if the top request in the buffer is the wife's request to check the balance of the bank account, the concurrency control unit 34 checks the semantics of this request and determines that this is a read request. The request is seeking only to read the balance of the bank account (not to change the value of anything in the database associated with the account). Now, if the only request executing on any of the execution threads (say, thread 33 a ) is the request of the bank official to check the prearranged overdraft on the account, the concurrency control unit 34 checks the semantics of this request and again determines that it is a read request (no stored values need be altered to simply obtain the overdraft value and return it to the official). Since these two requests are both read requests, the concurrency control unit 34 dispatches the top request in the object adapter 32 to one of the other threads (say, thread 33 b ).
If, however, the account owner's request to withdraw money is presently being executed on thread 33 a, and the top request in object adapter 32 is the account owner's wife's request to check the balance of this account, a different result is achieved. Because the semantics of the presently executing request on thread 33 a indicate that this is a write request (as it will result in lowering the balance of the bank account), the top request in the object adapter buffer (which is seeking to read the same value) is not dispatched to a thread but is instead made to wait until the request executing on thread 33 a is finished.
The steps carried out by the preferred embodiment of the present invention are illustrated in the flowchart of FIG. 4 .
At step 41 , the concurrency control unit 34 examines the semantics of the top request sitting in the buffer of the object adapter 32 (this is the request which is next to be dispatched from the buffer). That is, the unit 34 determines whether this request is requesting read or write access to the server object resource.
At step 42 , the unit 34 examines the semantics of the requests presently executing on each of the execution threads 33 a, 33 b and 33 c. That is, the unit 34 determines whether each of these requests is performing read or write access to the server object resource.
At step 43 , the unit 34 uses the information that it has gathered from steps 41 and 42 in order to determine whether the top request can be dispatched (step 44 ) to one of the available execution threads, or whether it should be made to wait (step 45 ) until the execution of at least one of the presently executing requests has finished accessing the server object resource. The way this is done is that if a read request is awaiting dispatch at the top of the buffer and all of the presently executing requests are also read requests, then the read request can be dispatched to an available thread for concurrent execution, as there is no conflict between concurrent read operations on the same server object resource. However, there is a conflict when a write operation is concurrently executing along with another write operation or with a read operation. Thus, the unit 34 would delay the dispatch of the top request in the object adapter 32 if this latter situation would exist upon dispatch.
Depending on the nature of the server object, the concurrency control unit 34 can also consider the present state of the server object in making a decision as to whether to allow a request to be dispatched. For example, assume that the server object is a queue with each element of the queue being separately addressable for read/write purposes. One request from a first transaction is requesting to read the element at the front of the queue and this request has already been dispatched to an execution thread. Now, a second request (that is awaiting dispatch) that is requesting to write to the last element of the queue can be concurrently dispatched to the same server object, even though this second request is requesting write access to the same server object that the first request has already been granted read access to (provided that the queue is non-empty). This is because the second request, albeit a write request, is not conflicting with the first request (which is a read request). Since the server object is made up of plural elements, each of these elements can be accessed separately by different requests without conflicting with each other.
Also, the concurrency control unit 34 does not need to always consider only the top request in the buffer as the next candidate for dispatch. The unit 34 can examine all of the requests in the buffer and take them out of order for dispatch.
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An apparatus for dispatching client requests for execution by a server object in a heterogeneous object-oriented client/server computing environment, the apparatus has: a request-holding buffer having an input connected to a communications channel which channels the client requests to the apparatus, and an output; a plurality of parallel execution threads connected to the output of the buffer; and a semantic concurrency control means for examining the semantics of a request in the buffer and the semantics of each request presently being executed on any of the plurality of parallel execution threads, and for delaying the request from being dispatched from the buffer to an execution thread if the examined semantics of the requests indicate that such dispatch would cause conflicting access to the server object's resources.
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BACKGROUND OF THE INVENTION
[0001] An optical fiber is not an ideal medium for transferring optical signals. The range and signal quality are limited by various optical effects; particularly, when transferring data with high bit rates. Wavelength-dependent attenuation can be compensated for by appropriate amplifiers. Other effects, such as delay/group dispersion, self-phase modulation and polarization mode dispersion have a particularly disruptive effect on the transfer of impulses, as they distort these significantly.
[0002] Special fibers are used to compensate for delay dispersion, the delay characteristics of which are inverted with respect to the transfer fibers. The use of Bragg filters for dispersion compensation dispersion is also known from “Fiber Optic Communication Systems”, 2 nd Edition, G. P. Agrawal, page 444. The use of a transverse filter, which allows simultaneous dispersion compensation with a number of wavelengths (WDM system) in a periodic filter pattern based on the channel interval is known from patent application EP 0 740 173 A2. Automatic filter optimization systems are already known.
[0003] Various methods and control arrangements for PMD compensation are known from OFC 2000 Pepa ThH1, pages 110 to 112 “PMD mitigation techniques and effectiveness in installed fibre” by H. Bühlow.
[0004] A method for PMD compensation via a first order optical compensator is compared with an adjustable electrical transverse filter in “Optics Communications”, Vol. 182, No. 1-3, pp. 135-141.
[0005] An adjustable electrical transverse filter, which is used for PMD and delay dispersion compensation is described in ECOC'99 Vol. 2, pp. 138-139, H. Bühlow et al.
[0006] A common feature of the known method and arrangements is the fact that they only allow inadequate compensation for high data rates from 40 GBit/s.
[0007] An object of the present invention is to specify a universally deployable arrangement, which is relatively simple to construct and which can be used to compensate for the major distortions caused by optical transfer.
SUMMARY OF THE INVENTION
[0008] Accordingly, in an embodiment of the present invention, a system is provided for compensating for distortions in optical signals, wherein the system includes a series circuit having a controllable polarization-dependent delay element and a controllable optical filter for signal distortion correction, and a control device for assessing quality of a corrected optical signal or a demodulated electrical signal and for transmitting control signals to the delay element and the optical filter.
[0009] In an embodiment, the series circuit further includes a number of delay elements and optical filters connected in series.
[0010] In an embodiment, the system includes a number of the series circuits.
[0011] In an embodiment, the series circuit includes a further non-adjustable optical filter for signal distortion correction.
[0012] In an embodiment, the polarization-dependent delay element contains a delay element with a fixed delay.
[0013] In an embodiment, the series circuit further includes a dispersion compensation element.
[0014] In an embodiment, both the delay element and the optical filter are controlled separately.
[0015] In an embodiment, the optical filter is an FIR filter.
[0016] In an embodiment, the system further includes an optical electronic converter and an electrical filter connected downstream from the series circuit for electronic signal optimization.
[0017] In an embodiment, the optical filter is periodic based on a channel interval of a WDM signal.
[0018] A major advantage of the system of the present invention is the purely optical design. The demodulating and squaring effect of a photodiode causes conversion to electrical signals to produce a data loss (carrier, phase), which restricts the compensation options. The optical components used are uncomplicated and relatively simple to activate. It is particularly suited to adaptive PMD control. As the parameters of the arrangement are automatically adjusted, irrespective of the physical cause, so that optimum reception is achieved, optimum reception quality is always achieved even when a number of effects occur simultaneously; for example, PMD, self-phase modulation and delay dispersion.
[0019] Multiplying the arrangement makes it possible to largely compensate for higher order non-linear distortions, such as third order PMD, as well. In addition to the distortions caused by the characteristics of the transfer fiber, distortions caused by transmitter or receiver devices also can be compensated for (to some extent).
[0020] The system according to the present invention advantageously can be used with permanent or permanently adjustable compensation devices, which produce basic compensation.
[0021] Additional features and advantages of the present invention are described in, and will be apparent from, the following Detailed Description of the Invention and the Figures.
BRIEF DESCRIPTION OF THE FIGURES
[0022] [0022]FIG. 1 shows a basic circuit diagram of the system according to the present invention.
[0023] [0023]FIG. 2 shows an extended system for compensating for higher order distortions.
DETAILED DESCRIPTION OF THE INVENTION
[0024] [0024]FIG. 1 shows the series connection of a polarization-dependent adjustable time element APD and of an adjustable optical filter AOF as the major distortion correction element. A controlled polarization regulator (not shown) is used to achieve constant polarization. A distorted optical signal OSD is fed to the polarization-dependent delay element APD. This contains a splitter SPL for dividing into signal components assigned to two orthogonal polarization levels, which are supplied via two routes with adjustable delay elements T 1 , T 2 , which determine the different spread speeds of the optical wave in both polarization levels (an adjustable and a permanent delay element also can be used). The signal components are combined again by a combiner (coupler) COM. The adjustable optical filter AOF is, for example, in the form of an analog transverse filter, the complex coefficients C 1 , C 2 , C 3 , . . . of which are adjustable. However, all known filter structures or a combination of a transverse filter (FIR filter) and a feedback filter (IIR filter) can be used.
[0025] A test signal MOSI derived from the compensated output signal OSI by a splitter SPM is fed to a control device CON, which checks the signal quality of the corrected optical signal OSI. For this, the optical signal is at present first converted to an electrical signal (demodulated), which also can be derived from the optoelectrical converter of the receiver. The delay elements T 1 and T 2 are adjusted via a first control signal ST 1 , and the filter coefficients by a second control signal T 2 .
[0026] Control of the delay element and filter can be serial in time, with a number of iteration stages possibly required to achieve an optimally corrected signal OSI. This is expedient if the optical diagrams are assessed. Control, however, also may be simultaneous for the delay element and the filter; for example, via analysis of the spectrum of the corrected signal.
[0027] The polarization-dependent delay element may, in principle, be designed in any way. At present, double refracting materials, such as lithium niobate (LINbO3), seem particularly advantageous. The polarization-dependent delay element may be first or higher order. Also, a number of delay elements or optical filters or compensation modules can be connected in series according to FIG. 1.
[0028] [0028]FIG. 2 shows the basic circuit diagram of a series circuit of optical compensation modules APD/ADF1 to APD/ADFN, each of which contains a series circuit of an adjustable time element APD and an adjustable filter OAF. This system can be used to compensate for higher order distortions. A number of polarization-dependent delay elements and a number of filters also can be connected in series.
[0029] While in high bit rate optical arrangements the PDM is compensated for on a channel basis, delay dispersion and self-phase modulation can be compensated for by designing the optical filter in WDM arrangements so that it is periodic, based on the channel interval. PMD compensation only takes place on a channel basis after distribution of the WDM signal to individual channels.
[0030] The series circuit also may contain non-adjustable or permanently adjustable elements, such as a dispersion compensation element DCF, generally a dispersion compensation fiber, a dispersion compensation filter element FID with fixed coefficients (also a number of permanently adjusted filters), which already produce basic compensation. Also an optoelectrical converter OEC can be used to connect an electrical filter EFI downstream from the series circuit described above for residual compensation purposes. This also can be controlled adaptively.
[0031] Although the present invention has been described with reference to specific embodiments, those of skill in the art will recognize that changes may be made thereto without departing from the spirit and scope of the present invention as set forth in the hereafter appended claims.
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A system for compensating for distortions in optical signals, wherein the series connection of a controllable polarization-dependent delay element and of a controllable filter allows good signal distortion correction; for example, due to group delay dispersion or polarization mode dispersion. The series circuit also may contain further devices for signal improvement.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to U.S. Provisional Application No. 61/539,314, filed Sep. 26, 2011, the disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] Embodiments of the invention relate to the field of photovoltaic power generation systems, and more particularly to methods and systems used to test and/or condition photovoltaic modules during manufacture.
BACKGROUND OF THE INVENTION
[0003] Photovoltaic (PV) modules convert solar radiation to electrical current using the photovoltaic effect. During manufacturing of the modules, minor variations in process parameters may result in modules having dissimilar performance characteristics. Dissimilar performance characteristics are undesirable because the design and performance of a photovoltaic array may rely on each module performing according to product specifications. Therefore, it is desirable to manufacture modules that exhibit similar performance characteristics when installed in the field. Moreover, it is desirable to manufacture modules that maintain similar performance characteristics over the life expectancies of the modules. An efficient way to test and/or condition manufactured modules is desired.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a perspective view of a PV module according to an exemplary embodiment.
[0005] FIG. 2 is a perspective view of a partially assembled PV module according to an exemplary embodiment.
[0006] FIG. 3 a is a diagram of a PV module testing and conditioning system according to an exemplary embodiment.
[0007] FIG. 3 b is a cross-sectional top view of the diagram of FIG. 3 a according to an exemplary embodiment.
[0008] FIG. 3 c is a side view of the PV module testing and conditioning system of FIG. 3 a according to an exemplary embodiment.
[0009] FIG. 4 is a side view of a portion of the PV module testing and conditioning system of FIG. 3 a according to an exemplary embodiment.
[0010] FIG. 5 is a method for testing and conditioning PV modules according to an exemplary embodiment.
[0011] FIG. 6 is a diagram of a PV module testing and conditioning system according to an exemplary embodiment.
[0012] FIG. 7 is a diagram of a PV module testing and conditioning system according to an exemplary embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0013] In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments that provide a system for inline testing and conditioning of PV modules while they are manufactured. These embodiments are described in sufficient detail to enable those skilled in the art to make and use them, and it is to be understood that structural, logical, or procedural changes may be made to the specific embodiments disclosed without departing from the spirit and scope of the invention.
[0014] FIG. 1 illustrates a bottom perspective view of a PV module 100 according to an exemplary embodiment. The PV module 100 may have any suitable geometry. For example, the PV module 100 may have a width of about 60 cm, a length of about 120 cm, a thickness ranging from 5 to 8 mm, and a weight of about 12 kg. The PV module 100 includes a plurality of layers between front and back covers that form a plurality of interconnected PV cells that generate electrical current from solar radiation.
[0015] The PV cells within the PV module 100 are electrically connected to a cord plate 110 attached to a back cover 120 of the PV module 100 . The cord plate allows external connections 112 and 114 to be connected to internal conductors of PV module 100 . As illustrated in FIG. 2 , during manufacturing of the PV module 100 , positive and negative lead foils 232 and 234 , which are electrically connected to the PV cells, are brought out of the PV module 100 through a hole 230 in the back cover 120 . The positive and negative lead foils 232 and 234 are brought out near the front edge 280 of the PV module 100 . In a subsequent step in the manufacturing process, the cord plate 110 is attached to the back cover 120 and external conductors are electrically connected to the positive and negative lead foils 232 and 234 within the cord plate 110 . Positive and negative lead foils 232 and 234 may be formed of any suitable material such as, gold, silver, copper, aluminum, or other conductive metals. In one embodiment, the positive and negative lead foils 232 and 234 may be formed of conductive tape.
[0016] FIG. 3 a illustrates a diagram of a testing and conditioning system (TCS) 300 according to an exemplary embodiment. The TCS 300 includes an enclosure 302 , a conveyor 310 , a testing and conditioning unit (TCU) 318 , and a system controller 330 .
[0017] The enclosure 302 has a box shape and includes a bottom 303 , a top 304 , a first opening 306 on one side and second opening 308 on an opposite side. The first and second openings 306 and 308 are large enough to allow the conveyor 310 and the PV module 100 atop the conveyor 310 to pass there through. The enclosure 302 is designed to limit access to the PV module 100 and other parts of the TCS 300 to prevent an operator or other object from conducting current applied to the PV module 100 during testing and/or conditioning. As illustrated in FIG. 3 c the enclosure 302 further includes first and second access doors 307 and 309 that are used to access the interior of enclosure 302 for maintenance. The access doors 307 and 309 allow an operator to remove broken modules or to repair components within the enclosure 302 . Additionally, the enclosure 302 may include solenoid-locking safety switches 390 to secure the access doors 307 and 309 and thereby secure the enclosure 302 during testing. The enclosure 302 may also contain a perimeter sensor that detects whether the access doors 307 and 309 are secure. The enclosure 302 is connected to and communicates with the control panel 335 through communication cable 352 , which in turn communicates with the system controller 330 through communication cable 350 . The enclosure 302 may provide information regarding the status of the enclosure 302 to the system controller 330 via the control panel 335 , such as, whether the perimeter of the enclosure 302 is secured.
[0018] The conveyor 310 passes through the enclosure 302 and through the first and second openings 306 and 308 in the direction of arrow 316 and supports a PV module 100 . The PV module 100 is positioned on the conveyor 310 with the leading edge 382 of the PV module 100 facing the opening 308 . Furthermore, the PV module 100 is positioned on the conveyor 310 with the PV module's 100 positive and negative lead foils 232 and 234 facing the top 304 of the enclosure 302 and the PV module's 100 front edge 280 facing into the page. A scanner 314 may be positioned outside the enclosure 302 and below the conveyor 310 to read an ID of the PV module 100 as it is brought into the enclosure 302 . The PV module 100 ID may be a bar code or any other computer readable identification system.
[0019] The movement of the conveyor 310 is, controlled by a conveyor controller 312 . The conveyor controller 312 operates the conveyor 310 to bring the PV module 100 into the enclosure 302 and align the PV module 100 with the TCU 318 . A presence sensor 366 located beneath the conveyor 310 and connected to the conveyor controller 312 is used to determine when the PV module 100 is aligned with the TCU 318 . The conveyor controller 312 also is connected to and communicates with the control panel 335 through communication cable 353 . The conveyor controller 312 sends status information to and receives commands from the system controller 330 via the control panel 335 .
[0020] The TCU 318 includes a contact unit 320 and a power unit 340 . The contact unit 320 has contact pads 324 and 325 that respectively contact the lead foils 232 and 234 of the PV module 100 during testing and conditioning of the PV module 100 . The power unit 340 provides an electrical bias to the PV module 100 and measure voltage and current on the PV module 100 during testing and/or conditioning of the PV module 100 . The electrical bias may be constant voltage, constant current, variable voltage, variable current, pulses of constant current, pulses of constant voltage, alternating constant or variable current and constant or variable voltage, or any combination thereof. In one embodiment, a relay may also be utilized with the power unit 340 to provide electrical bias to the PV module 100 .
[0021] The contact unit 320 is positioned within the enclosure 302 between the conveyor 310 and the top 304 of the enclosure 302 . The contact unit 320 includes a plunger switch 322 , first and second contact pads 324 and 325 (as illustrated in FIG. 3 b ), and an edge sensor 326 . The plunger switch 322 is used to sense the presence of a module 100 below contact unit 320 while the edge sensor 326 is used to align the contact pads 324 and 325 over the positive and negative lead foils 232 and 234 respectively of the PV module 100 in a direction perpendicular to the direction of PV module 100 conveyance during testing and conditioning of the PV module 100 . The plunger switch 322 , edge sensor 326 , and first and second contact pads 324 and 325 are further illustrated and described with respect to FIG. 4 . A control panel 335 is provided to operate and control the contact unit 320 . The control panel 335 is also connected to and communicates with system controller 330 through communication cable 350 . The control panel 335 may also connect to the power unit 340 via communication cable 351 , contact unit 320 via communication cable 352 , and the sensors (e.g. 360 and 366 ), scanner 314 , and conveyor controller 312 via communication cable 353 . The contact unit 320 sends status information to the control panel 335 , and ultimately the system controller 330 and receives commands from the system controller 330 via the control panel 335 .
[0022] FIG. 3 b illustrates a top view of the diagram of FIG. 3 a according to an exemplary embodiment with the contact unit 320 in a home position. The contact unit 320 resides in the home position during periods when the PV module 100 is not being conditioned or tested. In the home position, the portion of the contact unit 320 positioned closest to the conveyor 310 is maintained at least 2.5 inches from the conveyor 310 . This clearance distance prevents the contact unit 320 from scratching or otherwise damaging the PV module 100 when it is brought in and out of the enclosure 302 . When a PV module 100 is brought into the enclosure 302 , the conveyor 310 positions the PV module 100 so that the contact unit 320 is centered between the leading and trailing edges 382 and 384 of the PV module 100 . Centering the contact unit 320 between the leading and trailing edges 382 and 384 of the PV module 100 aligns the contact pads 324 and 325 with the lead foils 232 and 234 in the direction of PV module 100 conveyance. As mentioned above, the edge sensor 326 is then used to center the contact pads 324 and 325 and align them with the lead foils 232 and 234 .
[0023] Referring again to FIG. 3 a , the power unit 340 is located outside of the enclosure 302 and is connected to the contact unit 320 by positive and negative wires 344 and 346 . In another embodiment, the power unit 340 may be contained within the enclosure 302 . The power unit 340 supplies current and voltage to the PV module 100 by way of the contact unit 320 and positive and negative wires 344 and 346 . More particularly, the power unit 340 supplies current and voltage to the positive and negative lead foils 232 and 234 of the PV module 100 by way of the contact pads 324 and 325 of the contact unit 320 . When the power unit 340 is enabled by the controller 330 , current flows between the power unit 340 and the PV module 100 . When the power unit 340 is disabled by the controller 330 , current stops flowing from the power unit 340 .
[0024] The power unit 340 may operate in a constant current mode with a current set point ranging between 0 to 11.0 amps with an accuracy of +/−0.15 amps. The power unit 340 may also supply an adjustable voltage that ranges between 0 and 300 volts. In total, the power unit 340 may provide up to 3300 watts of power to the PV module 100 . In another embodiment, the power unit 340 may also operate in a varying current mode with a current set point ranging between 0 to 11.0 amps with an accuracy of +/−0.15 amps and a voltage ranging between 0 and 300 volts. Furthermore, in another embodiment, the power unit 340 may operate in a mixed mode and provide varying levels of current and voltage.
[0025] The power unit 340 further includes voltage sensor 347 and current sensor 348 used to measure the voltage and current within the PV module 100 during testing and/or conditioning of the PV module 100 . For example, in a testing mode, the power unit 340 may measure the voltage and/or current generated by the PV module 100 when the PV module 100 is exposed to light. In a conditioning mode, the electrical bias provided by the contact unit 320 to the PV module 100 during a conditioning event may be monitored by the voltage and current sensors 347 and 348 . Using voltage sensor 347 , the power unit 340 measures the voltage between the positive and negative lead foils 232 and 234 of the PV module 100 . In another embodiment, the power unit 340 uses the voltage sensor 347 to measure the voltage on a voltage divider that corresponds to the voltage between the positive and negative lead foils 232 and 234 . Using the current sensor, the power unit 340 measures the actual current flow within the PV module 100 .
[0026] The power unit 340 is connected to and communicates with the control panel 335 through communication cable 351 . The power unit 340 receives commands from the system controller 330 via the control panel 335 and the power unit 340 sends data, such as voltage and/or current measurements, and status information to the system controller 330 via the control panel 335 .
[0027] The TCS 300 may further include first and second temperature sensors 360 and 362 (as illustrated in FIG. 4 ) within the enclosure 302 . The temperature sensors 360 and 362 are positioned above the conveyor 310 and are centered between the leading and trailing edges 382 and 384 of the PV module 100 . For example, as illustrated in FIG. 4 , the first temperature sensor 360 is positioned one-quarter of the length 464 of the PV module 100 from the front edge 280 of the PV module 100 and the second temperature sensor 362 is positioned three-quarters of the length 464 of the PV module 100 from the front edge 280 . The first and second temperature sensors 360 and 362 are used to measure the temperature of the PV module 100 before, during, and after testing. In one embodiment, the temperature sensors 360 and 362 may be non-contact pyrometers. In another embodiment, the temperature sensors 360 and 362 may be contact sensors that move into and out of contact with the PV module 100 . The temperature sensors 360 and 362 are connected to and communicate with system controller 330 via the control panel 335 to send the temperature readings of the PV module 100 .
[0028] As illustrated in FIG. 3 a , the system controller 330 is connected to and communicates with various components in the TCS 300 through communication cable 350 and the control panel 335 according to one embodiment. In another embodiment, the system controller 330 may communicate with components in the TCS 300 using a wireless network, Bluetooth, or other means of communication. In yet another embodiment, the system controller 330 may communicate with some of the components in the TCS 300 using a wired connection and other of the components using a wireless connection.
[0029] The system controller 330 controls the operation of the TCS 300 , executes self-diagnostics, and may interface with a plant-wide communications network. In particular, the system controller 330 may support the TCS's 300 operational functions, diagnostic systems, process parameters, status reporting, program download functions, and program upload functions. To allow for self-diagnostics, the system controller 330 may include diagnostic software to allow for trouble shooting causes of process alarms. For example, the software may store alarm histories that include event details such as the type of alarm, the time stamp of the alarm, and the time stamp of the TCS 300 reset following the alarm. The diagnostic software may also allow for viewing and trouble shooting of machine functions through the network connection.
[0030] The data that is received by the system controller 330 from the TCS 300 may be collected, displayed, transmitted, and stored. For example, data concerning the PV module 100 , including testing and conditioning data, may be displayed on a console 398 to an operator. The data may also be transmitted and stored in a database 396 . The data may be transmitted to the database 396 by way of a network server. For example, in one embodiment, the server may be an OPC server and the database 396 may be an SQL database. Furthermore, the data may be stored in a process table within the database 396 . Within the table, an entry may be created for each PV module 100 that is processed by the TCS 300 . For example, module ID, electrical current set point, actual electrical current, start time stamp, end time stamp, start voltage, end voltage, start temperature, end temperature, and equipment status may be stored for each PV module 100 .
[0031] The data may be collected and continuously uploaded to the database 396 in real-time. Alternately, the data may be collected and stored locally within the system controller 330 and periodically uploaded to the database 396 . In one example, data may be uploaded at the end of each testing and/or conditioning cycle. The uploaded data may include raw data collected from the sensors. Alternately, the uploaded data may also include data processed by the system controller 330 . As described above, data may be uploaded from the system controller 330 to the database 396 . Data may also be downloaded from the database 396 to the system controller 330 . In one embodiment, the system controller 330 is a programmable logic controller. In another embodiment, the system controller 330 is a computer.
[0032] FIG. 4 illustrates a detailed front view of the contact unit 320 and the PV module 100 within the TCS 300 according to an exemplary embodiment. As illustrated in FIG. 4 , the contact unit 320 is mounted on horizontal rails 470 and a vertical rail 472 to allow the contact unit 320 to move laterally and vertically.
[0033] The contact unit 320 , as illustrated in FIG. 4 , is in an aligned position above the PV module 100 . To begin testing and/or conditioning of the PV module 100 , the contact unit 320 moves from the home position, into the aligned position, and then into contact with the PV module 100 . Specifically, the first and second contact pads 324 and 325 are moved into electrical contact with the positive and negative lead foils 232 and 234 of the PV module 100 .
[0034] To place the contact unit 320 into contact with the PV module 100 from the home position, the contact unit 320 first moves laterally, i.e. parallel to the back cover 120 of the PV module 100 , in the direction of arrow 490 along the horizontal rails 470 to the aligned position. The contact unit 320 moves laterally until either the edge sensor 326 detects the front edge 280 of the PV module 100 or the contact unit 320 reaches an end position along the horizontal rails 470 . If the end position along the horizontal rails 470 is reached, as determined by a horizontal position sensor 494 , the contact unit 320 returns to the home position and indicates to the system controller 330 that it was unable to detect the edge of the PV module 100 . If the edge sensor 326 detects the front edge 280 , the contact unit 320 stops moving laterally and commences to descend toward the PV module 100 along the vertical rail 472 . In one embodiment, the edge sensor 326 may be a photo eye sensor capable of identifying the location of the front edge 280 of the PV module 100 with an accuracy of 3 mm. In another embodiment, the edge sensor 326 may be another type of sensor.
[0035] The contact unit 320 descends toward the PV module 100 until the contact unit 320 reaches an end position along the vertical rail 472 as determined by a vertical position sensor 496 , such as a Hall Effect sensor. With the contact unit 320 at an end position along the vertical rail 472 , the first and second contact pads 324 and 325 are in contact with the positive and negative lead foils 232 and 234 respectively. The system uses the plunger 322 to verify that the contact unit 320 is on the PV module 100 and infers that first and second contact pads 324 and 325 are in contact with the positive and negative lead foils 232 and 234 respectively. The plunger 322 extends lower than the first and second contact pads 324 and 325 by a known distance 492 and is fixed to the contact unit 320 by a plunger spring 423 . As the contact unit 320 descends toward the PV module 100 , the plunger 322 contacts the PV module 100 before the first and second contact pads 324 and 325 contact the positive and negative lead foils 232 and 234 . As the contact unit 320 continues to descend with the plunger 322 in contact with the module 100 , the plunger spring 322 is compressed. A proximity switch sensor 498 detects the compression of the plunger spring 322 , which indicates that the contact unit 320 contacted the module 100 . The contact unit 320 then indicates to the system controller 330 that contact has been made.
[0036] In another embodiment, the contact unit 320 may use sensors to determine the vertical distance between the PV module 100 and the contact pads 324 and 325 and place the contact pads 324 and 325 into contact with the PV module 100 . Various devices may be used to move the contact unit 320 along the horizontal rails 470 and the vertical rail 472 . For example, in one embodiment, air cylinders may be used to move the contact unit 320 . In another embodiment, servos, an electric motor, or a hydraulic system may be used. Furthermore, different mechanics may be used to move the contact unit 320 horizontal and vertically. For example, air cylinders may move the contact unit 320 vertically, while an electric motor may move the contact unit 320 horizontally. In any event, the placement and design of the contact unit 320 should be controlled to limit the pressure applied by the contact unit 320 to the PV module 100 . For example, in one embodiment, the pressure applied by the contact unit 320 to the PV module 100 should be limited to 25 lbs of force over a 6 square inch area.
[0037] FIG. 5 illustrates a method 500 implemented by the TCS 300 to test and/or condition the PV module 100 inline during manufacture of the PV module 100 according to an exemplary embodiment. To begin, in step 505 , the system controller 330 waits to receive confirmation from the enclosure 302 that the doors 307 and 309 are closed and the enclosure 302 is secured. Once the system controller 330 confirms that the enclosure 302 is secured, in step 510 , the system controller 330 indicates to the conveyor controller 312 to bring the PV module 100 into the enclosure 302 . The conveyor controller 312 operates the conveyor 310 to bring the PV module 100 into the enclosure 302 . The PV module 100 is brought into the enclosure 302 after the back cover 120 of the PV module 100 has been installed and the lead foils 232 and 234 have been brought out of the hole 230 of the back cover 120 and folded back onto the surface of the back cover 120 . In one embodiment, the PV module 100 may be brought into the enclosure 302 from a laminator that installs the back cover 120 . To install the back cover 120 , the laminator typically heats the PV module to between 100 and 200 degrees Celsius. As a result, the PV module 100 enters the enclosure 302 with a temperature between 20 and 200 degrees Celsius.
[0038] As the PV module 100 enters the enclosure 302 , a previously read ID of the PV module 100 is sent to the system controller 330 so that the system controller 330 may customize the testing and/or conditioning for the individual PV module 100 . As the conveyor 310 brings the PV module 100 further into the enclosure 302 , the presence sensor 366 senses the PV module 100 and sends a signal to the conveyor controller 312 which stops the conveyor 310 . The PV module 100 is now aligned in the direction of PV module 100 conveyance beneath the contact unit 320 and above the temperature sensors 360 and 362 as illustrated in FIG. 3 b . The conveyor controller 312 then sends a signal to the system controller 330 that the PV module 100 is aligned. In step 515 , the system controller 330 commands the conveyor controller 312 to disengage the conveyor 310 so that no movement of the PV module 100 may occur during testing and/or conditioning of the PV module 100 .
[0039] In step 520 , the system controller 330 determines if the doors 307 and 309 are closed and if one or more start criteria for the testing and/or conditioning of the PV module 100 have been meet. In one embodiment, the start criteria may be programmed into the system controller 330 by the operator before hand. In another embodiment, the start criteria may be set by the operator using the console 398 in real time. In yet another embodiment, the operator may override programmed start criteria in real time using the console 398 .
[0040] In one embodiment, start criteria may include the temperature of the PV module 100 falling within a specified range, such as between 20 and 200° C. The system controller 330 may determine the temperature of the PV module 100 using the temperature sensors 360 and 362 . If the temperature of the PV module 100 is above 200° C., the system controller 330 may wait for the PV module 100 to cool before continuing. Additionally, if the temperature of the PV module 100 is outside the specified range, the system controller 330 may determine the start criterion has not been met. In another embodiment, the start criteria may include the TCS 300 having an allotted amount of time, such as between 0 and 10 minutes, to perform the testing and/or conditioning during the manufacturing process. For example, the start criteria may indicate that 5 minutes is needed to perform testing and/or conditioning during the manufacturing process. If the system controller 330 determines that there is only 3 minutes to perform the testing and/or conditioning, then the start criteria would not be met.
[0041] If the start criteria cannot be met, the method 500 advances to step 580 . Otherwise, in step 525 , the system controller 330 commands the contact unit 320 to place the contact pads 324 and 325 into contact with the lead foils 232 and 234 as explained with respect to FIG. 4 . If the contact unit 320 is unable to place the contact pads 324 and 325 into contact with the lead foils 232 and 234 then the method 500 advances to step 570 . If contact between the contact pads 324 and 325 and the lead foils 232 and 234 is established then, in step 530 , the system controller 330 commands the power unit to output power.
[0042] Once the power unit is enabled, in step 540 , the electrical contact between the contact pads 324 and 325 and the lead foils 232 and 234 is verified. To verify the electrical contact, the system controller 330 commands the power unit 340 to supply an electrical bias to the PV module 100 through the contact pads 324 and 325 . For verification, a low current, for example 0.25 amps may be used. For testing and/or conditioning purposes, the current supplied by the power unit 340 may range between 0 and 11 amps and the voltage may range between 0 and 300 volts. After the electrical bias has been applied for a set amount of time, for example, 5 seconds, the power unit 340 measures the current and voltage of the PV module 100 and sends the data to the system controller 330 . The system controller 330 compares the measured current and voltage to set thresholds to determine if the PV module 100 is faulty or if the contact between the contact unit 320 and the PV module 100 is not sound. For example, in one embodiment, a PV module with a measured current below 20 milliamps or a measured voltage below 20 volts would be considered faulty or as having an unsound contact between the PV module and the contact unit 320 . If the measured current and voltage are found acceptable, the method 500 advances to step 550 . If either of the measured current and voltage levels is found unacceptable, the method 500 advances to step 560 . Furthermore, if during step 540 the system controller 330 receives data indicating that the enclosure 302 is no longer secured, the method 500 advances to step 560 .
[0043] In step 550 , the PV module 100 is tested and/or conditioned using electrical bias provided by the power unit 340 as controlled by the system controller 330 . The electrical bias applied to the PV module 100 during the testing and conditioning may be constant, alternating, pulsating, or any combination thereof. Additionally, the system controller 330 may adjust the testing and/or conditioning procedures and conditions based on information known about the PV module 100 being tested and on feedback received during the testing and/or conditioning procedure. For example, data on the PV module 100 may be collected during the manufacturing processes that occur before the testing and/or conditioning of the PV module 100 . This collected data may then be used when selecting parameters for the testing and/or conditioning of the PV module 100 . For example, information relating to a vapor deposition process for the PV module 100 , such as the temperature and chemical composition of the melt material, may be stored in the database 396 . Based on this stored data, the testing and/or conditioning may be adjusted. Furthermore, the system controller 330 may adjust the testing and/or conditioning procedures and conditions based on real time operator input received through the console 398 .
[0044] Current and/or voltage measurements may be taken during the testing or conditioning process by the power unit 340 and sent to the system controller 330 . The measurements may be taken at set time intervals. For example, the measurements may be taken every 15, 30, or 60 seconds, or after any other reasonable time period. Once testing and/or conditioning is commenced, the system controller 330 also monitors stop conditions to determine when the testing and/or conditioning should end. Stop conditions may include measurable quantities, such as, the temperature of the PV module 100 falling below a set point, the voltage on the PV module 100 rising above a set point, the duration of the testing and/or condition lasting for a predetermined period. If one of the stop conditions is fulfilled, the method 500 advances to step 560 . The stop conditions may be preset or determined in real time by the operator. Furthermore, if during step 550 the system controller 330 receives data indicating that the enclosure 302 is no longer secured, the method 500 advances to step 560 .
[0045] In step 560 , the system controller 330 commands power unit 340 to stop providing power. Then in step 570 , the system controller 330 commands the contact unit 320 to return to the home position. In step 580 , the system controller 330 sends a signal to the conveyor controller 312 to move the PV module 100 out of the enclosure 302 . The conveyor controller 312 operates the conveyor 310 to bring the PV module 100 out of the enclosure 302 . It should be understood that additional steps may be performed in the method 500 as described. Furthermore, some of the steps may not be performed, or the steps described may be performed in a different order.
[0046] The TCS 300 may include more than one TCU 318 to allow the TCS 300 to process more than one PV module at a time. For example, as illustrated in FIG. 6 , the TCS 600 may include five TCUs 318 spread along the conveyor 310 to enable the TCS 600 to test and/or condition five PV modules 100 a - 100 e simultaneously according to an exemplary embodiment. In this embodiment, the five PV modules 100 a - 100 e are brought into the enclosure 302 at the same time along the conveyor 310 . The system controller 330 controls the testing and/or conditioning of each PV module 100 a - 100 e individually and may change the testing and/or conditioning performed on an individual PV module 100 a - 100 e based on the data previously collected for the PV module 100 a - 100 e or based on the information collected during the testing and/or conditioning of the PV module 100 a - 100 e . Furthermore, the system controller 330 may change the testing and/or conditioning for each individual PV module 100 a - 100 e based on input from the operator.
[0047] The TCS 300 operates to test and/or condition every PV module 100 a - 100 e independently. For example, if one of the five TCUs 318 is unable to locate or contact its corresponding PV module 100 a - 100 e , the remaining PV modules 100 a - 100 e are tested and/or conditioned. Likewise, if one of the PV modules 100 a - 100 e fails the initial testing, the remaining PV modules 100 a - 100 e are tested and/or conditioned. Additionally, the TCS 300 continues testing and/or conditioning each PV modules 100 a - 100 e until a stop condition is fulfilled for that individual PV module 100 a - 100 e . For example, if the PV module 100 e has met its stop condition, the testing and/or conditioning on the PV module 100 e will stop while the remaining PV modules 100 a - 100 d continue to be tested and/or conditioned. The remaining PV modules 100 a - 100 d will continue to be tested and/or conditioned until they fulfill a stop condition. In this example, after fulfilling the stop condition, the PV module 100 e performs steps 560 and 570 . When all five PV modules 100 a - 100 e have fulfilled their stop conditions and completed steps 560 and 570 , the TCS 300 performs step 580 and the testing and/or conditioning of the PV modules 100 a - 100 e is completed.
[0048] In another embodiment, the TCS 300 operates to test and/or condition each PV module 100 a - 100 e dependent on the condition of the remaining PV modules 100 a - 100 e . For example, once the stop condition for one of the PV modules (e.g. 100 a ) is fulfilled, testing and conditioning for every module 100 a - 100 e may stop. Likewise, in this embodiment, the TCS 300 may not perform testing and conditioning on any of the PV modules 100 a - 100 e if one of the TCUs 318 is unable to locate or contact one of the PV modules 100 a - 100 e.
[0049] A system 700 may also be implemented where multiple TCSs 600 are operated in parallel. For example, as illustrated in FIG. 7 , the system 700 may include eight TCSs 600 a - 600 h operating in parallel according to an exemplary embodiment. The system 700 may simultaneously test and/or condition forty PV modules individually periodically, for example, every ten minutes. In this embodiment, each of the TCSs 600 a - 600 h are controlled by a single system controller 730 . Furthermore, each of the TCSs 600 a - 600 h has a console 398 that allows an operator to control the testing and conditioning of each PV module 100 within the individual TCSs 600 a - 600 h . Additionally, the TCSs 600 a - 600 h may operate independently of each other so that the conditions and situations in one TCS 600 a - 600 h does not affect the operation of the remaining TCSs 600 a - 600 h . In another embodiment, a system controller may be used to control and operate each TCSs 600 a - 600 h individually. In yet another embodiment, a single console 398 may be used for all of the TCSs 600 a - 600 h . Other embodiments may use more or fewer TCSs as required by the system 700 .
[0050] While embodiments have been described in detail, it should be readily understood that the invention is not limited to the disclosed embodiments. Rather the embodiments can be modified to incorporate any number of variations, alterations, substitutions, or equivalent arrangements not heretofore described without departing from the spirit and scope of the invention.
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An apparatus and a method for testing and/or conditioning photovoltaic modules. The apparatus includes a set of contacts for contacting electrical conductors of the module and a testing and/or conditioning system for testing and/or conditioning of the module and measuring parameters associated therewith.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of invention relates to seat and desk structure, and more particularly pertains to a new and improved multiple desk and seat apparatus wherein the same permits selective orientation of an individual relative to a selective desk, wherein the desks are annularly positioned about a central coaxially positioned seat.
2. Description of the Prior Art
Seating arrangements of various types have been utilized throughout the prior art to accommodate various requirements of individuals. The instant invention sets forth an organization to provide a convenient orientation of an individual relative to a multiple of replaceable desks to accommodate various needs, and particularly to accommodate children and the like, and to keep such children amused by providing a variety of entertainment and refreshment positions relative to a child. Examples of prior art seating arrangements may be found in U.S. Pat. No. 3,109,678 to Wilson wherein a multiple of seats are positioned relative to a central table, and wherein the organization is interfolded for convenience of storage.
U.S. Pat. No. 4,216,993 to Schumaker sets forth a central table, including a series of seats positioned thereabout.
U.S. Pat. No. 4,607,880 to Gastebled provides a knock-down picnic table utilizing spaced parallel seats and a medially oriented table.
U.S. Pat. No. 1,797,717 to Coates sets forth a work bench providing a central table for accommodating a variety of operations thereon.
As such, it may be appreciated that there continues to be a need for a new and improved multiple desk and seat apparatus wherein the same provides a multiple of accessible peripheral tables positioned exteriorly of a medially positioned seat for entertainment and accommodation of a variety of activities of an individual mounted within the seat.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of desk and seat apparatus now present in the prior art, the present invention provides a multiple desk and seat apparatus wherein the same includes a medial positioned seat and a surroundingly oriented array of desks to accommodate a variety of activities by an individual. As such, the general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new and improved multiple desk and seat apparatus which has all the advantages of the prior art desk and seat apparatus and none of the disadvantages.
To attain this, the present invention provides an apparatus including a central seat rotatably mounted to selectively confront one of an annular array of desks positioned about the seat. The desks are mounted to an upper ring, wherein a lower ring concentrically positioned below the upper ring provides a foot rest for an individual positioned within the seat. The seat is mounted upon a dampener member to accommodate bouncing of an individual upon the seat structure. The desks are removably mounted relative to the upper ring to accommodate various positions and desks for secruement to the upper ring.
My invention resides not in any one of these features per se, but rather in the particular combination of all of them herein disclosed and claimed and it is distinguished from the prior art in this particular combination of all of its structures for the functions specified.
There has thus been outlined, rather broadly, the more important features of the invention 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, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. 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 present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new and improved multiple desk and seat apparatus which has all the advantages of the prior art desk and seat apparatus and none of the disadvantages.
It is another object of the present invention to provide a new and improved multiple desk and seat apparatus which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new and improved multiple desk and seat apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new and improved multiple desk and seat apparatus which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such multiple desk and seat apparatus economically available to the buying public.
Still yet another object of the present invention is to provide a new and improved multiple desk and seat apparatus which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new and improved multiple desk and seat apparatus wherein the same accommodates a variety of activities surroundingly positioned about a central seat.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a top orthographic view, partially in section, of a prior art desk and seat apparatus.
FIG. 2 is a top orthographic view of a further prior art desk and seat apparatus.
FIG. 3 is an isometric illustration of the instant invention.
FIG. 4 is an orthographic side view, taken in elevation, of the instant invention.
FIG. 5 is an isometric sectional illustration of the pedestal portion of the instant invention.
FIG. 6 is an isometric illustration of the section 6 as set forth in FIG. 4.
FIG. 7 is an orthographic view, taken along the lines 7--7 of FIG. 5, in the direction indicated by the arrows.
FIG. 8 is an isometric illustration of a desk clamp utilized by the instant invention.
FIG. 9 is an isometric illustration of the desk clamp mounted to an associated desk for securement to the top rail of the instant invention.
FIG. 10 is an orthographic view, taken along the lines 10--10 of FIG. 4, in the direction indication by the arrows.
FIG. 11 is an isometric illustration of a desk structure utilized by the instant invention.
FIG. 12 is an isometric illustration of a tray structure utilized by the instant invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 to 12 thereof, a new and improved multiple desk and seat apparatus embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
FIG. 1 illustrates a prior art seat and table organization 1, wherein a central table member 2 includes a plural series of seats 3 positioned on either side longitudinally of the table mounted on a central framework 4 that is interfolded for storage during periods of non-use. FIG. 2 illustrates a further prior art organization 5, with a central table 6 and a plurality of side seats 7 and end seats 8 in association with the central table 6.
More specifically, the multiple desk and seat apparatus 10 of the instant invention essentially comprises a support base housing 11 mounting a pedestal 12 orthogonally and medially of the housing 11. The pedestal 12 includes a spring bellows housing 12a in surrounding relationship relative to a central support rod, including a lower support rod 39 mounted to an upper support rod 40, with a gas-filled dampener 38 positioned intermediate and coaxially of the lower and upper support rods 39 and 40 respectively (see FIG. 10). The pedestal 12 mounts an "L" shaped seat 13 thereon fixedly mounted to a seat support plate 41 that in turn is fixedly mounted to the upper support rod 40. The dampener 38, as well as the spring bellows housing 12a, accommodates impact and bouncing by an individual upon the seat structure 13.
A first support ring 15 is spaced coaxially of the pedestal 12 and underlying a second support ring 16 (see FIG. 4). The first support ring 15 provides a support for an individual's foot rest mounted within the seat, while the second support ring 16 selectively mounts a series of desks thereon. Securing and positioning the first and second rings relative to the pedestal 12 are a first, second, third, and fourth arcuate rib 17, 18, 19, and 20 respectively. The arcuate ribs are positioned at ninety degrees relative to one another to define an encircling relationship relative to the upper support base 14 that supports the pedestal 12 thereon. The upper support base 14 is rotatably mounted upon a lower base 22 by use of an intermediate swivel plate 23. The swivel plate (see FIG. 6) includes an upper plate 28 rotatably mounted and coaxially positioned coextensively with a lower plate 29. Spaced pairs of apertures 30 mount spherical bearings 31 thereon positioned and secured within the apertures 30 by bearing plates 32 that secure and position the spherical bearings 31 within their respective apertures 30. The upper support base 14 is fixedly mounted to the upper plate, with the lower support base fixedly mounted to the support base housing 11 to permit relative rotation of the first and second support rings 15 and 16 relative to the "L" shaped seat, as the "L" shaped seat 13 is fixedly mounted, via shaft 39 and support base 14 relative, the central opening of the upper plate 28 and secured to the lower plate 29 that defines an integral association with the lower base 22 to permit relative rotation of the second and first support rings 16 and 15 and the associated desks mounted thereon. The desks include a first, second, and third desk 24, 25, and 26, with a fourth desk tray mounted thereon. The desks are typically positioned ninety degrees apart relative to one another and are selectively securable to the second ring 16 utilizing desk support brackets 33. A typical desk support bracket 33, as illustrated in FIG. 3, including a slotted top bracket plate 34 that is fixedly mounted to a bottom surface of each desk utilizing a second fastener 37 (see FIG. 9), with a cup-shaped lower bracket 35 underlying the support bracket 33 receiving the second support ring 16 therethrough and clamp in place by a first threaded fastener bolt 36.
A typical desk, as illustrated in FIG. 11, provides a desk 24a including a support clip 43 at an upper end thereof to secure a book or the like therewithin, with an abutment lip 42 mounted fixedly to a lower edge of each desk to maintain articles mounted within the desk from falling therefrom.
Accordingly, an individual may sit within the seat 13 permitting rotation of the first and second rings 15 and 16 relative to that individual to position various selective ones of the desks 24-27 for operative association with that individual.
It should also be noted that the support base housing 11 includes a lift lever 21 that is arranged for vertical deflection to permit a vertical adjustment of the seat 13.
As to the manner of usage and operation of the instant invention, the same should be apparent from the above disclosure, and accordingly no further discussion relative to the manner of usage and operation of the instant invention shall be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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An apparatus including a central seat rotatably mounted to selectively confront one of an annular array of desks positioned about the seat. The desks are mounted to an upper ring, wherein a lower ring concentrically positioned below the upper ring provides a foot rest for an individual positioned within the seat. The seat is mounted upon a dampener member to accommodate bouncing of an individual upon the seat structure. The desks are removably mounted relative to the upper ring to accommodate various positions and desks for securement to the upper ring.
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FIELD OF THE INVENTION
The present invention pertains generally to devices and systems for altering the surface of a substrate by either etching or deposition. More particularly, the present invention pertains to systems and processes which use plasma for etching or deposition. The present invention is particularly, but not exclusively useful for the etching and deposition of a substrate surface in the manufacture of integrated circuits.
BACKGROUND OF THE INVENTION
As is well known, a plasma is an ionized gaseous discharge which includes free electrons, charged ions and neutral species which are sometimes referred to simply as neutrals. It is also well known that, depending on the particular constituents of the plasma, a plasma can be used either to etch a substrate surface or to deposit material onto the substrate surface. Present methods for plasma etching and plasma deposition, however, have some shortcomings.
Insofar as plasma etching and plasma deposition are concerned, certain physical characteristics of a plasma are of particular importance. Firstly, it is basic knowledge that the velocities of free electrons in a plasma, greatly exceed the velocities of charged ions. It is also known that particulates can form from negatively charged species in a plasma. Further, it is known that a magnetic field has a significant effect upon free electron transport in the plasma. Specifically, plasma flux in a direction perpendicular to the magnetic field is significantly inhibited. With the above in mind, certain phenomena should be considered.
If there is no control over the flux of the faster moving free electrons in a plasma, the free electrons will leave the plasma. Accordingly, the plasma will tend to become positively charged. This condition, in turn, promotes the formation and retention of negatively charged particulates in the plasma. These particulates, however, undesirably degrade the quality of the deposition or etching on the substrate surface. Another problem stems from the fact that if the plasma is not somehow insulated from the surface of the substrate, the substrate can become overheated and, thereby, possibly damaged. This becomes even more troublesome when high plasma densities are achieved.
In addition to merely generating a plasma, an efficient plasma etching or plasma deposition system needs to have a control over the functioning of the system. Stated differently, it is desirable if the system operator is able to control independently the flux of positive ions and neutrals toward the substrate surface to be altered. Further, it is obviously desirable if the surface is predictably altered. The implied consequence of this is that the plasma needs to have a uniform density over the substrate surface that is to be altered. Finally, it is desirable that the system be responsive and able to function in a short period of time.
In light of the above it is an object of the present invention to provide a system for processing a plasma to alter the surface of a substrate having a large surface area. Another object of the present invention is to provide a system for processing a plasma to alter the surface of a substrate which can etch the surface of a substrate, or deposit material onto the surface of a substrate, at a relatively high speed. Still another object of the present invention is to provide a system for processing a plasma to alter the surface of a substrate which can control the flux of ions or neutrals from the plasma toward the surface of the substrate. Another object of the present invention is to provide a system for processing a plasma to alter the surface of a substrate which produces a beam-like ion flux into the substrate so that deep trenches can be cut into the substrate. Yet another object of the present invention is to provide a system for processing a plasma to alter the surface of a substrate which inhibits the unwanted formation of particulates in the plasma. Another object of the present invention is to provide a system for processing a plasma to alter the surface of a substrate which allows for the generations of a plasma having a uniform density. Still another object of the present invention is to provide a system for processing a plasma to alter the surface of a substrate which shields the substrate from a high electric field. It is also an object of the present invention to provide a system for processing a plasma to alter the surface of a substrate which is relatively easy to manufacture, is easy to use and comparatively cost effective.
SUMMARY OF THE PREFERRED EMBODIMENTS
In accordance with the present invention, a system for altering the surface of a substrate includes a vessel for holding the substrate in a gaseous environment, an antenna for ionizing gas in the vessel to form a plasma, and a magnet for creating a magnetic field which insulates the substrate from the plasma. As intended for the present invention, the system can be used to alter the substrate surface either by the deposition of neutral material from the plasma onto the surface, or by etching the surface with ions and neutrals from the plasma.
The vessel which is to be used for the system of the present invention is preferably cylindrical in shape, and the cylinder is hollow to form a chamber for the vessel. The walls of this chamber are preferably made with an insulating material, such as glass. In an alternate embodiment for the vessel, the walls of the vessel can be made with a stronger material, such as a metal. For this alternate embodiment, however, the metal walls are preferably lined with an insulator. For the present invention this insulative liner can either cover the entire wall area or only partially cover the wall area.
The antenna for the system of the present invention is located externally to the vessel, and is positioned to direct RF energy into the chamber. Specifically, RF energy from the antenna, which is preferably in the form of a so-called Electron Magneto-Sonic Wave, is directed toward predetermined ionization zones in the chamber. The plasma in the chamber is thus generated in these ionization zones.
The magnet, like the antenna, is located externally to the vessel. Importantly, the flux lines of the magnetic field generated by the magnet are aligned in the chamber so they will be substantially parallel to the surface of the substrate. For purposes of the present invention, either a permanent magnet or an electrical magnet can be used. Further, the magnetic field in the chamber can be rotated to enhance uniformity of the field. This, rotation, however, can be done only so long as the flux lines remain substantially parallel to the surface of the substrate.
To set up the system of the present invention, the substrate is axially centered in the chamber of the vessel. Also, as indicated above, the substrate is placed in the chamber so that the substrate surface to be altered is substantially parallel to the flux lines of the magnetic field. The antenna is then adjusted to direct RF energy into ionization zones which are located between the surface of the substrate and the walls of the chamber.
In the operation of the system of the present invention, once the substrate has been properly placed in the chamber, and after the chamber has been filled with the appropriate gases, the antenna is activated to ionize the portion of the gas that is in the predetermined ionization zones. As is well known, this ionization results in a plasma which contains free electrons, ions, and un-ionized molecules or atoms (i.e. neutrals). In the absence of a magnetic field, the faster traveling free electrons will eventually leave the plasma and cause it to become positively charged with respect to the substrate. For the present invention, however, due to the insulated chamber walls and the orientation of the magnetic field in the chamber, several different consequences result for the plasma.
The first consequence is, the plasma which is created in the vessel is magnetically insulated from the surface of the substrate. This happens because, in the order of their influence on charged particles, magnetic fields have a greater affect on free electrons, while they have much less effect on ions, and no effect on neutrals. Accordingly, for the system of the present invention, the travel of free electrons in a direction perpendicular to the magnetic field (i.e. toward the substrate surface) is inhibited more so than is the travel of the slower moving positively charged ions. Consequently, free electrons tend to remain with the plasma and, in turn, to attract the positively charged ions. Thus, these ions also tend to remain with the plasma because the walls are electrically insulated. One result of this is that the plasma flux to the substrate is greatly reduced without affecting the flux of neutral species.
Secondly, because the magnetic field causes a much slower rate of electron transport to the substrate compared to the ion transport, the plasma charges up negative with respect to the substrate. Thus, the plasma does not retain and promote the growth of negatively charged particulates which can easily contaminate the surface of the substrate.
As indicated above, plasma in the vessel is generated in predetermined ionization zones. Further, as also indicated above, these ionization zones are located between the walls of the vessel and the surface of the substrate. In addition, the ionization zones are located diametrically opposite from each other in the chamber. Consequently, there is a region between the ionization zones that is directly above the surface of the substrate. In fact, the entire surface of the substrate is positioned under this region. Importantly, due to the fact that the plasma flows readily along the magnetic field, whereas the plasma transport across the magnetic field is very slow, there is a uniform density for the plasma in the region.
For operations of the system where the deposition of material onto a substrate surface is desired, a plasma is created in the region above the substrate surface as indicated above. Due to the fact the magnetic field has negligible effect on the neutrals in the plasma, these neutrals will not be effectively inhibited in their travel toward the substrate surface. Thus, and because there is a uniform density for plasma in the region, the neutrals can be uniformly deposited over the surface of the substrate. Because the plasma flux to the substrate is reduced by the magnetic field, the heat load and damage by the impinging ions to the substrate are also reduced. Thus, a high deposition rate can be achieved without undue heating of the substrate.
For operations of the system where it is desired to etch the surface of the substrate, the plasma is created in a manner that is similar to that used for deposition. Additionally, for etching, the substrate is periodically charged to attract ions from the plasma to the surface of the substrate. These ions and the neutrals then etch the surface in a manner well known in the art. Preferably, for the purposes of the present invention, the substrate is capacitively charged. In an alternate embodiment, however, an electrode can be placed in the vessel wall for contact with the plasma. The electrode can then be electrically connected to the substrate. This, in turn, will cause the now negatively charged substrate to attract the positively charged etching ions from the plasma. Because of the magnetic insulation, the mobility of the electrons is greatly reduced and this allows a high voltage to be applied for extraction and acceleration of the ions. Beam-like ion streams thus produced are suitable for narrow trench etching.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features of this invention, as well as the invention itself, both as to its structure and its operation, will be best understood from the accompanying drawing, taken in conjunction with the accompanying description, in which similar reference characters refer to similar parts, and in which:
The FIGURE is a cross sectional schematic representation of the component subassemblies of the system of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the FIGURE, a system for processing a plasma to alter the surface of a substrate is shown and generally designated 10. As seen in the FIGURE, system 10 includes a vessel 12 which has walls 14 and a top 16. Preferably, the vessel 12 is generally cylindrical in shape and is made of an insulating material, such as glass. For purposes of the present invention, the vessel 12 is placed on a base 18 to form a chamber 20 between the walls 14 and top 16 of vessel 12, and the base 18. It is to be understood that materials other than glass may be used for the manufacture of vessel 12. If so, the walls 14 of vessel 12 should be lined with a dielectric material so that the chamber 20 is insulated.
System 10 also includes an antenna 22. As shown in the FIGURE, antenna 22 is mounted externally to the vessel 12 and is positioned generally across the top 16 of vessel 12. From this position, antenna 22 propagates radio frequency (r-f) power into the chamber 20. The antenna 22 can be of any type well known in the pertinent art. Preferably, however, antenna 22 is a spiral antenna which has the ability to control the propagation pattern of r-f power that is transmitted by antenna 22. As will become apparent from subsequent disclosure, it is important that this propagation pattern be tailored to direct r-f power into predetermined ionization zones within the chamber 20.
The FIGURE also shows that system 10 includes a pedestal 24. Specifically, the pedestal 24 is mounted on base 18 and is surrounded by the vessel 12. This configuration places the pedestal 24 so that it projects somewhat into the chamber 20. A substrate 26 is placed on pedestal 24 to expose a surface 28 of the substrate 26 to the chamber 20. As intended for the present invention, the substrate 26 can be made of any material having a surface 28 which the operator of system 10 desires to alter by plasma etching or plasma deposition.
A magnet 30 is positioned externally to the vessel 12 substantially as shown in the FIGURE. Importantly, the magnetic field of the magnet 30, as shown and represented by the lines 32, are oriented substantially parallel to the surface 28 of substrate 26. As envisioned by the present invention, the magnet 30 can be of any type well known in the art, such as a permanent magnet or an electro-magnetic device. Regardless what type magnet is used, as stated above, it is important that the magnetic field 32 be oriented substantially parallel to the surface 28 which is to be altered. Also, it may be advantageous to rotate the magnetic field 32 about an axis which is symmetrically central to the vessel 12 and generally perpendicular to the surface 28. If so, and again as stated above, it is important that the magnetic field 32 remain oriented substantially parallel to the surface 28 and, therefore, perpendicular to the central axis of the vessel 12. For purposes of the present invention, the magnetic field 32 can be rotated by any means now known in the pertinent art.
If desired, a voltage source 34 can be provided which, via a connector 36, is electrically connected to a charge plate 38. As shown, the charge plate 38 is mounted on pedestal 24 and is capacitively connected to the substrate 26. In a manner well known to the skilled artisan, the voltage source 34 can be activated to selectively change the potential of the substrate 26. In another arrangement, which can be established for the same purpose of changing the potential of substrate 26, an electrode 40 can be mounted in chamber 20 on the wall 14 of vessel 12. In this arrangement, the electrode 40 is connected via connector 42 and switch 44 to voltage source 34. Operation of switch 44 can then complete the connection of voltage source 34 directly to the substrate 26 via a line 45.
OPERATION
In the operation of the system 10 of the present invention, a substrate 26 is placed on pedestal 24 with the surface 28 exposed. The pedestal 24 and substrate 26 are then positioned inside the chamber 20 of vessel 12. At this time, the chamber 20 is sealed. Next, the gaseous material that is to be ionized into a plasma is introduced into the chamber 20. Although the particular gas to be used with the system 10 of the present invention is generally a matter of choice, it is known that carbon tetrafluoride gas is well suited for etching operations, while Silane is suitable for a deposition operation.
Once the substrate 26 has been positioned in chamber 20, all adjustments are made on magnet 30 that are needed to orient its magnetic field 32 substantially parallel to the surface 28 of substrate 26. For purposes of the present invention, modest field strengths in the range of from fifty to one thousand gauss (50-1,000 gauss) can be used. Next, the antenna 22 is activated to direct r-f power into the chamber 20. It happens for the present invention that a rather wide range of frequencies can be used. Preferably, the frequency of the r-f power from antenna 22 is in the range of from 1 MHz to 1 GHz.
For the purposes of the present invention, antenna 22 is a generator which is configured to direct its r-f power primarily into ionization zones 46 which are located in the chamber 20. Specifically, these ionization zones 46 are located between the substrate 26 and the walls 14 of vessel 12. Preferably, this r-f power is in the form of an Electron Magneto-Sonic (EMS) Wave. This preference for an EMS Wave is due to the fact that the magnetic insulation established by the system 10 prevents inducement of an azimuthal as is normally generated by similar antennas used for Transformer Coupled Plasma (TCP). Thus, it is important to use an r-f heating method for system 10 which is compatible with the magnetic insulation. Because it can propagate across a magnetic field, an EMS Wave is suitable for this purpose. Consequently, the design for antenna 22 and the particular r-f frequency to be used must be chosen in a way to generate an EMS Wave.
The ionization zones 46a and 46b shown in the FIGURE are representative of the zones 46. Above the surface 28 of substrate 26, and between the ionization zones 46a and 46b in the chamber 20 is a region 48. The importance of this region 48 in the operation of system 10 comes into play as the plasma is generated in the chamber 20.
As implied above, as r-f power is propagated into the chamber 20, plasma is generated in the ionization zones 46. Because the walls 14 of vessel 12 are made of an insulating material (e.g. glass), and due to the orientation of the magnetic field 32 in chamber 20 (i.e. parallel to surface 28), the plasma which is generated will generally be confined to the zones 46 and to the region 48 between the zones 46. This happens for several interrelated reasons. Firstly, the insulating properties of the walls force the electron and the ion flux to the wall to be equal by keeping free electrons in the plasma from leaving the plasma by conduction through wall 14. Secondly, magnetic field 32 inhibits plasma transport in a direction perpendicular to the magnetic field 32. Thus, the flux of free electrons toward substrate 28 is greatly reduced. Thirdly, because the magnetic field 32 has relatively little, if any, effect on plasma transport in a direction parallel to the magnetic field 32, plasma density is freely and uniformly increased in the region 48. As a consequence of all this, the plasma remains negatively charged relative to the substrate 26. Also, and very importantly, the magnetic field 32 effectively insulates substrate 26 from the heat that is generated in the plasma and, accordingly, substrate 26 does not suffer unacceptable heat damage.
For a deposition operation, a plasma is generated in region 48 and the neutrals which result from the generation of this plasma are allowed to deposit onto the surface 28 of substrate 26. As will be appreciated by those skilled in the art, masks can be used to cover surface 28 so that deposition occurs on only selected portions of the surface 28. Further, due to the increased plasma densities and the uniformity of the plasma density in the region 48 that are possible with system 10, the deposition onto surface 28 can be done quickly and with a sufficient yield.
For etching operations, it is necessary that positively charged ions be attracted to the surface 28 of substrate 26. Consequently, it is desirable to establish a negative potential for the substrate 26 relative to the plasma. With this potential, the positively charged ions from the plasma will be attracted to the surface 28 for etching the surface. The establishment of a negative potential for the substrate 26 can be accomplished in several ways.
Again referring to the FIGURE, it will be seen that the voltage source 34 can be selectively activated to place a negative charge on the charge plate 38 and capacitively on substrate 28. This, then, will attract positively charged ions toward the surface 28 in an ion beam. It happens that this ion beam is very useful for creating trench etching in the surface 28. In an alternate embodiment, the free electron in the plasma can be collected by the electrode 40. Then in accordance with activation of the switch 44 the substrate 28, which is directly connected to the voltage source 34 can be negatively charged to attract ions in the plasma toward the surface 28 for etching.
For capacitive coupling between the charge plate 38 and substrate 26 it is well known that a net electric charge can not be transmitted capacitively. The time average must vanish. With this in mind, the charge plate 38 is pulsed negatively to accelerate the plasma ions towards the substrate 26. Between these negative pulses, a small positive voltage is put on to the charge plate for a duration of time which is much longer than the duration of the negative pulses. The plasma electrons slowly reach the substrate across the magnetic insulation during the period when the charge plate is slightly positive. In other words, the substrate receive bursts of the ions followed by slow arrival of the electrons. The time integrated net electric charge is nil.
While the particular system/device for processing a plasma to alter the surface of a substrate as herein shown and disclosed in detail is fully capable of obtaining the objects and providing the advantages herein before stated, it is to be understood that it is merely illustrative of the presently preferred embodiments of the invention and that no limitations are intended to the details of construction or design herein shown other than as described in the appended claims.
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A device, and a method for using the device, for altering the surface of a substrate with a plasma includes a vessel having a chamber, a magnet and a plasma generator. Both the generator and the magnet are positioned outside the vessel while the substrate to be altered is placed in the chamber. The magnetic field is established substantially parallel to the substrate surface that is to be altered to insulate the plasma from the substrate surface. Also, a radio frequency wave is propagated from the generator into the chamber to generate the plasma in chamber which alters the surface. Specifically, the plasma is generated in ionization zones located between the substrate surface and the vessel walls. A region in the chamber is thus defined between the ionization zones where the plasma is established with substantially uniform density. Additionally, electrodes can be placed to voltage bias directly or capacitively the plasma for ion etching or deposition on the substrate surface.
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FIELD OF THE INVENTION
[0001] The present invention relates to emissions control systems for vehicles, and more particularly to emissions control systems that reduce oxides of nitrogen in vehicle emissions.
BACKGROUND OF THE INVENTION
[0002] Vehicle engines produce oxides of nitrogen (NOx) as a component of vehicle emissions. In particular, lean-burn gasoline and diesel engines tend to produce higher levels of NOx than conventional gasoline engines.
[0003] In an effort to reduce NOx levels in vehicle emissions, manufacturers employ emissions control systems with engine sensors and NOx storage catalysts. The NOx storage catalysts absorb and decompose the NOx with combustible gases such as carbon monoxide (CO) or hydrocarbon (HC). While reducing NOx levels, these systems tend to increase the level of hydrocarbons in vehicle emissions.
[0004] Recent designs in NOx sensors allow improved reduction of NOx emissions. NOx sensors may be integrated in the NOx storage catalyst. The NOx sensor detects NOx concentrations in emissions. The sensor communicates with an engine control system and provides data regarding NOx levels. The engine control system takes actions to reduce the NOx levels.
SUMMARY OF THE INVENTION
[0005] A control system regulates vehicle emissions with a valve that controls recirculation of exhaust gas in an engine. A sensor communicates with the exhaust gas to measure oxides of nitrogen levels in the exhaust gas. A controller communicates with the sensor and the valve. The processor adjusts the valve if the oxides of nitrogen levels are not within a threshold.
[0006] In another feature of the invention, a control system regulates vehicle emissions with a cam phaser that controls recirculation of exhaust gas in an engine. A sensor communicates with the exhaust gas to measure oxides of nitrogen levels in the exhaust gas. A controller communicates with the sensor and the cam phaser. The processor adjusts the cam phaser if the oxides of nitrogen levels are not within a threshold.
[0007] In another feature of the invention, a calibration map is generated on the controller. The calibration map is a predetermined lookup table that determines the threshold based on an accelerator position and an engine speed. The processor adjusts the valve and/or cam phaser according to the lookup table.
[0008] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
[0010] FIG. 1A is a block diagram of an engine control system providing exhaust gas recirculation using an exhaust gas recirculation (EGR) valve according to prior art;
[0011] FIG. 1B is a block diagram of an engine control system providing exhaust gas recirculation using a cam phaser according to prior art;
[0012] FIG. 2 is a block diagram of an engine control system including a NOx sensor; and
[0013] FIG. 3 is a block diagram of an engine control system according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements.
[0015] Referring now to FIG. 1A , an engine controller 10 monitors and adjusts engine performance based on various input signals. For example, the controller 10 may modulate an exhaust gas recirculation (EGR) valve 12 to reduce NOx emissions. Higher combustion temperatures in the engine 14 increase levels of NOx emissions in exhaust gas 16 . Directing some of the exhaust gas 16 back into the engine 14 with intake air 18 reduces the combustion temperatures. The EGR valve 12 meters the amount of exhaust gas 16 that is recirculated with the intake air 18 . The recirculated exhaust gases lower the combustion temperatures, which reduces NOx emissions. The calculation of the valve position for the EGR valve 12 is estimated based on engine conditions such as engine speed and desired air per cylinder. The valve position calculation is not directly related to the actual NOx level.
[0016] Alternatively, a cam phaser 22 may be incorporated with the engine 14 to reduce NOx emissions, as shown in FIG. 1B . The cam phaser 22 changes a phase of a camshaft in the engine 14 , which draws the exhaust gas 16 back into the engine 14 . The cam phaser 22 simulates the function of an EGR system by reintroducing the exhaust gas 16 into the engine 14 , which reduces the combustion temperature and NOx emissions. The controller 10 manages phase settings of the cam phaser 22 . As with an EGR system, the phase setting of the cam phaser 22 is an estimation that is derived from engine conditions and is not directly related to the actual NOx level.
[0017] Referring now to FIG. 2 , an engine control system 30 is shown. The controller 10 communicates with various components of the engine control system 30 , including but not limited to a throttle position sensor 32 (TPS), a fuel system 34 , an ignition system 36 , and the engine speed sensor 34 (RPM). The controller 10 receives a mass airflow from the MAF 40 and uses the information to determine airflow into the engine 14 . The airflow data is then used to calculate fuel delivery from the fuel system 34 to the engine 14 . The controller 10 further communicates with the ignition system 18 to determine ignition spark timing. The controller 10 may receive additional inputs from other components in the engine control system 8 , including a mass airflow sensor (MAF) 40 and an accelerator pedal 42 .
[0018] In an EGR system, a conduit 44 connects the exhaust manifold 46 to the intake manifold 48 . The EGR valve 12 that is positioned along the conduit 44 meters EGR according to input from the controller 10 . Alternatively, the cam phaser 22 operates according to input from the controller 10 to simulate an EGR system. In the preferred embodiment, a NOx sensor 50 measures NOx levels and communicates the data to the controller 10 . The controller 10 may communicate with the EGR valve 12 or the cam phaser 22 in response to the data from the NOx sensor 50 . The controller 10 adjusts the EGR valve 12 and/or the cam phaser 22 to correct performance thereof. For example, the controller 10 selectively adjusts the EGR valve 12 or the cam phaser 22 to meter the exhaust gas directed back into the engine.
[0019] Referring now to FIG. 3 , the controller 10 manages data tables such as a desired power table 60 , a desired air throttle position table 62 , a desired EGR/cam phaser position table 64 , an expected NOx emission level 66 , and a main spark table 68 . These tables determine the parameters for various engine operations using predetermined lookup tables, as will be described below.
[0020] The desired power table 60 calculates desired airflow into the engine. Inputs for the desired power table 60 include an accelerator pedal position signal 70 from the accelerator pedal 42 and an rpm signal 72 from the engine speed sensor 38 . A desired airflow signal 74 is divided by the rpm signal 72 to determine a desired air per cylinder signal 76 . The desired air per cylinder signal 76 and the rpm signal 72 are inputs for the desired air throttle position table 62 , the desired EGR/cam phaser position table 64 , and the expected NOx emission level table 66 .
[0021] The mass airflow sensor 40 outputs a measured power signal 78 . The measured power signal 78 is divided by the rpm signal 72 to determine a measured air per cylinder signal 80 . The rpm signal 72 and the measured air per cylinder signal 80 are inputs for the main spark table 68 .
[0022] The desired air throttle position table 62 determines a position of a throttle 82 based on the desired air per cylinder 76 and rpm 72 input signals. The throttle 82 controls the amount of air input to the engine. The desired EGR and/or cam phaser table 64 adjusts an EGR and/or cam phaser actuator position based on the input signals.
[0023] Still referring to FIG. 3 , the expected NOx emission level 66 is a calibration map that generates target levels for NOx emissions according to various vehicle conditions. The target NOx level from the calibration map is compared to a measured NOx emission level from the NOx sensor 50 to determine a NOx error. The NOx error is communicated to the controller 10 whereby the NOx error may be used for control purposes such as diagnoses and remedial action. For example, the calibration map may specify a preferred range for NOx error. If the NOx error is outside the specified range, the controller 10 adjusts an EGR valve or cam phaser actuator 84 to compensate for the NOx error.
[0024] Alternatively, the controller 10 may communicate with the desired power table 60 , the desired air throttle position table 62 , or the main spark table 68 to make adjustments in response to the NOx error. For example, the controller 10 may alter the main spark table 68 to adjust spark timing to optimize combustion, further affecting NOx levels. Additionally, the controller 10 may alter the desired air throttle position table 62 to adjust the flow of intake air.
[0025] The controller 10 may also diagnose the performance of the actuator 84 . If the NOx error is outside of the range specified by the calibration map, the controller 10 may determine that the actuator 70 is malfunctioning. For example, the controller 10 may observe that the NOx error remains outside of the specified range despite remedial action taken by the controller 10 and the various data tables. In this situation, the controller 10 flags the actuator as faulty and in need of maintenance.
[0026] Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification and the following claims.
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A vehicle control system regulates oxides of nitrogen levels in vehicle emissions. Recirculation of exhaust gas in an engine is controlled with an exhaust gas regulator valve and/or a cam phaser. An oxides of nitrogen sensor determines the level of oxides of nitrogen levels in the exhaust gas and communicates the information to a vehicle controller. The controller determines if the oxides of nitrogen levels are within a predetermined threshold according to a lookup table. The controller adjusts the valve and/or cam phaser if the oxides of nitrogen levels are not within the threshold.
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CLAIM OF PRIORITY
[0001] This application is a non-provisional application and claims no priority to any patent or patent application.
FIELD OF THE EMBODIMENTS
[0002] The field of the invention and it embodiments relate to layout tools for determining various measurements used in carpentry and general construction, namely building framing. In particular, the present invention and its embodiments relate to a framing tool to be used for the simultaneously marking headers and footers for proper alignment with studs of the frame.
BACKGROUND OF THE EMBODIMENTS
[0003] When a building or structure is being built during construction, one of the most fundamentally important steps is the prepping and constructing of the layout of the structure. This process is commonly referred to as framing. Typically all interior and exterior walls are framed with at least one horizontal header and one horizontal footer with a plurality of vertically situated studs spaced therebetween. The wall material, typically drywall or gypsum is placed on interior framed walls, whereas siding and roofing of various materials are placed on the exterior walls.
[0004] In framing a structure, both wood and metal studs can be used, however, in most residential buildings, wood is the most frequently used framing material. The framing materials are typically 2×4 and 2×6 pieces of lumber. As opposed to their common naming, the actual dimensions of such pieces of lumber are 1.5×3.5 inches and 1.5×5.5 inches respectively. Such dimensions must be taken into account when framing a structure as to provide proper spacing between studs and at the correct point along the footers and headers.
[0005] A carpenter, or other worker, will mark the pieces of wood to be used in the framing for the structure. These marks are usually positioned with the guidance from a measuring tape and a general standard placement of the studs on 16″ centers and in rarer occasions 24″ centers. The framing is then typically assembled on the ground and lifted into position or alternatively positioning the headers and footers and then placing the studs therebetween.
[0006] Problems with the aforementioned methodology can begin to arise when the wood or lumber is being marked. The measuring tape being used may slip, unbeknownst to the worker, or other human error may both result in improper marking along the wood. Once a mistake happens, it is often only caught late in the process, once the framed wall is at least partially assembled, thereby requiring the work to be redone with the proper measurement and costing the company or other entity time and resources. Additionally, the process can be slow as the headers and footers are often individually marked. In many structures, this requires many calculations and speed efficiency thereby increasing the chance of an error being made.
[0007] Thus, there is a need for a process for marking materials used in framing quickly and expeditiously. Further, it is imperative that such a process removes or limits the occurrence of human error associated with slippages or miscalculations. The present invention and its embodiments meet and exceed these objectives.
REVIEW OF RELATED TECHNOLOGY
[0008] U.S. Pat. No. 6,895,683 pertains to a carpenter's layout tool that has various measurements thereon, which measurements are used during stud wall construction. The tool has a pair of feet, each with a centrally disposed opening, the feet being joined at a lower surface of each by a connecting bar. The connecting bar has measurements, both left justified and right justified, for joining corner marks, corner marks, and intersecting wall marks, using either 2×4 or 2×6 inch construction. The tool is dimensioned so that the feet provide stud spacing with one of the openings in the respective foot being used for measurement initialization.
[0009] U.S. Pat. No. 6,775,916 pertains to a layout tool for laying out or “marking” positions at a predetermined spacing for the attachment of studs having a nominal thickness to a length of dimensioned lumber comprising a plate, when framing walls during construction of a building. The layout tool includes an elongated rail for placement against the plate, and a first stud marking guide extending perpendicularly from the elongated rail. The first stud marking guide has left and right side edges, and width between the side edges corresponding to the nominal thickness of the studs. A separate stud marking guide extends perpendicularly from the elongated rail. The second stud marking guide likewise has left and right side edges and a width between the side edges corresponding to the nominal thickness of the studs. The left edge of the second stud marking guide is spaced from the left edge of the first stud marking guide a distance equal to the predetermined stud spacing. A primary starter marking indication is provided on the elongated rail intermediate the first and second stud marking guides. The primary starter marking indication is spaced from the second stud marking guide a distance equal to one-half the nominal thickness of the studs.
[0010] U.S. Pat. No. 5,960,554 pertains to a stud layout template for marking locations for the placement of studs on a floor plate or a ceiling plate using center lines on the respective floor or ceiling plate. The stud layout template includes a plate having a main portion and an end portion outwardly extending from the main portion. The main portion has a cutout therethrough having an outer periphery comprising a pair of ends and a pair of sides extending between the ends of the cutout. The plate has an extent extending into the cutout from a first end of the cutout. The extent of the plate has a pair of side edges converging together to form a pointer vertex positioned substantially equidistantly between the sides of the cutout.
[0011] U.S. Patent Application 2006/0174500 pertains to a carpenter's framing square, which utilizes an opening located on the centerline of the blade. This centering window allows the user to place the 1½″ wide blade on the centerline of a layout mark in order to strike parallel edge marks to locate a framing stud on the top/bottom plates of a stud wall.
[0012] Various devices are known in the art. However, their structure and means of operation are substantially different from the present disclosure. The other inventions fail to solve all the problems taught by the present disclosure. The present invention and its embodiments provide for a tool that quickly and easily enables one to mark positions for studs on the footers and headers used in framing a structure. At least one embodiment of this invention is presented in the drawings below and will be described in more detail herein.
SUMMARY OF THE EMBODIMENTS
[0013] The present invention and its embodiments describe and teach a layout tool for measuring and marking a dimensioned length of material, the layout tool having at least two first marking sections, wherein each of the at least two first marking sections has at least one first marking cutout; at least two second marking sections, wherein each of the at least two second marking sections has at least one second marking cutout; a bar body having a first end and a second end which couples the at least two first marking sections and the at least two second marking sections, wherein one of the at least two first marking sections and one of the at least two second marking sections are positioned on the first end, and wherein one of the at least two first marking sections and one of the at least two second marking sections are positioned on the second end of the bar body.
[0014] In another embodiment of the present invention there is a layout tool having at least two first marking sections, wherein each of the at least two first marking sections has at least one first marking cutout; at least two second marking sections, wherein each of the at least two second marking sections has at least one second marking cutout; an angled bar body having a first end and a second end which couples the at least two first marking sections and the at least two second marking sections, wherein one of the at least two first marking sections and one of the at least two second marking sections are positioned on the first end, and wherein one of the at least two first marking sections and one of the at least two second marking sections are positioned on the second end of the bar body; and a plurality of markings along a length of the bar body, the plurality of markings being spaced equidistant from one another. In general, the present invention succeeds in conferring the following, and others not mentioned, benefits and objectives.
[0015] Generally, the present invention and its embodiments embody a layout tool used to mark pieces of dimensioned lumber for framing a structure during the construction process. The layout tool is about 17.5 inches in length to facilitate the framing process. Marking sections are placed on either end of the length of the layout tool that are 1.5 inches wide. This accommodates and enables one to mark the position of the studs which are typically 1.5 inches by 3.5 inches. Various measurements may be marked in between the first end and the second end of the layout tool.
[0016] The main body or bar body of the layout tool is angled allowing it to extend over multiple pieces of dimensioned lumber. The angle formed is approximately 90° thus enabling the layout tool to lie flush with the dimensioned lumber. The bend or angling in the bar body is done down a midline of the length of the bar body. Graduated markings are positioned along each edge of the bar body on each side of the angling or bending.
[0017] The layout tool is typically laid over three pieces of dimensioned lumber to be used in framing a structure. Markings are made on each side of each of the markings sections and a mark is made in the middle of these sections via the marking section cutouts. The layout tool is then shift down the lumber to the next position for marking. The process is repeated until the length of dimensioned lumber is marked. The dimensioned lumber can then be arranged as headers and footers. Once secured, the studs can be attached thereto using the markings made using the layout tool. This greatly increases the expediency in framing a structure and reduces or prevents human error.
[0018] It is an object of the present invention to provide a layout tool that can facilitate the marking of multiple items at once.
[0019] It is an object of the present invention to provide a layout tool that enables proper spatial measurements for studded framing.
[0020] It is an object of the present invention to provide a layout tool that saves time and money connected with marking building materials.
[0021] It is another object of the present invention to provide a layout tool that reduces or limits worker error.
[0022] It is another object of the present invention to provide a layout tool that is durable and lightweight.
[0023] It is another object of the present invention to provide a layout tool that is inexpensive.
[0024] It is yet another object of the present invention to provide a layout tool that can mark multiple measurement points.
[0025] It is yet another object of the present invention to provide a layout tool that is angled and sized to accommodate standard building materials.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] FIG. 1 is a top view of an embodiment of the present invention.
[0027] FIG. 2 is a perspective side view of an embodiment of the present invention.
[0028] FIG. 3 shows an embodiment of the present invention positioned over a length of material for marking.
[0029] FIG. 4 is a view of the length of material that has been marked using the present invention.
[0030] FIG. 5 is a view demonstrating how the present invention and its embodiments can be used to expedite the marking process in the construction of structures.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified with the same reference numerals.
[0032] Reference will now be made in detail to each embodiment of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto.
[0033] Referring now to FIG. 1 , there is a plan view of the layout tool 100 demonstrating the positions of the elements in relation to one another. The layout tool 100 generally comprises a bar body 110 , a first end 112 , a second end 114 , first marking sections 102 with first marking cutouts 104 , second marking sections 106 with second marking cutouts 108 , and a plurality of markings 116 along the bar body 110 .
[0034] The layout tool 100 is approximately 17.5 inches in length as shown by distance A. The bar body 110 forms the general length of the layout tool 100 and is defined by a first end 112 and a second end 114 . The first marking sections 102 and the second markings sections 106 extend substantially perpendicularly from the bar body 110 . The bar body 110 has a midline M running the length of the bar body, where the bar body 110 is bent or angled about the midline M as shown in FIG. 2 . The bar body 110 is preferably bent at about a 90° angle allowing it to be laid over a length of dimensioned lumber 200 as shown in FIG. 3 .
[0035] On each side of the midline M is a set of marking sections disposed on each of the first end 112 and the second end 114 of the bar body 110 . The first marking sections 102 are disposed on a first end 112 and a second end 114 of the bar body 110 . The second marking sections 106 are disposed on a first end 112 and a second end 114 of the bar body 110 on the opposing side of the midline M from the first marking sections 102 .
[0036] Each of the first marking sections 102 and the second marking sections 106 have first marking cutouts 104 and second marking cutouts 108 respectively. The marking cutouts can be virtually any shape but are preferably in the form of an “x.” The center of the marking cutout should be positioned to be about 15.25 inches center to center on one side of the bar body 110 .
[0037] The first marking sections 102 have a width B that is approximately 1.5 inches and a length C as measured from the midline M of the bar body 110 . The length C is about 4.5 inches. The second marking section 106 has a width B which is equal to that of the first marking section 102 . The length D, however, is about 3.5 inches which is shorter than that of the first marking section 102 . These differences in lengths are to accommodate the dimensioned lumber as shown in FIG. 3 .
[0038] A plurality of markings 116 span the length of the bar body 110 . The markings preferably are spaced equidistant between one another and record distances of about 0 to about 17.5 inches. The number of markings and division of the distance may vary and could be shown in 1/32, 1/16, ⅛, ¼, or ½ inch increments. Other increments and units of measure including metric units may be displayed. In some instances, the plurality of markings start at 0 on the first end 112 and end at 17.5 on the second end 114 on one side of the bar body. On the opposite side (of the midline M) of the bar body 110 the markings 116 may begin with 0 at the second end 114 and end at 17.5 on the first end 112 .
[0039] From the midline M to an edge E the distance is about 1.5 inches which provides for additional flexibility in using the layout tool 100 . For example, when laid upon a piece of dimensioned lumber the 1.5 inch mark can be laterally marked to the piece of dimensioned lumber for marking and positioning of a box beam.
[0040] In some instances, the layout tool 100 may be a number of different sizes to provide for framing of structures that has studs placed on centers other than 16 inches. For example, other common centering of studs may occur on 12 inch, 19⅜ inch, and 24 inch centers. In at least one embodiment, the bar body 110 may be able to collapse or expand thereby changing the overall length of the layout tool 100 . This may be achieved with a thumb screw or tightening mechanism to secure the position or length of the layout tool 100 and two slidable pieces that are slidably engaged to one another. There may be numerous other iterations that accomplish the same goal and are covered by the scope of this invention and its embodiments.
[0041] The layout tool 100 may comprise a number of materials including but not limited to metals, rubbers, plastics, composites, glass, wood, and the like or any combination thereof. Preferably, the layout tool 100 comprises a durable, lightweight plastic. Suitable plastics may include but are not limited to polyethylene terephthalate (PET), polyethylene (PE), high-density polyethylene, polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), low-density polyethylene (LDPE), polypropylene (PP), polystyrene (PS), high impact polystyrene (HIPS) and polycarbonate (PC), or any combination thereof. However, as noted other materials and combinations of materials may be used for all or some of the features of the layout tool 100 .
[0042] Referring now to FIG. 2 there is a perspective view of the layout tool 100 showing the spatial relationships of the layout tool 100 as a whole. The layout tool 100 is generally shown and defined by the bar body 110 , first marking sections 102 , and second marking sections 106 .
[0043] The bar body 110 is bent along the midline M that runs lengthwise down the bar body 110 . The midline M is preferably the middle of the bar body 110 discounting the first marking sections 102 and second marking sections 106 extending therefrom. The bend in the bar body 110 forms an angle F which is preferably between about 75° to about 100° and is preferably about 90°. In some instances, it may be preferential for the bar body 110 to flex to adjust to different angles. In other embodiments there may be a hinge or comparable structure that allows for manipulation of the bar body 110 for storage purposes and flexibility in usage.
[0044] The angle F formed by the bar body 110 allows the layout tool 100 to lay flat across multiple pieces of dimensioned lumber. This enables the multiple pieces of dimensioned lumber to be marked at once and in a number of differing fashions.
[0045] Referring to FIGS. 3-5 , there are representations that show the layout tool 100 in at least one of the intended use scenarios along with the end result. In FIG. 3 , the layout tool 100 is shown positioned over three pieces of dimensioned lumber 200 . The second marking sections 106 reside on one face of the individual pieces of dimensioned lumber 200 . The first marking sections 102 are positioned on a second face of the same piece of dimensioned lumber 200 in addition to the faces of two additional pieces. Each of the faces is marked via the first marking cutouts 104 or the second marking cutouts 108 . The markings 120 represent the alignment of lumber as shown in FIG. 5 . The layout tool 100 is then shifted to a new position along the length of the dimensioned lumber 200 where the process is repeated. This shift occurs based on the position of the initial marking(s) made.
[0046] In FIGS. 4-5 , the dimensioned lumber 200 has been marked by the layout tool 100 . Typically, the markings 120 cover a footer 210 and one or two headers 220 . The markings 120 are aligned in a way that enables the wall to be framed correctly. As shown the header 220 is placed along the top of the frame and the footer 210 along the bottom of the frame. In the event that two headers 220 are used, the headers 220 are stacked upon one another.
[0047] The studs 230 are positioned on the markings 120 and aligned with the markings present on each of the footer 210 and the header(s) 220 . The studs 230 can then be secured to the header 220 and footer 210 at the proper places forming a wall. The remaining walls can be framed as needed and then covered with the appropriate covering such as sheet rock, gypsum, and the like.
[0048] As noted a number of other methodologies made be employed to provide for marking lengths of dimensioned lumber not expressly shown or described in FIGS. 3-5 . For example, the position for a box beam can be ascertained by using the about 1.5 inch distance from the midline M of the layout tool 100 to the edge E. The width of the first marking sections 102 or the second marking sections 106 , which is also about 1.5 inches, can be used to mark and ascertain the position of the ceiling beams and rafters. Thus, the layout tool 100 is extremely flexible in providing a number of carefully dimensioned surfaces that can be used in conjunction with one another to provide for a complete marking system.
[0049] Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention.
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A layout tool may have a length and several marking areas or sections by which the headers, footers, and studs of a wall can be marked and subsequently assembled. The layout tool has a bend at about a right angle along the length of the layout tool allowing it to lay over multiple pieces of building material at once. Once marked, the building materials can be assembled quickly and with limited or no human error.
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BACKGROUND OF THE INVENTION
Conventional US production motor vehicles today include fuel systems in which a canister containing an adsorbent bed of activated charcoal granules is used to recover fuel vapors that would otherwise be lost to atmosphere. The fuel vapors so recovered include those produced from the carburetor bowl in conventionally aspirated engines, and the vapors produced in the fuel tank as it sits, the so called diurnal losses, which vapors must be vented to control tank pressure. Instead of venting the diurnal tank losses to atmosphere, they are now vented to and stored in the canister, from which they are later purged and sent to the engine air intake to be burned. Another not inconsiderable source of vapors from the fuel tank are those that are displaced from the empty tank volume during refueling. These have to be vented somewhere, in order to prevent the pressure in the tank from building and restricting the inflow of fuel. Typically, these fill loss vapors are vented to atmosphere, either through a separate vent line, or out the end of the filler pipe, or both.
Proposed new regulations that would require the recovery of the fill loss vapors as well as the diurnal loss vapors have stimulated research and patent activity directed at new systems that would collect and store the fill loss vapors in the same canister. In the public debate over whether the responsibility for the recovery of fill loss vapors should rest with the automobile companies or with the oil companies, such systems have come to be referred to as "on board" systems, meaning that they are part of the vehicle, as opposed to being part of the filling station fuel pump apparatus. Several patents for various on board vapor recovery systems have issued already, and more certainly will in the future. Although they have not yet been generally adopted in production, the typical proposed on board system includes a seal in the filler pipe, and a valve, usually contained in a housing on the side of the filler neck, just below the open end thereof. A vent line runs from the valve housing to the canister. As the filler nozzle is inserted, it wipes through the seal, blocking the flow of vapors out of the end of the filler pipe, and also opens the valve by engaging some mechanism near the housing. Alternatively, removal of the cap alone opens the valve. After valve opening, fill loss vapors that would normally have exited the now blocked filler pipe are forced to vent through the valve housing and vent line to the canister. Other systems add a second line from the tank to the filler pipe that enters the filler pipe below the seal and valve housing, so that vapors displaced from the filling tank can flow out of the tank through the second line, into the filler pipe and then out, without having to pass the junction of the tank and filler pipe. A drawback of such systems is the number and expense of the various vent lines. Another potential drawback is in packaging. If the filler pipe is at the back of the tank, and the canister at the front, then the various lines running from the filler pipe to the canister will be long and heavy. Likewise, the valve housing may occupy a significant volume on the side of the filler pipe.
SUMMARY OF THE INVENTION
The invention discloses an on board fill loss recovery system in which no filler pipe valve or vent lines running from the filler pipe to the canister are necessary, providing a simpler, more economical, and more compact system. The invention is disclosed in a vehicle fuel system in which the filler pipe is at the rear of the fuel tank, and the vapor storage canister at the front. A primary tank venting line runs directly from the front of the tank to the canister, and has a diameter large enough to allow the fuel vapors displaced from the filling tank to quickly vent therethrough to the canister. A spring loaded valve located inside the primary venting line between the tank and canister is normally biased closed against a valve seat, blocking any vapor flow through the primary vent line. To accommodate diurnal losses without encouraging vapor formation in the tank, a secondary tank venting line of significantly smaller diameter runs from the front of the tank into the primary venting line at a point between the canister and the valve. There are no lines running from the filler pipe to the canister, and the primary and secondary vent lines can be relatively short, since they run directly from the front of the tank to the front mounted canister.
While the filler pipe contains no valve, housing or venting line inlets, it does contain a wiping seal sized so as to surround the inserted filler nozzle and a rotatable lever that is pushed down by the insertion of the fuel nozzle. A cable running from the lever, down the filler pipe and through the tank to the valve pulls the valve down from its seat. Therefore, during fill, the displaced vapors can quickly vent from the tank up the large diameter primary vent line to the canister. Otherwise, vapor flow from the tank to the canister takes place only through the small diameter tank venting line. The overall configuration and weight of the system is essentially the same as a conventional system, since there are no external valves or actuators, and the vent lines are relatively short.
It is, therefore, an object of the invention to provide an on board vapor recovery system without the use of valves within the filler pipe or long vent lines running to and from the filler pipe.
It is another object of the invention to eliminate the vent lines running from the filler pipe by providing instead a vent line that runs directly from the tank to the canister, a valve which is normally closed but which is openable by a remote actuator that is operated by insertion of the fuel nozzle.
It is another object of the invention to provide a primary venting line that is large enough to allow displaced tank vapors to quickly vent during fuel fill, and a short secondary venting line of smaller diameter that by passes the valve in the primary line to allow the tank to vent at times other than during fill.
DESCRIPTION OF THE PREFERRED EMBODIMENT
These and other objects and features of the invention will appear from the following written description, and from the drawings, in which:
FIG. 1 is a schematic view of a vehicle fuel system incorporating a preferred embodiment of the invention, and illustrating its operation during refueling;
FIG. 2 is a schematic view of selected portions of FIG. 1, illustrating the situation at times other than during refueling.
Referring first to FIG. 1, a vehicle fuel system is illustrated which has a fuel tank 10 with a filler pipe 12 closed by a cap 14 and a vapor storage canister 16. A purge line 18 runs from canister 16 to an engine combustion air intake, not shown, so that stored fuel vapors may be burned in conventional fashion. Upon the removal of cap 14, filler pipe 12 receives a standard nozzle 20 therein incident to filling tank 10, which displaces fuel vapors from tank 10. Filler pipe 12 is located at one end of tank 10, here the, back, while canister 16 is at the opposite end or front of tank 10. There may be other situations where the canister 16 must be mounted relatively remote from filler pipe 12. The invention provides a compact means for venting the displaced tank vapors to the canister 16 which is well suited to such situations.
Still referring to FIGS. 1 and 2, a primary tank venting line designated generally at 22, which is basically a round tube of metal or suitable plastic, runs directly from the front of tank 10 to canister 16. Specifically, primary venting line 22 runs from a flared end 24 that is located at a fairly high point inside of tank 10 out the front of tank 10 to canister 16. Primary venting line 22 also includes an enlarged section just above the point where it exits tank 10 that provides a cylindrical valve housing 26. Housing 26 tapers into the rest of line 22 to provide a conical valve set 28. Housing 26 also has a plurality of guiding ribs 30 therein, for a purpose described below. The primary venting line 22, even at its smallest cross section, has an area sufficient to allow fuel vapors displaced from the tank 10 during fuel fill to flow quickly therethrough to the canister 16, but this path is not always open, as will be described next.
A selectively openable valve 32 is located within the primary venting line 22, specifically within the ribs 30 of housing 26. Valve 32 is generally cylindrical, although it may be conically chamfered at the upper end, as shown, and would ideally be formed of a tough, but buoyant material. A coil spring 34 compressed between the bottom wall of housing 26 and the bottom end of valve 32 normally biases the upper end of valve 32 into valve seat 28, closing off and blocking primary line 22. In order to allow for diurnal loss venting from a secondary tank venting line 36 runs from the front of tank 12 into the primary venting line 22 at a point between the canister 16 and the valve seat 28, thereby by passing the valve 32. Secondary tank venting line 36 has a cross sectional area substantially smaller than the primary tank venting line 22, and may also, if desired, include a reduced orifice 37 to even further restrict vapor flow. Thus, secondary line 36 provides diurnal loss tank venting without encouraging diurnal vapor formation, as would a line as large in diameter as the primary line 22. An advantage of the invention is that the primary venting line 22 may be relatively short, since it runs from the front of tank 10 and not from top of the filler pipe 12. Of course, the shorter a line, the less expensive, bulky and heavy it is. A further advantage is the way in which the secondary and primary venting lines meet to provide a complete vapor path to canister 16 for diurnal tank venting, which allows secondary line 36 to be even shorter. The way in which primary line 22 provides fill venting will be described next.
An annular seal 38 in the filler pipe 12 is sized so as to surround and seal the outside of filler nozzle 20 when it is inserted, blocking the flow of displaced tank fuel vapors to atmosphere out of the open end of filler pipe 12. A flapper door 40 securely pivoted inside of filler pipe 12 below seal 38 helps to block the escape of vapors to atmosphere after cap 14 is removed, but before nozzle 20 is inserted. The insertion of nozzle 20 pushes down and pivots flapper door 40 clockwise, causing a lever 42 that is rigid thereto to pivot up. A flexible cable 44 runs from lever 42 under a rounded bearing protrusion 46 junction between the body of tank 10 and filler pipe 12, through the flared end 24 of primary venting line 22 and finally to a round plate 48 that sits between the top coil of spring 34 and the bottom of valve 32. Thus, when nozzle 20 is inserted, the pivoting lever 42 pulls up on cable 44, which slides over the surfaces of 46 and 24, pulling down on plate 48 to compress spring 34, as shown in FIG. 1. Then, valve 32 falls away from valve seat 28, guided by ribs 30, opening up primary venting line 22 so that the tank vapors displaced during fuel fill can rapidly vent to canister 16 without restriction. Ribs 30 do not occupy enough volume in housing 26 to significantly interfere with that flow. As an additional advantage, the buoyancy of valve 32 allows it to float up if liquid fuel should rise through flared end 24, guided by ribs 30, to hit valve seat 28 and protect canister 16 from contamination by liquid fuel. A conventional weight and float type shut off valve 50 can be used beneath secondary venting line 36, if desired, to provide similar protection, as well as roll over protection. When nozzle 20 is pulled out and moves away from flapper door 40, spring 34 can again expand, simultaneously pushing valve 32 back to its closed position against valve seat 28 and pulling on plate 48 and cable 44 to pivot flapper door 40 back to its closed position, as seen in FIG. 1. This remote actuation of valve 32 within the primary venting line 22 means that is not necessary to have the valves mounted on the side of the filler pipe or the long filler pipe to canister venting lines found in the systems described above. Furthermore, the fact seal 38, flapper door 40, and cable 44 are all internal to the conventionally sized tank 10 and file pipe 12 adds to the compact quality and potentially lighter weight of the whole system.
Variations of the embodiment disclosed may be made within the spirit of the invention. For example, if the valve 32 were designed to not completely close off primary line 22, but to leave enough open area for diurnal venting, then it is possible that secondary venting line 36 could be dispensed with. However, the advantageous way in which the two lines 22 and 36 cooperate allows secondary line 36 to be quite short, and therefore not add a great deal of extra cost to the system. Remote actuation systems other than the cable 44 could be used to open and shut valve 32, but cable 44 is inexpensive, reliable, and compact. Therefore, it will be understood that the invention is not intended to be limited to just the preferred embodiment disclosed.
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An onboard refueling vapor recovery system uses a primary venting line from the tank to the canister with an internal valve operated remotely from the filler pipe by the insertion of the fuel nozzle. This eliminates the need for valves and vent lines at the filler neck, giving a simpler and more compact package.
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FIELD OF THE INVENTION
[0001] The present invention is directed generally to a border or beading for use in attachment of an article to another article or surface. In particular, the present invention is directed to a border or beading for use in attachment of a swimming pool liner to an upper edge of a swimming pool wall. The present invention also provides a swimming pool liner with a dual purpose beading circumferentially connected thereto for attachment to a swimming pool wall.
BRIEF DESCRIPTION OF THE DRAWING
[0002] For a better understanding of the invention, reference is made to the drawings incorporated herein by reference and in which
[0003] [0003]FIG. 1 is a perspective view of a first embodiment of a beading according to the invention.
[0004] [0004]FIG. 2 is a cross-sectional view of the first embodiment.
[0005] [0005]FIG. 3A is a cross-sectional view of the beading of the first embodiment with a swimming pool wall liner attached thereto.
[0006] [0006]FIG. 3B is a cross-sectional view of an upper perimeter edge of an overlap-type swimming pool wall.
[0007] [0007]FIG. 3C is a cross-sectional view of the beading of the first embodiment seated upon the overlap-type swimming pool wall.
[0008] [0008]FIG. 3D is a cross-sectional view of a pool rail.
[0009] [0009]FIG. 3E is a cross sectional view of the pool rail mounted on the beading.
[0010] [0010]FIG. 4A is a cross-sectional view of a second embodiment of a beading according to the invention.
[0011] [0011]FIG. 4B is a cross-sectional view of the second embodiment with an outer flange folded under.
[0012] [0012]FIG. 5A is a cross-sectional view of an upper perimeter edge of a receptor-type swimming pool wall.
[0013] [0013]FIG. 5B is a cross-sectional view of the beading of the second embodiment mounted to the receptor-type swimming pool wall.
[0014] [0014]FIG. 6 is a dimensional view of the beading according to the invention.
[0015] [0015]FIG. 7 is a perspective view of a third embodiment of a swimming pool liner with the beading according to the invention attached thereto.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Illustrative embodiments of the present invention described below are directed to a border or beading for use in attachment of a swimming pool liner to a swimming pool wall. The beading comprises an elongated member with a first portion constructed and configured for attachment of a swimming pool liner thereto, and a second hook-shaped portion constructed and configured to couple the beading to an upper edge of a swimming pool wall. The beading enables the liner to be joined to the swimming pool wall to provide for installation of the liner. Those skilled in the art will appreciate that the border or beading of the present invention may be used in other types of installations, wherein an article requires joining with another article or surface.
[0017] Embodiments are described herein with reference to FIGS. 1 - 6 which are presented for the purpose of illustrating embodiments and are not intended to limit the scope of the invention.
[0018] Referring to FIG. 1, a perspective of a first embodiment of the invention illustrates a beading 10 comprising an elongated member 12 including a first portion 14 constructed and configured to receive a swimming pool liner, wherein the first portion 14 includes a substantially planar surface 14 a to which the swimming pool liner is adhered or annealed thereto. The elongated member 12 further comprises a second hook-shaped portion 16 constructed and configured to define a seating groove 18 to couple the beading 10 to a swimming pool wall. Referring to FIGS. 1 - 2 , the seating groove 18 is constructed and configured as a substantially inverted U-shaped end 18 b which defines an internal groove 18 a . An outer flange 20 extends from the seating groove 18 adjacent to the elongated member 12 and terminates into a terminal bead 22 .
[0019] Referring to FIGS. 3 A- 3 E, cross-sectional views of the first embodiment illustrate the seating groove 18 and the outer flange 20 of the beading 10 that serve to seat the beading 10 to an upper perimeter edge 34 of a swimming pool wall 32 in order to mount the beading 10 to the swimming pool wall. As shown in FIG. 3A, a swimming pool liner 30 is attached to a surface 14 a of the first portion 14 of the elongated member 12 .
[0020] The beading 10 is joined to the swimming pool wall 32 by positioning the seating groove 18 on the upper perimeter edge 34 of the pool wall 32 . The beading 10 conforms to the upper perimeter edge 34 of the swimming pool wall 32 , such as the overlap-type of swimming pool wall shown in FIG. 3B. As shown in FIG. 3C, the internal groove 18 a is constructed and configured such that it receives and closely couples with the upper perimeter edge 34 of the pool wall 32 . In one embodiment, the beading may further comprise a pool rail 36 , such as the pool rail shown in FIG. 3D, including a hollow, elongated member with an opening 36 a to permit mounting of the pool rail 36 upon the seating groove 18 of the beading 10 . As shown in FIG. 3E, the pool rail 36 attaches to the seating groove 18 of the beading 10 , thereby securely mounting the beading 10 to the upper perimeter edge 34 and joining the wall liner 30 with the swimming pool wall 32 .
[0021] The beading 10 of the first embodiment is used with swimming pools that are referred to as an overlap-type swimming pool, as shown in FIG. 3B, which denotes the construction and configuration of the swimming pool wall and the nature of coupling of the beading 10 to the wall. As shown in FIG. 3B, the first embodiment of the beading 10 according to the invention “overlaps” the upper perimeter edge 34 of the swimming pool wall 32 to mount the beading 10 thereto.
[0022] The beading 10 is constructed of a durable, flexible material suitable for use with a swimming pool, such as, although not limited to, extruded plastics, polyvinylchloride, nylon, polyurethane, and neoprene. Those of ordinary skill in the art may select other materials to accommodate the particular configuration and dimensions of a swimming pool wall liner and swimming pool wall. The beading is manufactured generally by an extrusion process, wherein the beading is formed as a single unit.
[0023] Referring to FIG. 6, the dimensions of the beading 10 according to the first and second embodiments of the invention are illustrated. The beading 10 is particularly suited for, although not limited to, use with above-ground swimming pools. In one embodiment, the beading 10 can have any size, dimensions, thickness and circumference to accommodate the use, size, dimensions, and circumference of a swimming pool liner and a swimming pool. Thus, it is understood by those of ordinary skill in the art that the dimensions of the beading 10 shown in FIG. 6 are illustrative of the embodiments described herein, and the beading 10 according to the invention is not limited to those dimensions disclosed in FIG. 6 but may include different dimensions as noted above.
[0024] As shown in FIG. 6, the elongated member 12 of the beading 10 is generally from about 1 inch to about 3 inches in overall height 60 . The first portion 14 is generally from about 0.5 inches to about 1.5 inches in height 64 and from about 0.03 inches to about 0.05 inches in thickness 62 . The second hook-shaped portion 16 is generally from about 0.5 inches to about 1.5 inches in height 66 with a thickness 67 of from about 0.050 inches to about 0.150 inches. At the seating groove 18 , the beading 10 has a thickness 61 of from about 0.14 inches to about 0.38 inches. The internal groove 18 a has a radius of from about 0.038 inches to about 0.042 inches, and the terminal bead 22 has a radius of from about 0.034 inches to about 0.042 inches. The outer flange 20 is generally from about 0.50 inches to about 0.75 inches in height 68 . The outer flange 22 has a thickness 70 of from about 0.050 inches to about 0.200 inches.
[0025] Referring to FIGS. 4 A- 4 B, cross-sectional views illustrate a second embodiment of a beading 10 according to the invention wherein the beading 10 further comprises the outer flange 20 with a notched groove 21 . The notched groove 21 permits the terminal bead 22 of the outer flange 20 to be folded under and into the internal groove 18 a of the seating groove 18 . The terminal bead 22 is constructed and configured such that when it is folded under and received by the internal groove 18 a , the bead 22 couples closely with the dimensions of the internal groove 18 a . As shown in FIG. 4A, the terminal bead 22 is circular-shaped and similar in shape and configuration as the internal groove 18 a in order to permit close coupling of the bead 22 with the internal groove 18 a when the outer flange 20 is folded under and into the internal groove 18 a . The shape and configuration of the internal groove 18 a and terminal bead 22 are not relevant to the invention and may include other shapes and configurations and limited only to the extent the internal groove 18 a and the terminal bead 22 must be similar in shape and configuration to permit close coupling when the outer flange 22 is folded under and into the internal groove 18 a . As shown in FIG. 6, in this embodiment the notched groove 21 is angled in a range of, although not limited to, from about 55 degrees to about 77 degrees in relation to an outer surface of the outer flange 22 .
[0026] Referring to FIGS. 5 A- 5 B, the beading 10 of the second embodiment couples with a swimming pool wall with a receptor-type coupling mechanism 40 , which is attached to the upper perimeter edge 34 of the swimming pool wall 32 . As shown in FIG. 5A, the receptor-type coupling mechanism 40 includes an insertion track 40 a that is similar in shape and configuration as a folded portion of the beading 10 formed when the outer flange 22 is folded under and into the internal groove 18 a of the seating groove 18 . As shown in FIG. 5B, the beading 10 , with the swimming pool liner 30 attached thereto, is inserted into and received by the insertion track 40 a to mount the beading 10 to the upper perimeter edge 34 of the swimming pool wall 32 , thereby joining the liner 30 with the swimming pool wall 32 .
[0027] The beading 10 of the second embodiment is used with swimming pools that are referred to as receptor-type swimming pools, which denotes the construction and configuration of the swimming pool wall and the nature of coupling of the beading 51 to the upper perimeter edge 34 of the swimming pool wall 32 . As shown in FIG. 5B, the beading 10 of the second embodiment of the invention is inserted into a “receptor” type of swimming pool wall 32 to mount the beading 10 thereto.
[0028] A feature and advantage of the embodiments of the beading according to the invention is that the construction and configuration of the beading is such that the beading is used with both the overlap- and receptor-type of swimming pools, thereby requiring manufacture of only one type of beading. With a single construction and configuration, the beading of the invention maintains the same height of the swimming pool wall for both overlap and receptor types of swimming pools, thereby requiring the manufacture of only one type of swimming pool liner. Thus, the beading of the present invention provides manufacturing efficiency and installation flexibility with respect to swimming pool wall liners.
[0029] Referring to FIG. 7, a third embodiment of the invention is illustrated including a swimming pool liner 70 comprising the beading 10 according to the invention, wherein the swimming pool liner 70 is attached to the planar surface 14 a of the first portion 14 of the beading 10 . The swimming pool wall liner 70 is constructed of a strong and flexible material suitable for use with swimming pools such as, although not limited to, flexible polyvinyl chloride sheet. The liner 70 is permanently adhered, bonded or annealed to the planar surface 14 a of the first portion 14 by any one of a number of methods or mechanisms well known in the art for adhering, bonding or annealing such materials, including, although not limited to, RF sealing, heat sealing, impulse welding, solvent bonding, and ultrasonically welding. The swimming pool liner 70 with the beading attached thereto according to the invention may be used with either the overlap- or receptor-type of swimming pool wall configurations to join the liner 70 to the wall 32 of the swimming pool. As noted above, a feature and benefit of the swimming pool liner and beading according to the invention is that such combination permits the swimming pool liner 70 to be manufactured in particular sizes with specific dimensions to accommodate the dimensions of swimming pools of various sizes.
[0030] Having thus described at least one illustrative embodiment of the invention, various alterations, modifications and improvements will readily occur to those skilled in the art. Such alterations, modifications and improvements are intended to be within the scope and spirit of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention's limit is defined only in the following claims and the equivalents thereto.
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The present invention relates to a dual purpose beading for swimming pool liners. The beading includes a first portion structured and arranged for attachment of a swimming pool liner thereto and a second hook shaped portion. The hooked shaped portion is adapted so that it is moveable from a first position that enables the beading to be placed over an upper edge of a pool wall and a second position that enables the beading to be inserted into a receptor type coupling in a pool wall.
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CROSS-REFERENCE TO RELATED CASES
[0001] The present application claims the benefit of the filing date of U. S. Provisional Application Ser. No. 60/482,342; filed Jun. 25, 2003, the disclosure of which is expressly incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to valve system ports, and particularly to those ports used in refrigeration systems for charging and evacuating the refrigerant system with refrigerant.
BACKGROUND OF THE INVENTION
[0003] Service valves are used in refrigerant systems to conveniently, add and remove refrigerant. Referring to FIG. 13, a common type of service valve is the front-seat valve 730 . An example of such a valve is shown in U.S. Pat. No. 4,644,973 to Itoh et al. Front seat valve 730 contains a charge port 735 through which the installation/service technician can gage the system pressure, evacuate the system, or add refrigerant charge to 15 the system. Front seat valve 730 has a front seat 744 that seals against a mating portion of valve body 732 . Charge port 735 is equipped with a valve core 737 , which prevents refrigerant from escaping charge port 735 until a stem 738 of valve core 737 is depressed by the service hose connection. Valve core 737 is sealed with elastomeric seals which can lose their sealing characteristics over time. When connected to a service hose, a flow path through charge port 735 is opened and the system can be accessed. The volumetric flow rate of gas, into or out of the system, is restricted by this generally small flow path. Therefore, the time required to service the system is negatively increased due to the size.
[0004] Another well-known charge port configuration is found on the more costly and bulky back-seat service valve 780 , shown in FIG. 14. The back-seat valve has both a front seat 794 and a back seat 791 which seal against sealing surfaces of valve body 783 . Front seat 794 works the same way as front-seat valve 730 . Back-seat valve 780 offers an isolated charge port without employing a valve core, therefore it must be capped (not shown). A valve stem 787 in this design is back-seated (at 791 ) during normal operation. Back seat 791 is typically a metal-to-metal seal and offers greater leak prevention than that of front seat valve 730 . In the back-seated position, a charge port 785 is sealed off, or isolated, from the system. Thus, the charge port cap can be removed while valve 780 is back-seated without any concern of refrigerant escaping the system. Once the service hose is attached to charge port 785 , valve's stem 787 is mid-seated so that charge port 785 is in communication with the system. Servicing the system (evacuation and charging of refrigerant) can be executed with a higher volumetric flow rate due to the lack of restriction in the flow path (no valve core). This larger flow path results in a shorter service time. However back-seat valve 780 is bulky and expensive to manufacture. Plus valve stem 787 has to be manipulated in order to access charge port 785 , which is inconvenient for the end user.
[0005] Other prior art service valves utilize valve stems that have a component which must be rotated in order to add or remove refrigerant. For example, in many designs the valve stem is threadedly connected to the charging hose assembly in order to add refrigerant. The valve stem is also threadedly connected to the service valve body. Since the valve stem has to be rotated in order to open the service port, the stem may undesirably rotate relative to the service hose. This can be problematic since the sealed threaded connection between the valve stem and charging hose assembly may come unsealed. It is helpful to provide a valve stem that doesn't rotate when it is being opened and closed.
[0006] Other prior art service valves have valve stems that can be completely removed from the service valve. If this happens, then a complete loss of refrigerant from the system will occur. This, of course, is quite undesirable not only from an end user vantage point, but also from an environmentally friendly one. For example, the component, lo which typically is the valve stem, needs to be unseated from the valve body in order to add and remove refrigerant from the system. Prior art designs do not prevent the complete removal of this component and a complete loss of system refrigerant will occur when this happens.
SUMMARY OF THE INVENTION
[0007] The present invention provides a service valve for a refrigerant system having a valve body with at least one fluid passage integrated therein including a longitudinal bore. An orifice is located at one end of the bore and an annular protrusion extends axially from the valve body and is symmetrical about the orifice. A valve seat generally surrounds the orifice. The service valve also includes a valve stem having a first end, a second end and a bore integrated within the service valve. The stem is movable within the annular protrusion between at least a first position and a second position. In the first position, the orifice is closed when the valve stem first end sealingly abuts the valve seat. In the second position, the orifice is open, the valve stem first end is offset from the valve seat and the valve stem is restricted from moving away from the valve body by the annular protrusion.
[0008] A further feature of the noted service valve is that the movement of the valve stem is in the axial direction. Another feature of the noted service valve is that annular protrusion is an annular collar having a first end affixed to the valve body and a second end having an internal groove with a base portion, a front wall and a rear wall. A further feature has the valve stem having a radially extending flange located between its first and second ends, an annular notch located between the first end and the flange for housing a stem retaining ring, and an annular valley located between the flange and the second end for housing a nut retaining ring. The stem retaining ring contacts the groove rear wall when the valve stem is in the second position. Still another feature has the annular collar second end having a series of external threads on its outer surface for threaded engagement with a series of internal threads of a nut. The nut has a first end with the internal threads and a second end with an inwardly directed shoulder. The shoulder has a front end abutting the stem flange and a rear end abutting the nut retaining ring. Wherein when the nut is rotated in a first direction, the nut shoulder forcedly contacts the stem flange, urging the stem axially towards the valve body, and when the nut is rotated in the opposite direction, the nut shoulder forcedly contacts the nut retaining ring, urging the stem axially away from the valve body. Still yet another feature has the stem retaining ring having a greater resistance to stress than the nut retaining ring.
[0009] Another attribute of the noted service valve includes having the valve stem with an outwardly projecting annular portion between the stem first and second ends having a surface shaped for mating with a torque tool. The stem also has an annular notch located between the stem first end and the outwardly projecting annular portion for housing a stem retaining ring, and a series of external threads on its outer surface located axially between the annular notch and the first end. The annular protrusion has a first end, a second end having an internal groove with a base portion, a front wall and a rear wall, and a series of internal threads located between the internal groove and the first end for mating engagement with the series of external threads of the valve stem.
[0010] Yet another attribute of the noted service valve includes the annular protrusion having a distal end with an internal groove having a base portion, a front wall and a rear wall. The valve stem further has an annular flange located between the first and second ends, an annular notch located between the first end and the annular flange, and an annular valley located between the annular flange and the second end. The annular notch houses a stem retaining ring. The annular valley houses a nut retaining ring. The stem retaining ring contacts the groove rear wall when the valve stem is in the second position. Further the valve can include a nut having a first end with a series of internal threads for threaded engagement with a series of external threads of the annular protrusion distal end. The nut has a second end with an inwardly directed shoulder having a front end abutting the stem annular flange and a rear end abutting the nut retaining ring.
[0011] Still yet another feature of the noted service valve includes the annular protrusion having a series of internal threads located at its distal end. The valve stem further has an annular flange located between the first and second ends, a series of external threads located between the first end and the annular flange, and an annular valley located between the annular flange and the second end for housing a nut retaining ring. The stem external threads abut the annular protrusion internal threads when the valve stem is in the second position. Further, the stem external threads and the annular protrusion internal threads are not engaged in the first and second positions. Yet further, the annular protrusion can have a series of external threads on the outer surface of its distal end for threaded engagement with a series of internal threads of a nut. The nut has a first end having the internal threads and a second end having an inwardly directed shoulder. The shoulder has a front end abutting the stem annular flange and a rear end abutting the nut retaining ring. Still yet, the stem external threads and the annular protrusion internal threads can be of the left-handed variety, whereas the nut internal threads and the annular protrusion external threads can be of the right-handed variety.
[0012] Yet another feature of the noted service valve has the annular protrusion with a proximal end, a distal end, an outwardly directed radial extension located between the proximal and distal ends, a flat outer surface located between the proximal end and the radial extension, and a series of external threads located between the radial extension and the distal end. The valve stem has an outwardly directed radially extending flange located between the first and second ends, and an outwardly directed radial extension located between the flange and the second end. The service valve also has a nut with a first end, a second end and a series of internal threads located between the first and second ends. The first end has an inwardly directed front shoulder. The second end has an inwardly directed rear shoulder with a front end abutting the stem radially extending flange and a rear end abutting the stem radial extension. The internal threads matingly engage with the annular protrusion external threads. The inner surface of the front shoulder abuts the annular protrusion flat outer surface and the front shoulder contacts the annular protrusion radial extension when the valve stem is in the second position. When the nut is rotated in a first direction, the nut shoulder front end contacts the stem radially extending flange and urges the stem axially towards the valve body. When the nut is rotated in the direction opposite the first direction, the nut shoulder rear end forcedly contacts the stem radial extension and urges the stem axially away from the valve body.
[0013] Still another feature of the present invention provides a service valve for a refrigerant system comprising a valve body, an annular protrusion extending from the valve body and a valve stem. The valve body has at least one fluid passage integrated therein including a bore and an orifice located at one end of the bore. The annular protrusion is symmetrical about the orifice and has a proximal end affixed to the valve body with an inwardly directed extension which provides a sealing edge. The extension has an inner diameter less than the inner diameter of the remainder of the annular protrusion. The annular protrusion further has a distal end with an internal groove with a base portion, a front wall and a rear wall. The valve stem has a first end, a second end and a bore integrated within. The stem is movable within the annular protrusion between at least a first position in which the orifice is closed when the valve stem first end sealingly abuts the protrusion extension sealing edge and a second position in which the orifice is open, the valve stem first end is offset from the protrusion extension and the valve stem is restricted from moving away from the valve body by the groove rear wall. Yet another feature of this noted service valve has the valve stem including an annular flange, an annular notch, and an annular valley. The flange is located between the first and second ends. The notch is located between the first end and the annular flange and houses a stem retaining ring. The valley is located between the annular flange and the second end and houses a nut retaining ring. The stem retaining ring contacts the groove rear wall when the valve stem is in the second position. Further, the annular protrusion second end can have a series of external threads on its outer surface for threaded engagement with a series of internal threads of a nut. The nut has a first end with the internal threads and a second end with an inwardly directed shoulder. The shoulder has a front end abutting the stem annular flange and a rear end abutting the nut retaining ring. When the nut is rotated in a first direction, the nut shoulder contacts the stem annular flange, urging the stem axially towards the valve body. When the nut is rotated in the direction opposite the first direction, the nut shoulder contacts the nut retaining ring and urges the stem axially away from the valve body.
[0014] Still a further attribute of the present invention includes having a charge port, in fluid communication with at least one internal passage inside a valve body, with an annular collar, a valve stem, and a nut. The annular collar extends from the valve body and has a proximal end affixed to the valve body with an inwardly directed extension defining a valve seat. The collar further has an external surface with a series of threads located on a portion thereof, and an internal notch for housing a stem retaining ring. The valve stem has a first end, a second end, a bore integrated within, an outwardly directed annular flange located between the first and second ends, a first outwardly directed shoulder located between the annular flange and the first end, and a second outwardly directed nut retaining shoulder located between the annular flange and the second end. The valve stem is moveable within the annular collar between at least a first position in which the stem first end abuts the valve seat and a second position in which the stem first shoulder abuts the stem retaining ring. The nut has a series of internal threads for engagement with the collar series of threads, an inwardly directed shoulder axially affixed to the valve stem between the stem annular flange and the stem nut retaining shoulder. When the nut is rotated in a first direction, the nut shoulder moves the stem axially towards the valve body, and when the nut is rotated in the direction opposite the first direction, the nut shoulder moves the stem axially away from the valve body.
[0015] Further features and advantages of the present invention will become apparent to those skilled in the art upon review of the following specification in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a cross-sectional view of a first embodiment for a charge valve according to the present invention.
[0017] [0017]FIG. 2 is a partial sectional view of the valve body bore for receiving the isolated port shown in FIG. 1.
[0018] [0018]FIG. 3 is a longitudinal, cross-sectional view of the braze body shown in FIG. 1.
[0019] [0019]FIG. 4 is a side, elevational view of the valve stem shown in FIG. 1.
[0020] [0020]FIG. 4 a is a longitudinal, cross-sectional view of the valve stem shown in FIG. 4.
[0021] [0021]FIG. 5 is a longitudinal, cross-sectional view of a second embodiment braze body component.
[0022] [0022]FIG. 6 is a side, elevational view of a valve stem according to the second embodiment of the present invention.
[0023] [0023]FIG. 7 is a longitudinal, cross-sectional view of a fourth embodiment braze body component according to the present invention.
[0024] [0024]FIG. 8 is a side, elevational view of a valve stem according to the fifth embodiment of the present invention.
[0025] [0025]FIG. 8 a is a longitudinal, cross-sectional view of the valve stem shown in FIG. 8.
[0026] [0026]FIG. 9 is a longitudinal, cross-sectional view of a braze body component according to the fifth embodiment of the present invention.
[0027] [0027]FIG. 10 is a longitudinal, cross-sectional view of a nut having a crimped end for attachment with a braze body component according to the sixth embodiment of the present invention.
[0028] [0028]FIG. 11 is a side, elevational view of the braze body component according to the sixth embodiment.
[0029] [0029]FIG. 11 a is a longitudinal, cross-sectional view of the braze body component shown in FIG. 11.
[0030] [0030]FIG. 12 is a cross-sectional view of third embodiment of a charge valve according to the present invention.
[0031] [0031]FIG. 13 is a cross-sectional view of a prior art front-seat valve.
[0032] [0032]FIG. 14 is a cross-sectional view of a prior art back seat valve.
[0033] [0033]FIG. 15 is a cross-sectional view of a seventh embodiment for a charge valve according to the present invention.
[0034] [0034]FIG. 16 is a side, elevational view of the braze body component shown in FIG. 15.
[0035] [0035]FIG. 16 a is a longitudinal, cross-sectional view of the braze body component shown in FIG. 16.
[0036] [0036]FIG. 17 is a side, elevational view of the nut component shown in FIG. 15.
[0037] [0037]FIG. 17 a is a longitudinal, cross-sectional view of the nut component shown in FIG. 17.
[0038] [0038]FIG. 18 is a side, elevational view of the valve stem component shown in FIG. 15.
[0039] [0039]FIG. 18 a is a longitudinal, cross-sectional view of the valve stem component shown in FIG. 18.
[0040] [0040]FIG. 19 is a side, elevational view of the isolated port shown in FIG. 15, removed from the valve body and without the end cap.
[0041] [0041]FIG. 19 a is a longitudinal, cross-sectional view of the isolated port shown in FIG. 19.
DETAILED DESCRIPTION OF THE INVENTION
[0042] Referring to the drawings and in particular to FIGS. 1 through 4 a, one embodiment of a refrigerant service valve 10 , according to the present invention, is shown. Service valve 10 has a unique self-contained isolated port 12 comprised of a valve body 15 , an annular braze body 17 , a valve stem 19 , a nut 23 , and a cap 29 . Isolated port 12 is used for conveniently charging and evacuation of a refrigerant system. Valve body 15 has a plurality of passages 31 integrated within for fluidly communicating and controlling refrigerant. Although the following passages are detailed for sake of description, it should be noted that service valve 10 could have differing passages without limiting the scope of the invention. Passages 31 include a first passage 32 that receives a front seat valve stem 95 which, as is well known in the art and discussed above, seals against valve body 15 in order to control the flow of refrigerant. A second passage 33 and a third passage 34 are also integrated within valve body 15 and receive tubing which leads to componentry, e.g. the evaporator, compressor and condensing unit, of the refrigerant system. Third passage 34 is shown connected with a tube 97 that would lead to such a component. While isolated port 12 will be described in the context of a refrigerant system, it is to be understood that this description is not intended to be limiting.
[0043] Valve stem 19 has a nose 42 at its front end which sealingly contacts valve body 15 and a rear portion 55 which sealingly fits within the charging conduit. In between, valve stem 19 has an annular groove 44 , an annular notch 46 and an annular valley 48 . Between notch 46 and valley 48 is an outwardly extending annular flange 50 . Adjacent rear portion 55 are external threads 52 which mate with internal threads of cap 29 . Valve stem 19 has an internal longitudinal bore 53 fluidly connected with an internal radial bore 54 . It should be noted that valve stem 19 does not have a valve core 737 as is shown in prior art FIG. 13. As discussed above, the elimination of valve core 737 not only expedites the charging and evacuation of refrigerant, but also eliminates a leak path. Valve core 737 has elastomeric seals around its peripheral surface which can leak.
[0044] Valve body 15 has a first orifice 84 which leads into a braze counter bore 85 to accept a front end 57 of braze body 17 , and a second orifice 88 which lead into a bore 87 having a sealing shoulder 89 onto which the nose 42 of valve stem 19 abuts in order to seal the charge port. Braze body 17 is permanently affixed, e.g. by brazing, to valve body 15 and symmetrically surrounds orifice 88 . Braze body 17 further has a rear end 59 with external threads 61 and an inner annular groove 63 . Annular groove is defined by a front annular wall 64 and a rear annular wall 65 , both having an inner diameter smaller than that of groove 63 . When fully assembled, annular groove 63 forms a cavity 72 with the outer surface of stem 19 , and particularly stem annular notch 46 . Cavity 72 houses a stem retaining ring 67 . Nut 23 has an inwardly directed shoulder 25 having an inner surface that abuts stem annular flange 50 when nut 23 is assembled onto valve stem 19 and internal threads 26 which mate with braze body external threads 61 . When fully assembled, shoulder 25 has an outer surface that contacts a nut retaining ring 75 which rests within stem annular valley 48 .
[0045] When it is not necessary to charge or evacuate the system, valve stem 19 is in the position shown in FIG. 1. By applying torque to nut 23 , valve stem 19 is forced to seal against valve body 15 . Specifically, when nut 23 is threaded (onto braze body 17 ) towards body 15 , nut shoulder 25 pushes valve stem annular flange 50 also towards body 15 . Valve stem nose 42 sealingly abuts valve body shoulder 89 and cap 29 is threaded onto stem external threads 52 so that isolated port 12 is sealed, preventing the escape of refrigerant.
[0046] In order to charge (or evacuate) the refrigerant system, valve stem nose 42 must be moved away from valve body 15 , and in particular sealing shoulder 89 . When unthreading nut 23 (away from valve body 15 ), shoulder 25 contacts retaining ring 75 and axially moves valve stem 19 away from valve body 15 . Stem 19 is restricted from fully separating from braze body 17 by stem retaining ring 67 located within cavity 72 . As nut 23 is unthreaded, shoulder can push valve stem 19 away from valve body 15 until ring 67 contacts rear wall 65 stopping stem 19 from moving further. When stem 19 is moved away from valve body 15 , an O-ring 77 seals the leak path between stem 19 and braze body 17 . O-ring 77 is located in valve stem annular groove 44 .
[0047] Refrigerant can be supplied by a conduit, more specifically a hose assembly, having an attached fitting (not shown). When cap 29 is unthreaded and removed from valve stem 19 , the hose assembly fitting is threaded onto valve stem external threads 52 . The fitting seals against the mating surface of valve stem rear portion 55 in order to prevent refrigerant from leaking at this connection. Refrigerant from the hose assembly enters the system through valve stem longitudinal bore 53 and passes through valve stem radial bore 54 before entering valve body 15 through bore 87 .
[0048] It should be noted that when nut 23 is rotated during its threading towards valve body 15 , in order to seal valve stem 19 against valve body 15 , or rotated during its unthreading, in order to move valve stem 19 away from valve body, valve stem 15 moves axially without rotation. This is important in order to retain the seal between valve stem 15 and the charging conduit assembly. If valve stem 15 were allowed to rotate (with nut 23 ) relative to charging hose assembly, it would begin to unthread from the charging assembly fitting and allow refrigerant to leak. Specifically, when nut 23 rotates during the threading, shoulder 25 pushes valve stem annular flange 50 without causing same to rotate. Annular flange 50 , and the entire stem 19 , moves in the longitudinal direction without any rotation. Further, when nut 23 rotates during the unthreading, shoulder 25 pushes nut retaining ring 75 , and valve stem 19 , away from valve body 15 without rotating valve stem 15 .
[0049] Another important feature of the present invention is the restriction of valve stem 19 from being completely removed from braze body 17 . It is imperative to prevent the removal of valve stem 19 so that refrigerant does not freely escape from the system. The torque used to remove valve stem 19 from braze body 17 is transmitted from nut 23 to nut retaining ring 75 . Retaining ring 75 is housed within and moves stem 19 . Since stem 19 is axially moving, then so does stem retaining ring 67 . Stem retaining ring 67 , which is housed within cavity 72 , comes in contact with rear wall 65 of braze body inner annular groove 63 , but can not move braze body 17 which is affixed to valve body 15 . In the event of excessive torque to nut 23 , nut retaining ring 75 will fail before stem retaining ring 67 fails. This is due to the fact that, by design, stem retaining ring 67 has a greater resistance to stress than nut retaining ring 75 . When this happens, nut 23 can continue to rotate but the input torque will no longer be transferred to stem 19 . Consequently, valve stem 19 cannot be removed from braze body 15 through over torque (and its resultant movement) of nut 23 .
[0050] A second embodiment of the present invention is shown in FIGS. 5 and 6. Components and features of this embodiment that are identical to that explained above with service valve 10 will retain the same element numbers as above but will not again be discussed for sake of brevity. This embodiment is similar to service valve 10 except that nut 23 and valve stem 19 have been combined into a one-piece valve stem 119 . Valve stem 119 has a hex 123 which replaces the function of nut 23 . Valve stem 119 has external threads 145 which mate with female threads 169 of braze body 117 . By torquing hex 123 , valve stem 119 rotates within braze body 117 and moves towards valve body 15 until stem nose 142 sealingly abuts valve body sealing shoulder 89 .
[0051] Similar to service valve 10 discussed above, valve stem 119 can not be completely removed from braze body 117 . In order to fluidly communicate stem radial bore 154 with the passages within valve body 15 (during the charging and evacuation steps), stem 119 is rotated away from body 15 by torquing hex 123 . Similar to the above embodiment, braze body 117 has an inner annular groove 163 that forms cavity 72 with stem annular notch 146 . Stem annular notch 146 receives stem retaining ring 67 . When stem 119 is unthreaded from braze body 117 , it moves away from valve body 15 . Stem 119 can no longer move outward when stem retaining ring 67 contacts shoulder 179 of groove 163 . This prevents the unwanted removal of stem 119 .
[0052] This embodiment provides a lower cost design with fewer components than the embodiment discussed above, but it does not provide the ability of stem 119 to be unthreaded from braze body 117 without the rotation of stem 119 relative to the charging hose assembly. When stem 119 is torqued (e.g. by a wrench) in order to rotate same within braze body 117 , it rotates relative to the charging hose assembly attached at its rear portion 155 .
[0053] Referring to FIG. 12, a third embodiment according to the present invention is shown. Again, components and features of this embodiment that are identical to that explained with service valve 10 will retain the same element numbers as above but will not again be discussed for sake of brevity. This embodiment illustrates a valve body 215 with an annular protrusion 217 integrated in one piece. Annular protrusion 217 is formed by directly machining the braze body features (shown in the previous embodiments) into valve body 215 . This eliminates any joint needed to connect separate components if the braze body and valve body were not of the same piece. This embodiment has the same additional attributes and functionalities as that described above.
[0054] Referring to FIGS. 1, 2 and 7 , a fourth embodiment according to the present invention is shown. Once again, since changes have been made to few components, and not the entire service valve, components and features of this embodiment that are identical to that explained with service valve 10 will retain the same element numbers as above but will not again be discussed for brevity sake. As discussed above, when valve stem 19 is moved towards valve body 15 so that its stem nose 42 abuts sealing shoulder 89 , valve stem bores, or passages, 53 and 54 are fluidly disconnected from those within valve body 15 . This embodiment has located a sealing diameter within a radially directed extension 387 of braze body 317 . On an edge of extension 387 is a sealing shoulder 389 . Therefore when valve stem 19 is moved completely inwards, stem nose 42 does not abut sealing shoulder 89 (as shown in FIG. 1), but rather abuts braze body sealing shoulder 389 . This eliminates the possibility of the sealing diameter 87 on valve body 15 from becoming misaligned with the braze body during assembly of the braze body within valve body 15 .
[0055] Referring to FIGS. 1 and 8- 9 , a fifth embodiment of the present invention is shown. Again, components and features of this embodiment that are identical to that explained with service valve 10 will retain the same element numbers as above but will not be discussed. This embodiment provides a valve stem 419 , having a series of male threads 436 , originally engage with braze body female threads 443 until all male threads 436 have passed female threads 443 so that there is no thread engagement there between during its use. During its operation all stem male threads 436 will be positioned longitudinally between valve body 15 and female threads 443 . When it is necessary to seal valve stem 419 against valve body 15 , nut 23 is torqued, as discussed above, and nut shoulder 25 abuts stem annular flange 450 and axially moves stem 419 so that stem nose 442 sealingly contacts body sealing shoulder 89 . This discontinues any fluid connection between stem bore 454 and passages within valve body 15 .
[0056] When it is desired to fluidly connect stem bore 454 with the passages within valve body 15 , nut 23 is rotated and unthreaded away from valve body 15 . Nut shoulder 25 contacts nut retaining ring 75 , housed within valve stem annular valley 448 , and axially moves stem 419 away from valve body 15 . It is important to note that valve stem 419 can not be completely removed from braze body 417 on account of threads 436 and 443 . Specifically, stem 419 is moving axially but not rotating so stem male threads 436 do not engage with braze body female threads 443 . Once stem external threads 436 abut with braze body female threads 443 , stem 419 no longer moves axially, since stem external threads 436 have not engaged with braze body female threads 443 . This provides a safety feature in that valve stem 419 is not inadvertently removed from braze body 417 during the rotation of nut 23 . To further provide a safe-guard, threads 436 and 443 can be of the left-handed variety if nut internal threads 26 and braze body external threads 61 are of the right-handed variety. Similarly, threads 436 and 443 can be of the right-handed variety if nut internal threads 26 and braze body external threads 61 are of the left-handed variety. This ensures that when nut 23 is rotated in a first direction (in mating contact with braze body external threads 61 ), valve stem threads 436 can not mate with braze body internal threads 61 . Valve stem 419 would have to be rotated in the opposite direction in order to engage with braze body internal threads 443 . Also, valve stem male threads 436 and braze body female threads 443 can have different thread pitches when compared to the threads on nut 23 .
[0057] Referring to FIGS. 1, 2, 4 and 10 - 11 a, a sixth embodiment according to the present invention is shown. Again, components and features of this embodiment that are identical to that explained with service valve 10 will retain the same element numbers as above but will not be discussed. This embodiment permanently affixes a nut 523 to a braze body 517 by crimping a front shoulder 534 of nut 523 over a shoulder 541 of braze body 517 . Nut 523 is free to swivel on braze body 517 , but is restricted in its axial movement. Similar to the embodiment shown in FIG. 1, braze body front end 557 is permanently affixed to valve body 15 within counter bore 85 . When it is desired to bring valve stem 19 into abutment with valve body 15 , nut 523 is rotated, or torqued, towards valve body 15 so that a series of internal threads 526 of nut 523 engage with a series of external threads 561 of braze body 517 . While nut 523 moves towards valve body 15 , the inside surface of nut front shoulder 534 travels on a flat outer surface 581 of braze body 517 away from braze body shoulder 541 and towards braze body front end 557 . Meanwhile nut rear shoulder 525 contacts valve stem annular flange 50 thus causing valve stem 19 to axially move towards valve body 15 until stem nose 42 contacts sealing shoulder 89 .
[0058] In order to remove stem 19 from valve body 15 (and fluidly connect passages within stem 19 and body 15 ), nut 523 is torqued in the opposite direction and moves away from valve body 15 . In doing so, nut rear shoulder 525 contacts nut retaining ring 75 and axially moves stem 19 away from valve body 15 . When nut 523 moves away from valve body 15 , the inside surface of nut front shoulder 534 travels on braze body flat outer surface 581 towards braze body shoulder 541 . Nut 523 is restricted in its movement away from valve body 15 when nut front shoulder 534 contacts braze body shoulder 541 . Since nut 523 is restricted in its axial movement at this point, so is the travel of stem 19 . Therefore the removal of stem 19 is prevented. It should be noted that the stem retaining ring 67 , shown in FIG. 1, is not needed in this embodiment since nut front shoulder 534 provides the same feature. The elimination of stem retaining ring 67 provides for an easier assembly of the components.
[0059] Referring to FIGS. 15-19 a, a seventh embodiment of the present invention is shown. Again, components and features of this embodiment that are identical to that explained with service valve 10 will not be discussed in detail. A service valve 610 is shown that retains the main components and features of service valve 10 but has several minor components that have been altered. Again, service valve 610 has an isolated port 612 that is comprised of an annular braze body 617 , a valve stem 619 , a nut 623 , and a cap 629 . Also again, valve stem 619 is axially moved towards and away from a valve body 615 and can not be completely removed from isolated port 612 . Further, isolated port 612 does not contain a valve core as is present with prior art designs.
[0060] Valve body 615 has a plurality of passages 631 integrated within for fluidly communicating and controlling refrigerant. Although the following passages are detailed for sake of description, it should be noted that service valve 610 of the present invention could have differing passages without limiting the scope of the invention. Passages 631 include a first passage 632 that receives a front seat valve stem 695 which, as is well known in the art and discussed above, seals against valve body 615 in order to control the flow of refrigerant. A second passage 633 and a third passage 634 are also integrated within valve body 615 and receive tubing which leads to componentry, e.g. the evaporator, compressor and condensing unit, of the refrigerant system. Third passage 634 is shown connected with a tube 697 that would lead to such a component. Also included within passages 631 is a first orifice 684 that leads into a braze counter bore 685 and a second orifice 688 that lead into longitudinal bore 686 . Braze body 617 has a proximal end 657 that is permanently affixed, e.g. by brazing, to valve body 615 and symmetrically surrounds both orifice 684 and 688 .
[0061] Braze body proximal end 657 has a radially inwardly directed extension 687 that defines a sealing shoulder 689 . Braze body 617 has a distal end 659 with external threads 661 . On the inside surface of braze body 617 is an annular groove 644 for housing an O-ring 677 located between proximal end 657 and distal end 659 . Also located on the inside surface of braze body 617 is an annular notch 646 for housing a stem retaining ring 667 located between annular groove 644 and distal end 658 . It should be noted that both groove 644 and notch 646 are now located on braze body 617 which differs from their location within the stem as in the prior embodiments.
[0062] Nut 623 has a first end 624 and a second end 627 . Nut second end has an inwardly directed shoulder 625 with an inner surface that abuts the outer surface of valve stem 619 when nut 23 is assembled onto valve stem 619 . It should be noted that in FIG. 17 a nut shoulder 625 is shown radially offset. During assembly of service valve 610 , nut 623 is slipped over valve stem 619 and nut second end 627 is inwardly moved, or crimped, into permanent position. Shoulder 625 is free to swivel on the outer surface of valve stem 619 , but it is generally locked into place. Nut first end 624 has a series of internal threads 626 which mate with braze body external threads 661 . Nut first end 624 has an outer surface 628 , for example a hexagonal surface, which is engagable with a torque tool in order to rotate nut 623 .
[0063] Valve stem 619 has a nose 642 at its front end which sealingly contacts sealing shoulder 689 on a radially inwardly directed extension 687 of braze body 617 . As discussed above, since sealing shoulder 689 is located on braze body 617 , the possibility of the sealing interface from becoming misaligned is minimized. Valve stem 619 has a rear portion 655 which sealingly fits within the charging conduit (not shown). Between nose 642 and rear portion 655 is an outwardly extending annular flange 650 . Located between nose 642 and flange 650 is an outwardly extending shoulder 665 . Located between flange 650 and rear portion 655 are external threads 652 which mate with the internal threads of seal cap 629 . When seal cap 629 is removed, threads 652 will mate with the charging hose assembly fitting internal threads. Between threads 652 and flange 650 is a nut retaining shoulder 675 . A valley 648 is located between flange 650 and nut retaining shoulder 675 . When nut 623 is assembled onto stem 619 , nut shoulder 625 is received within valley 648 . As mentioned above, nut 623 is free to rotate about stem 619 but is axially restricted by flange 650 and shoulder 675 . Valve stem 619 has an internal longitudinal bore 653 fluidly connected with an internal radial bore 654 . It should be noted that valve stem 619 does not have a valve core 737 as is shown in prior art FIG. 13. As discussed above, the elimination of valve core 737 not only expedites the charging and evacuation of refrigerant, but also eliminates a leak path. Valve core 737 has elastomeric seals around its peripheral surface which can leak.
[0064] When it is not necessary to charge or evacuate the system, valve stem 619 is in the position shown in FIG. 15. By applying torque to nut 623 , valve stem 619 is forced to seal against braze body sealing shoulder 689 . Specifically, when nut 623 is threaded (onto braze body 617 ) towards body 615 , nut shoulder 625 contacts valve stem annular flange 650 and pushes valve stem 619 towards body 15 . When valve stem nose 642 sealingly abuts braze body sealing shoulder 689 , valve stem 619 can no longer move. Cap 629 is then threaded onto stem external threads 652 so that isolated port 612 is sealed, preventing the escape of refrigerant.
[0065] In order to charge (or evacuate) the refrigerant system, valve stem nose 642 must be moved away from valve body 615 , and in particular sealing shoulder 689 . When unthreading nut 623 (away from valve body 615 ), shoulder 625 contacts nut retaining shoulder 675 and axially moves valve stem 619 away from valve body 615 . Stem 619 is restricted from fully separating from braze body 617 by stem retaining ring 667 located within annular notch 646 . As nut 623 is unthreaded, shoulder 625 can push valve stem 619 away from valve body 615 until stem outwardly extending shoulder 665 contacts stem retaining ring 667 stopping stem 619 from moving further. When stem 619 is moved away from valve body 615 , an O-ring 77 seals the leak path between stem 619 and braze body 617 . O-ring 677 is located in braze body annular groove 644 .
[0066] Again, it should be noted that when nut 623 is rotated during its threading towards valve body 615 , in order to seal valve stem 619 against braze body sealing shoulder 689 , or rotated in the opposite direction, in order to move valve stem 619 away from valve body 615 , valve stem 615 moves axially without rotation. This is important in order to retain the seal between valve stem threads 652 and the charging assembly fitting (not shown). When it is desired to charge or evacuate the system, the charging assembly fitting is attached to valve stem threads 652 . Then nut 623 is rotated in order to axially move valve stem 619 away from sealing shoulder 689 , thus fluidly connecting passages 653 , 654 to valve body bore 686 . If valve stem 615 were allowed to rotate (with nut 623 ) relative to charging hose assembly, it would begin to unthread from the charging assembly fitting and allow refrigerant to leak at this connection. To prevent this leakage, when nut 623 rotates in order to seal off isolated port 612 , shoulder 625 pushes valve stem annular flange 650 without causing same to rotate. Annular flange 650 , and the entire stem 619 , moves in the longitudinal direction without any rotation. Further, when nut 623 rotates during the opening of isolated port 612 to bore 686 , shoulder 625 pushes nut retaining 675 , and valve stem 619 , away from valve body 615 without rotating valve stem 615 . It should be noted nut retaining shoulder 675 has replaced the nut retaining ring 75 shown in the prior embodiments.
[0067] Another important feature of the present invention is the restriction of valve stem 619 from being completely removed from braze body 617 . It is imperative to prevent the removal of valve stem 619 so that refrigerant does not freely escape from the system. The torque used to remove valve stem 619 from braze body 617 is transmitted from nut 623 to nut retaining shoulder 675 thus moving stem 619 and its outwardly extending shoulder 665 . Stem shoulder 665 will contact stem retaining ring 667 , which is housed within fixed brazed body annular notch 646 , and will stop since it can not move braze body 617 which is affixed to valve body 615 . This is the greatest extent of axial movement of valve stem 619 away from valve body 615 . In the event of excessive torque to nut 623 , nut retaining shoulder 675 will fail before stem retaining ring 667 fails. By design, stem retaining ring 667 has a greater resistance to the stress forces than does nut retaining shoulder 675 . When this happens, nut 623 can continue to rotate but the input torque will no longer be transferred to stem 619 . Consequently, valve stem 619 cannot be removed from braze body 615 through over torque (and its resultant movement) of nut 623 .
[0068] It should be noted that the present invention is not limited to the specified preferred embodiments and principles. Those skilled in the art to which this invention pertains may formulate modifications and alterations to the present invention. These changes, which rely upon the teachings by which this disclosure has advanced, are properly considered within the scope of this invention as defined by the appended claims.
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A service valve for a refrigerant system comprising a valve body and a system port. The valve body has at least one fluid passage integrated therein including a longitudinal bore. An orifice is located at one end of the bore. An annular protrusion axially extends from the valve body and is symmetrical about the orifice. A valve seat generally surrounds the orifice. The system port includes a valve stem having a first end, a second end, and a bore integrated within. The stem is axially movable within the annular protrusion between at least a first position in which the orifice is closed when the valve stem first end sealingly abuts the valve seat and a second position in which the orifice is open when the valve stem first end is offset from the valve seat. The valve stem is restricted from moving further away from the valve body by the annular protrusion.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application Nos. 61/412,042, filed Nov. 10, 2010 and 61/495,431, filed Jun. 10, 2011.
FEDERALLY SPONSORED RESEARCH STATEMENT
[0002] Not applicable.
FIELD OF THE INVENTION
[0003] This invention relates generally to a method for synthesizing lactic acid and alkyl lactate from the direct conversion of carbohydrate-containing raw materials, such as monosaccharides and/or polysaccharides, over catalysts in solvent.
BACKGROUND OF THE INVENTION
[0004] Glucose, sugarcane, starch, and celluloses are the most abundant renewable carbon sources found naturally on earth. The high content of oxygenated functional groups in these carbohydrates has advantages in making use of them to produce fundamental chemicals. In particular, these carbohydrates are the most attractive feedstocks for intermediate chemical production in a sustainable way without emitting CO 2 .
[0005] Theoretically, two moles of lactic acid could be obtained from one mole of hexose either from fermentation or from catalytic reaction. Lactic acid itself is a monomer for the biodegradable polylactate synthesis. Lactic acid and its derivatives (alkyl lactates and polylactate) could act as platform compounds for the synthesis of other carbon-3 building blocks, such as propylene glycol, acrylic acid, and allyl alcohol for the productions of polymers.
[0006] Lactic acid is produced from the fermentation of glucose in present chemical industry. In the fermentation process, only very diluted lactic acid broth (<10% water solution) is obtained through reacting with Ca(OH) 2 to obtain calcium lactate solid, and then reacting with a H 2 SO 4 solution to isolate lactic acid. The fermentation process generates huge amounts of waste water and CaSO 4 solid waste. The fermentation process for lactic acid production only uses glucose as the feed stock. During production, if starch is used as the feed stock, the starch must be prehydrolyzed to glucose either by acid catalyzed chemical reaction, or by fermentation. Existing fermentation processes could produce lactic acid from glucose in large scale (120,000 tons/year). However, the biological processes generally suffer from low reaction rates and low product concentration (in water), resulting in long reaction times, larger reactors, and high energy consumption in the product purification process (Fermentation of Glucose to Lactic Acid Coupled with Reactive Extraction: Kailas L. Wasewar, Archis A. Yawalkar, Jacob A. Moulijn and Vishwas G. Pangarkar, Ind. Eng. Chem. Res. 2004, 43, 5969-5982). It is known that, in the presence of aqueous alkali hydroxides, monosaccharides can be converted to lactate (R. Montgomery, Ind. Eng. Chem, 1953, 45, 1144; B. Y. Yang and R. Montgomery, Carbohydr. Res. 1996, 280, 47). However, the stoichiometric amount of base (Ca(OH) 2 ) and acid (H 2 SO 4 ) in the lactic acid recovery process would be consumed and, therefore, the stoichiometric amount of salt waste would be produced. Although the commercial fermentation approach can produce large scale lactic acid, it only uses starch as a feedstock and the starch must be prehydrolyzed (or through fermentation) to glucose in advance. The fermentation process produces large amounts of waste water and solid waste (CaSO 4 ). The fermentation process for producing lactic acid includes many steps which consume substantial amounts of energy. The infrastructure of the fermentation process is very complicated and uneconomical. FIG. 1 is the scheme of the commercial fermentation process for the production of lactic acid and its derivatives.
[0007] It is desired to have a process to convert both monosaccharides and/or polysaccharides to lactic acid and its derivatives directly in a more efficient and economical way. The current invention provides a method for converting monosaccharides and/or polysaccharides to lactic acid and lactate over a homogeneous catalyst system. The catalysts are combinations of nitrogen-heterocycle aromatic ring cation salts and metal compounds dissolved in a solvent. Presently, very few compounds of commercial interest are directly obtainable from carbohydrates by using non-fermentation approaches. There is also no other approach available for the production of lactic acid and its derivatives directly from naturally occurring carbohydrates, such as sugarcane, starch, and cellulose.
SUMMARY OF THE INVENTION
[0008] The present invention provides a method for synthesizing lactic acid and alkyl lactate, comprising: (a) preparing a mixture of at least one carbohydrate-containing raw material, at least one alcohol, at least one catalyst comprised of nitrogen-heterocycle aromatic cation salts and metal compounds, and at least one solvent; and (b) heating the mixture to obtain lactic acid and alkyl lactate.
[0009] In addition, polylactic acid can be obtained in the resultant mixture in step (b).
[0010] The alkyl lactate in the current invention is selected from the group consisting of methyl lactate and ethyl lactate.
[0011] The carbohydrate is selected from the group consisting of polysaccharides and monosaccharides. More specifically, the carbohydrate is selected from the group consisting of cotton, cellulose, starch, dextran, sucrose, fructose and glucose. All substances, which could be converted into carbohydrates by fermentation, hydrolysis, or alcoholysis, can be employed as the reactants of the current invention.
[0012] The alcohol is selected from the group consisting of monohydroxyl alcohols, dihydroxyl alcohols, and multihydroxyl alcohols. Further, the monohydroxyl alcohol is selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, and tert-butanol. The dihydroxyl alcohol is selected from the group consisting of ethylene glycol, 1,2-propandiol, and 1,3-propandiol. The multihydroxyl alcohol is glycerol.
[0013] The nitrogen-heterocycle aromatic cation salts in the catalyst of the current invention are comprised of cations and anions. The anion of the nitrogen-heterocycle aromatic cation salts is selected from the group consisting of F − , Cl − , Br − , I − , CH 3 SO 4 − , CH 3 SO 3 − , C 6 H 5 SO 3 − (benzenesulfenate anion), SO 4 2− , HSO 4 − , H 2 PO 4 − , HPO 4 2− , PO 4 3− , PF 6 − , BO 2 − , BF 4 − , SiF 6 2− , and CH 3 CO 2 − —.
[0014] The cation of the nitrogen-heterocycle aromatic cation salts is an organic cation that contains at least one hex-member aromatic ring and/or at least one pent-member aromatic ring that contains at least one nitrogen atom on the ring and carries a positive charge.
[0015] More specifically, the cation is an organic cation that contains a hex-member aromatic ring and/or a pent-member aromatic ring that contains at least one nitrogen atom on the ring and carries a positive charge. Yet more specifically, the organic cation is selected from the group consisting of:
[0000]
[0000] (wherein the two Nitrogen atoms could be on 1, 2, 3, and 4 positions for each ring per N),
[0000]
[0000] (wherein the three Nitrogen atoms could be on 1, 2, 3 and 4 positions for each ring per N atom),
[0000]
[0000] (wherein the two Nitrogen atoms on the two hex-member rings (each ring per N atom) could take any position among 1, 2, 3 and 4),
[0000]
[0000] (wherein the two Nitrogen atoms on the two hex-member rings (each ring per N atom) could take any position among 1, 2, 3, and 4; n and m are positive integers), and derivatives thereof; the substituting group R n on carbon atoms is selected from the group consisting of H—, C n H 2n+1 — (n≧1), C n H 2n−1 —, C n H 2n−3 —, C n H m —(m≧3), C n H 2n−7 — (n≧6), Cl—, Br—, I—, and —OSO 3 − . The substituting group R n on nitrogen atoms is selected from the group consisting of C n H 2n+1 — (n≧1), C n H 2n−1 —, C n H 2n−3 —, C n H m — (m≧3), and C n H 2n−7 — (n≧6).
[0016] In a specific embodiment, the organic cation is selected from the group consisting of 1,3-dimethylimidazolium, 1-ethyl-3-methylimidazolium ([EMIM] + ), and 1,3-dimethylimidazolium ([DMIM] + )
[0017] The metal compound in the catalyst of the current invention is selected from the group consisting of Sn, Ti, Zr, and Ge. A useful metal compound for the conversion of carbohydrate-containing raw material is preferably a tin-containing compound, wherein the tin-containing compound comprises Sn 4+ , Sn 2+ , or mixtures thereof.
[0018] The anion of the tin-containing compound is selected from the group consisting of F − , Cl − , Br − , I − , SO 4 2− , HSO 4 − , CH 3 SO 3 − , C 6 H 5 SO 3 − , H 2 PO 4 − , HPO 4 2− , PO 4 3− , PF 6 − , BO 2 − , BF 4 − , SiF 6 2− , and CH 3 CO 2 − .
[0019] In a specific embodiment, the catalyst of the current invention is a combination of 1,3-dimethylimidazolium methyl sulfate and SnCl 4 .5H 2 O.
[0020] In another specific embodiment, the catalyst is a combination of 1-ethyl-3-methylimidazolium chloride and SnCl 4 .5H 2 O.
[0021] In another specific embodiment, the catalyst is a combination of 1,3-dimethylimidazolium methyl sulfate and SnCl 2 .
[0022] In another specific embodiment, the catalyst is a combination of 1-ethyl-3-methylimidazolium chloride and Sn(CH 3 SO 3 − ) 2 .
[0023] In another specific embodiment, the catalyst is a combination of 1-ethyl-3-methylimidazolium chloride and Sn(C 6 H 5 SO 3 − ) 2 .
[0024] According to the method of the current invention, the solvent comprises a polar solvent, such as water, or alcohols, or mixtures thereof, which could dissolve the catalyst to form a homogeneous catalyst solution.
[0025] More specifically, the alcohol is selected from the group consisting of methanol, ethanol, 1-propanol, 2-propanol, 1-butanol, 2-butanol, tert-butanol, ethylene glycol, 1,2-propandiol, 1,3-propandiol, and glycerol.
[0026] In another specific embodiment, the mixture of lactic acid and alkyl lactate is prepared by heating a mixture of carbohydrates, alcohols, solvents, and nitrogen-heterocycle aromatic ring cation salts and metal compounds as catalysts in a one-pot reactor.
[0027] The amount of alcohol is about at least one mass times or more with respect to amount of carbohydrate in the carbohydrate-containing raw material. In a specific embodiment, the ratio of alcohol to carbohydrate in the carbohydrate-containing raw material by mass is about at least 3:2.
[0028] In the current invention, the heat processing of carbohydrate-containing raw material is carried out between 25 and 200° C. In a specific embodiment, the reactants solution is allowed to carry out reaction at a temperature between 25 and 180° C. Yet more specifically, the carbohydrate-containing raw material is cellulose and the reaction temperature is between 80 and 180° C.; more preferably, the reaction temperature is between 100 and 180° C.
[0029] In a specific embodiment, the carbohydrate-containing raw material is starch and the reaction temperature is between 80 and 180° C.; more preferably, the reaction temperature is between 80 and 160° C.
[0030] In a specific embodiment, the carbohydrate-containing raw material is sucrose and the reaction temperature is between 25 and 180° C.; more preferably, the reaction temperature is between 25 and 140° C.
[0031] In a specific embodiment, the carbohydrate-containing raw material is glucose and the reaction temperature is between 25 and 180° C.; more preferably, the reaction temperature is between 25 and 140° C.
[0032] According to the current invention, a carbohydrate-containing raw material is heat-processed in a solvent in the presence of catalyst, to obtain lactic acid and/or lactate. The carbohydrate-containing raw material is processed by an environment-friendly method. Lactic acid and/or lactate is manufactured efficiently and simply by processing the carbohydrate-containing raw material under mild conditions. In addition, polylactic acid could be produced in the process as a by-product. With the method of current invention, effective usage of carbohydrate-containing raw material is enabled.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 shows the scheme for lactic acid and alkyl lactate preparation at modern industrial plants.
[0034] FIG. 2 shows one embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0035] The detailed descriptions of the present invention set forth below in connection with the examples are preferred embodiments of the present invention, but the present invention is not limited to the embodiments and forms described hereinafter.
Example 1
Reaction Results of Fructose
[0036] The results listed in Table 1 were obtained using 1,3-dimethylimidazolium methylsulfate and SnCl 4 .5H 2 O as catalyst. After adding 1,3-dimethylimidazolium methylsulfate (see the amount in Table 1), SnCl 4 .5H 2 O (see the amount in Table 1), 0.200 g of fructose, and 5.0 mL of methanol into a 10 mL batch reactor, the reactor was sealed and heated to 140° C. under stirring to carry out the reaction. The reaction time is listed in Table 1. After reaction, NaOH solution (0.50M, 10.0 mL) was added to carry out a hydrolysis reaction at 60° C. for 5 hours to obtain a solution. HCl solution (0.50M, 10.0 mL) was added into the resulting solution to convert sodium lactate to lactic acid, and then the solution was analyzed on a HPLC to obtain the total percent yield of lactic acid and methyl lactate (as that listed in Table 1). In Table 1, “DMIMMS” stands for the 1,3-dimethylimidazolium methylsulfate; “t” stands for reaction time in hours; “T” stands for the reaction temperature in degrees Celsius; and “Y” stands for the total percent yield of lactic acid and methyl lactate.
[0000]
TABLE 1
Reaction results of fructose
SnCl 4 •5H 2 O
DMIMMS
t
T
Y
(g)
(g)
Carbohydrate
(h)
(° C.)
(%)
0.2
0.200
fructose
2.0
140
94
0.2
0.200
fructose
4.0
140
91
0.2
0
fructose
2.0
140
28
Example 2
Reaction Results of Glucose
[0037] The results listed in Table 2 were obtained using 1,3-dimethylimidazolium methylsulfate and SnCl 4 .5H 2 O as catalyst. After adding 1,3-dimethylimidazolium methylsulfate (see the amount in Table 2), SnCl 4 .5H 2 O (see the amount in Table 2), 0.200 g of glucose, and 5.0 mL of methanol into a 10 mL batch reactor, the reactor was sealed and heated to 140° C. under stirring to carry out the reaction. The reaction time is listed in Table 2. After reaction, NaOH solution (0.50M, 10.0 mL) was added to carry out a hydrolysis reaction at 60° C. for 5 hours to obtain a solution. HCl solution (0.50M, 10.0 mL) was added into the resulting solution to convert sodium lactate to lactic acid, and then the solution was analyzed on a HPLC to obtain the total percent yield of lactic acid and methyl lactate (as that listed in Table 2). In Table 2, “DMIMMS” stands for the 1,3-dimethylimidazolium methylsulfate; “t” stands for reaction time in hours; “T” stands for the reaction temperature in degrees Celsius; and “Y” stands for the total percent yield of lactic acid and methyl lactate.
[0000]
TABLE 2
Reaction results of glucose
SnCl 4 •5H 2 O
DMIMMS
t
T
Y
(g)
(g)
Carbohydrate
(h)
(° C.)
(%)
0.2
0
glucose
2
140
26
0.2
0.200
glucose
2
140
64
0.2
0.200
glucose
4
140
66
Example 3
Reaction Results of Sucrose
[0038] The results listed in Table 3 were obtained using different 1,3-dialkyl imidazolium salts and SnCl 4 .5H 2 O as catalyst. After adding 1,3-dialkyl imidazolium salt (see the amount in Table 3), SnCl 4 .5H 2 O (see the amount in Table 3), 0.200 g of sucrose, and 5.0 mL of methanol into a 10 mL batch reactor, the reactor was sealed and heated to reaction temperature (listed in Table 3) under stirring to carry out the reaction. The reaction time is listed in Table 3. After reaction, NaOH solution (0.50 M, 10.0 mL) was added to carry out a hydrolysis reaction at 60° C. for 5 hours to obtain a solution. HCl solution (0.50 M, 10.0 mL) was added into the resulted solution to convert sodium lactate to lactic acid. The solution was analyzed on a HPLC to obtain the total percent yield of lactic acid and methyl lactate (as that listed in Table 3). In Table 3, “t” stands for reaction time in hours; “T” stands for the reaction temperature in degrees Celsius; and “Y” stands for the total percent yield of lactic acid and methyl lactate. DMDIMDC has the following structure:
[0000]
[0000]
TABLE 3
Reaction results of sucrose
SnCl 4 •5H 2 O
1,3-dialkyl imidazolium
t
T
Y
(g)
salt (g)
(h)
(° C.)
(%)
0.200
DMIMMS (0.200)
4
140
54
0.200
DMIMMS (0.200)
10
140
55
0.200
DMIMMS (0.200)
15
140
61
0.200
DMIMMS (0.200)
20
140
59
0.200
DMIMMS (0.500)
4
140
60
0.500
DMIMMS (0.200)
4
140
66
0.500
DMIMMS (0.500)
4
140
72
0.200
DMIMMS (0.200)
15
150
55
0.200
DMIMMS (0.200)
15
160
50
0.200
DMIMMS (0.200)
15
170
43
0.200
methyl pyridine
15
140
7
sulfate (0.200)
0.200
N-methyl-N-ethyl-
15
140
26
imidazolium chloride
(0.200)
0.200
DMDIMDC (0.200)
15
140
29
Example 4
Reaction Results of Starch
[0039] The results listed in Table 4 were obtained using different amounts of DMIMMS and SnCl 4 .5H 2 O as catalyst. After adding DMIMMS (see the amount in Table 4), SnCl 4 .5H 2 O (see the amount in Table 4), water (1.0 g), 0.200 g of starch, and 5.0 mL of methanol into a 10 mL batch reactor, the reactor was sealed and heated to reaction temperature (listed in Table 4) under stirring to carry out the reaction. The reaction time is listed in Table 4. After reaction, NaOH solution (0.50 M, 10.0 mL) was added to carry out a hydrolysis reaction at 60° C. for 5 hours to obtain a solution. HCl (0.50 M, 10.0 mL) was added into the resulting solution to convert sodium lactate to lactic acid, and then the solution was analyzed on a HPLC to obtain the total percent yield of lactic acid and methyl lactate (as that listed in Table 4). In Table 4, “t” stands for reaction time in hours; “T” stands for the reaction temperature in degrees Celsius; and “Y” stands for the total percent yield of lactic acid and methyl lactate.
[0000]
TABLE 4
Reaction results of starch
H 2 O
SnCl 4 •5H 2 O
DMIMMS
t
T
Y
(g)
(g)
(g)
(h)
(° C.)
(%)
1.0
0.200
0.500
8
170
16
1.0
0.500
0.200
8
170
36
1.0
0.500
0.500
8
170
40
1.0
0.200
0.500
8
150
37
1.0
0.500
0.200
8
150
45
1.0
0.500
0.500
8
150
55
1.0
0.200
0.200
15
160
33
1.0
0.200
0.200
15
180
30
1.0
0.200
0.200
15
150
41
1.0
0.200
0.200
15
160
33
1.0
0.200
0.200
15
170
25
1.0
0.200
0
10
140
6
1.0
0.200
0.200
10
140
39
1.0
0.200
0.200
15
140
32
1.0
0.200
0.500
15
140
37
1.0
0.500
0.200
15
140
45
1.0
0.500
0.500
15
140
54
Example 5
Reaction Results of Cellulose
[0040] The results listed in Table 5 were obtained using DMIMMS and SnCl 4 .5H 2 O as catalyst. After adding DMIMMS (see the amount in Table 5), SnCl 4 .5H 2 O (see the amount in Table 5), water (1.0 g), 0.200 g of cellulose, and 5.0 mL of methanol into a 10 mL batch reactor, the reactor was sealed and heated to reaction temperature (listed in Table 5) under stirring to carry out the reaction. The reaction time is listed in Table 5. After reaction, NaOH solution (0.50 M, 10.0 mL) was added carry out a hydrolysis reaction at 60° C. for 5 hours to obtain a solution. HCl (0.50 M, 10.0 mL) was added into the resulting solution to convert sodium lactate to lactic acid, and then the solution was analyzed on a HPLC to obtain the total percent yield of lactic acid and methyl lactate (as that listed in Table 5). In Table 5, “t” stands for reaction time in hours; “T” stands for the reaction temperature in degrees Celsius; and “Y” stands for the total percent yield of lactic acid and methyl lactate.
[0000]
TABLE 5
Reaction results of cellulose
H 2 O
SnCl 4 •5H 2 O
DMIMMS
t
T
Y
(g)
(g)
(g)
(h)
(° C.)
(%)
1.0
0.2
0.2
15
160
3
1.0
0.2
0.2
15
170
11
1.0
0.2
0.2
15
180
9
Example 6
Reaction Results of Corn Starch
[0041] The results listed in Table 6 were obtained using 1-ethyl-3-methylimidazolium chloride (EMIMC) and SnCl 4 .5H 2 O as catalyst. After adding 1-ethyl-3-methylimidazolium chloride (see the amount in Table 6), SnCl 4 .5H 2 O (see the amount in Table 6), water (1.0 g), 0.500 g of starch, and 4.0 mL of methanol into a 10 mL batch reactor, the reactor was sealed and heated to reaction temperature (listed in Table 6) under stirring to carry out the reaction. The reaction time is listed in Table 6. After reaction, NaOH solution (0.50 M, 10.0 mL) was added to carry out a hydrolysis reaction at 60° C. for 5 hours to obtain a solution. HCl (0.50 M, 10.0 mL) was added into the resulting solution to convert sodium lactate to lactic acid, and then the solution was analyzed on a HPLC to obtain the total percent yield of lactic acid and methyl lactate (as that listed in Table 6). In Table 6, “t” stands for reaction time in hours; “T” stands for the reaction temperature in degrees Celsius; and “Y” stands for the total yield of lactic acid and methyl lactate.
[0000]
TABLE 6
Reaction results of corn starch
H 2 O
SnCl 4 •5H 2 O
EMIMC
t
T
Y
(g)
(g)
(g)
(h)
(° C.)
(%)
1.0
0.5005
1.0112
2
160
27
1.0
0.5004
1.0092
6
160
32
1.0
0.4999
1.0465
4
170
34
1.0
0.5005
1.0384
6
170
36
1.0
0.5005
1.0321
7
170
37
1.0
0.4998
1.0104
8
170
39
1.0
0.5004
1.0035
10
170
39
1.0
0.5002
1.0083
15
170
40
Example 7
Reaction Results of Sucrose
[0042] The results listed in Table 7 were obtained using 1,3-dimethylimidazolium sulfate ((DMIM) 2 SO 4 ) and SnCl 4 .5H 2 O as catalyst. After adding (DMIM) 2 SO 4 (see the amount in Table 7), SnCl 4 .5H 2 O (see the amount in Table 7), water (1.0 g), 0.500 g of sucrose, and methanol (5.0 mL) were added into a 10 mL batch reactor, the reactor was sealed and heated to reaction temperature (listed in Table 7) under stirring to carry out the reaction for 2 hours. The reaction time is listed in Table 7. After reaction, NaOH solution (0.50 M, 10.0 mL) was added to carry out a hydrolysis reaction at 60° C. for 5 hours to obtain a solution. HCl (0.50 M, 10.0 mL) was added into the resulting solution to convert sodium lactate to lactic acid, and then the solution was analyzed on a HPLC to obtain the total percent yield of lactic acid and methyl lactate (as that listed in Table 7). In Table 7, “t” stands for reaction time in hours; “T” stands for the reaction temperature in degrees Celsius; and “Y” stands for the total percent yield of lactic acid and methyl lactate.
[0000]
TABLE 7
Reaction results of sucrose
H 2 O
SnCl 4 •5H 2 O
(DMIM) 2 SO 4
t
T
Y
(g)
(g)
(g)
(h)
(° C.)
(%)
1.0
1.00
1.00
2
160
10
1.0
1.00
1.00
2
140
12
1.0
1.00
1.00
2
120
10
1.0
1.00
1.00
2
100
40
Example 8
Reaction Results of Sucrose
[0043] The results listed in Table 8 were obtained using 1,3-dimethylimidazolium sulfate ((DMIM) 2 SO 4 ) and SnCl 4 .5H 2 O as catalyst. After adding (DMIM) 2 SO 4 (see the amount in Table 8), SnCl 4 .5H 2 O (see the amount in Table 8), water (1.0 g), 0.200 g of sucrose, and methanol (5.0 mL) were added into a 10 mL batch reactor, the reactor was sealed and heated to reaction temperature (listed in Table 8) under stirring to carry out the reaction for 2 hours. After reaction, NaOH solution (0.50 M, 10.0 mL) was added to carry out a hydrolysis reaction at 60° C. for 5 hours to obtain a solution. HCl (0.50 M, 10.0 mL) was added into the resulting solution to convert sodium lactate to lactic acid, and then the solution was analyzed on a HPLC to obtain the total percent yield of lactic acid and methyl lactate (as that listed in Table 8). In Table 8, “t” stands for reaction time in hours; “T” stands for the reaction temperature in degrees Celsius; and “Y” stands for the total yield of lactic acid and methyl lactate.
[0000]
TABLE 8
Reaction results of sucrose
H 2 O
SnCl 4 •5H 2 O
(DMIM) 2 SO 4
t
T
Y
(g)
(g)
(g)
(h)
(° C.)
(%)
1.0
1.00
1.00
2
160
11
1.0
1.00
1.00
2
140
26
1.0
1.00
1.00
2
120
28
1.0
1.00
1.00
2
100
78
1.0
1.00
1.00
2
80
75
Example 9
Reaction Results of Glucose
[0044] The results listed in Table 9 were obtained using 1,3-dimethylimidazolium sulfate ((DMIM) 2 SO 4 ) and SnCl 4 .5H 2 O as catalyst. After adding (DMIM) 2 SO 4 (see the amount in Table 9), SnCl 4 .5H 2 O (see the amount in Table 9), water (1.0 g), 0.500 g of glucose, and methanol (5.0 mL) were added into a 10 mL batch reactor, the reactor was sealed and heated to reaction temperature (listed in Table 9) under stirring to carry out the reaction for 5 hours. After reaction, NaOH solution (0.50 M, 10.0 mL) was added to carry out a hydrolysis reaction at 60° C. for 5 hours to obtain a solution. HCl (0.50 M, 10.0 mL) was added into the resulting solution to convert sodium lactate to lactic acid, and then the solution was analyzed on a HPLC to obtain the total percent yield of lactic acid and methyl lactate (as that listed in Table 9). In Table 9, “t” stands for reaction time in hours; “T” stands for the reaction temperature in degrees Celsius; and “Y” stands for the total percent yield of lactic acid and methyl lactate.
[0000]
TABLE 9
Reaction results of glucose
H 2 O
SnCl 4 •5H 2 O
(DMIM) 2 SO 4
t
T
Y
(g)
(g)
(g)
(h)
(° C.)
(%)
1.0
1.00
1.00
5
160
14
1.0
1.00
1.00
5
140
16
1.0
1.00
1.00
5
120
25
1.0
1.00
1.00
5
100
34
Example 10
Reaction Results of Glucose
[0045] The results listed in Table 10 were obtained using 1,3-dimethylimidazolium sulfate ((DMIM) 2 SO 4 ) and SnCl 4 .5H 2 O as catalyst. After adding (DMIM) 2 SO 4 (see the amount in Table 10), SnCl 4 .5H 2 O (see the amount in Table 10), water (1.0 g), 0.200 g of glucose, and methanol (5.0 mL) were added into a 10 mL batch reactor, the reactor was sealed and heated to reaction temperature (listed in Table 10) under stirring to carry out the reaction for 2 hours. After reaction, NaOH solution (0.50 M, 10.0 mL) was added to carry out a hydrolysis reaction at 60° C. for 5 hours to obtain a solution. HCl (0.50 M, 10.0 mL) was added into the resulting solution to convert sodium lactate to lactic acid, and then the solution was analyzed on a HPLC to obtain the total percent yield of lactic acid and methyl lactate (as that listed in Table 10). In Table 10, “t” stands for reaction time in hours; “T” stands for the reaction temperature in degrees Celsius; and “Y” stands for the total percent yield of lactic acid and methyl lactate.
[0000]
TABLE 10
Reaction results of glucose
H 2 O
SnCl 4 •5H 2 O
(DMIM) 2 SO 4
t
T
Y
(g)
(g)
(g)
(h)
(° C.)
(%)
1.0
1.00
1.00
5
140
24
1.0
1.00
1.00
5
120
31
1.0
1.00
1.00
5
100
75
Example 11
Reaction Results of Starch
[0046] The results listed in Table 11 were obtained using 1,3-dimethylimidazolium sulfate ((DMIM) 2 SO 4 ) and SnCl 4 .5H 2 O as catalyst. After adding (DMIM) 2 SO 4 (see the amount in Table 11), SnCl 4 .5H 2 O (see the amount in Table 11), water (1.0 g), starch, and methanol (5.0 mL) were added into a 10 mL batch reactor, the reactor was sealed and heated to reaction temperature (listed in Table 11) under stirring to carry out the reaction for 5 hours. After reaction, NaOH solution (0.50 M, 10.0 mL) was added to carry out a hydrolysis reaction at 60° C. for 5 hours to obtain a solution. HCl (0.50 M, 10.0 mL) was added into the resulting solution to convert sodium lactate to lactic acid, and then the solution was analyzed on a HPLC to obtain the total percent yield of lactic acid and methyl lactate (as that listed in Table 11). In Table 11, “T” stands for the reaction temperature in degrees Celsius and “Y” stands for the total percent yield of lactic acid and methyl lactate.
[0000]
TABLE 11
Reaction results of starch
H 2 O
SnCl 4 •5H 2 O
(DMIM) 2 SO 4
starch
T
Y
(g)
(g)
(g)
(g)
(° C.)
(%)
1.0
1.00
1.00
0.500
140
22
1.0
1.00
1.00
0.500
120
10
1.0
1.00
1.00
0.200
160
30
1.0
1.00
1.00
0.200
100
8
Example 12
Reaction Results of Sucrose
[0047] The results listed in Table 12 were obtained using 1,3-dimethylimidazolium hydrogen sulfate (DMIMHSO 4 ) and SnCl 4 .5H 2 O as catalyst. After adding DMIMHSO 4 (see the amount in Table 12), SnCl 4 .5H 2 O (see the amount in Table 12), sucrose, and methanol (5.0 mL) were added into a 10 mL batch reactor, the reactor was sealed and heated to reaction temperature (listed in Table 12) under stirring to carry out the reaction for 5 hours. After reaction, NaOH solution (0.50 M, 10.0 mL) was added to carry out a hydrolysis reaction at 60° C. for 5 hours to obtain a solution. HCl (0.50 M, 10.0 mL) was added into the resulting solution to convert sodium lactate to lactic acid, and then the solution was analyzed on a HPLC to obtain the total percent yield of lactic acid and methyl lactate (as that listed in Table 12). In Table 12, “T” stands for the reaction temperature in degrees Celsius and “Y” stands for the total percent yield of lactic acid and methyl lactate.
[0000]
TABLE 12
Reaction results of sucrose
SnCl 4 •5H 2 O
DMIMHSO 4
sucrose
T
Y
(g)
(g)
(g)
(° C.)
(%)
1.00
1.00
0.500
160
10
1.00
1.00
0.500
140
18
1.00
1.00
0.500
120
16
Example 13
Reaction Results of Sucrose
[0048] The results listed in Table 13 were obtained using 1,3-dimethylimidazolium hydrogen sulfate (DMIMHSO 4 ) and SnCl 4 .5H 2 O as catalyst. After adding DMIMHSO 4 (see the amount in Table 13), SnCl 4 .5H 2 O (see the amount in Table 13), glucose, and methanol (5.0 mL) were added into a 10 mL batch reactor, the reactor was sealed and heated to reaction temperature (listed in Table 13) under stirring to carry out the reaction for 5 hours. After reaction, NaOH solution (0.50 M, 10.0 mL) was added to carry out a hydrolysis reaction at 60° C. for 5 hours to obtain a solution. HCl (0.50 M, 10.0 mL) was added into the resulting solution to convert sodium lactate to lactic acid, and then the solution was analyzed on a HPLC to obtain the total percent yield of lactic acid and methyl lactate (as that listed in Table 13). In Table 13, “T” stands for the reaction temperature in degrees Celsius and “Y” stands for the total percent yield of lactic acid and methyl lactate.
[0000]
TABLE 13
Reaction results of glucose
SnCl 4 •5H 2 O
DMIMHSO 4
glucose
T
Y
(g)
(g)
(g)
(° C.)
(%)
1.00
1.00
0.500
160
23
1.00
1.00
0.500
140
8
1.00
1.00
0.500
120
9
Example 14
Reaction Results of Starch
[0049] The results listed in Table 14 were obtained using 1,3-dimethylimidazolium hydrogen sulfate (DMIMHSO 4 ) and SnCl 4 .5H 2 O as catalyst. After adding DMIMHSO 4 (see the amount in Table 14), SnCl 4 .5H 2 O (see the amount in Table 14), starch, and 5.0 mL of methanol added into a 10 mL batch reactor, the reactor was sealed and heated to reaction temperature (listed in Table 14) under stirring to carry out the reaction for 5 hours. After reaction, NaOH solution (0.50 M, 10.0 mL) was added to carry out a hydrolysis reaction at 60° C. for 5 hours to obtain a solution. HCl (0.50 M, 10.0 mL) was added into the resulting solution to convert sodium lactate to lactic acid, and then the solution was analyzed on a HPLC to obtain the total percent yield of lactic acid and methyl lactate (as that listed in Table 14). In Table 14, “T” stands for the reaction temperature in degrees Celsius and “Y” stands for the total yield of lactic acid and methyl lactate.
[0000]
TABLE 14
Reaction results of starch
CH 3 OH
SnCl 4 •5H 2 O
DMIMHSO 4
starch
H 2 O (g)
(mL)
(g)
(g)
(g)
T (° C.)
Y (%)
0
5.0
1.00
1.00
0.500
160
20
1.0
4.0
1.00
1.00
0.500
160
22
0
5.0
1.00
1.00
0.200
80
2
Example 15
[0050] The results listed in Table 15 were obtained using 1-ethyl-3-methylimidazolium chloride (EMIMC) and Sn(CH 3 SO 3 ) 2 as catalyst. After adding EMIMC (see the amount in Table 15), Sn(CH 3 SO 3 ) 2 , sucrose, and methanol were added into a batch reactor (volume 15 mL), the reactor was sealed and heated to reaction temperature (listed in Table 15) under stifling to carry out the reaction for 2 hours. After reaction, the solution was analyzed on a GC to obtain the total percent yield of methyl lactate (as that listed in Table 15). In Table 15, “T” stands for the reaction temperature in degrees Celsius and “Y ml ” stands for the total yield of methyl lactate.
[0000]
TABLE 15
The reaction results of sucrose at different temperature
T
Sn(CH 3 SO 3 ) 2
sucrose
CH 3 OH
EMIMC
Y ml
(° C.)
(g)
(g)
(mL)
(g)
(%)
80
0.20
0.20
8.0
0.50
1
90
0.20
0.20
8.0
0.50
20
100
0.20
0.20
8.0
0.50
41
110
0.20
0.20
8.0
0.50
43
120
0.20
0.20
8.0
0.50
42
130
0.20
0.20
8.0
0.50
50
140
0.20
0.20
8.0
0.50
41
Example 16
[0051] The results listed in Table 16 were obtained using 1-ethyl-3-methylimidazolium chloride (EMIMC) and Sn(CH 3 SO 3 ) 2 as catalyst. After adding EMIMC (see the amount in Table 16), Sn(CH 3 SO 3 ) 2 , sucrose, and methanol were added into a batch reactor (volume 15 mL), the reactor was sealed and heated to 130° C. under stirring to carry out the reaction from 0.5 to 4 hours. After reaction, the solution was analyzed on a GC to obtain the total percent yield of methyl lactate (as that listed in Table 16). In Table 16, “t” stands for the reaction time in hours and “Y ml ” stands for the total yield of methyl lactate.
[0000]
TABLE 16
The reaction results of sucrose at
130° C. for different reaction time
t
Sn(CH 3 SO 3 ) 2
sucrose
CH 3 OH
EMIMC
Y ml
(h)
(g)
(g)
(mL)
(g)
(%)
0.5
0.20
0.20
8.0
0.50
10
1
0.20
0.20
8.0
0.50
30
1.5
0.20
0.20
8.0
0.50
35
2
0.20
0.20
8.0
0.50
50
2.5
0.20
0.20
8.0
0.50
35
3
0.20
0.20
8.0
0.50
35
4
0.20
0.20
8.0
0.50
18
Example 17
[0052] The results listed in Table 17 were obtained using different ionic liquid and Sn(CH 3 SO 3 ) 2 as catalyst. After adding ionic liquid (0.50 g, see Table 17), Sn(CH 3 SO 3 ) 2 (0.20 g), sucrose (0.20 g), and methanol (8.0 mL) were added into a batch reactor (volume 15 mL), the reactor was sealed and heated to 130° C. under stirring to carry out the reaction for 2 hours. After reaction, the solution was analyzed on a GC to obtain the total percent yield of methyl lactate (as that listed in Table 17). In Table 17, “Y ml ” stands for the total yield of methyl lactate.
Note:
[0053] DMDIMDC stands for the following compound:
[0000]
[0000] DMBIMC stands for the following compound:
[0000]
[0000]
TABLE 17
The reaction results of by using different ionic liquids
Y ml
ionic liquid
(%)
1-ethyl-3-methylimidazolium chloride
50
DMDTMDC
65
1-butyl-2,3-dimethylimidazolium chloride
59
DMBIMC
13
1,3-dimethylimidazolium iodide
23
Example 18
[0054] The results listed in Table 18 were obtained using 1-ethyl-3-methylimidazolium chloride (EMIMC) and Sn(CH 3 SO 3 ) 2 as catalyst. After adding EMIMC (see the amount in Table 18), Sn(CH 3 SO 3 ) 2 , starch, and methanol were added into a batch reactor (volume 15 mL), the reactor was sealed and heated to 160° C. under stirring to carry out the reaction from 2 to 15 hours. After reaction, the solution was analyzed on a GC to obtain the total percent yield of methyl lactate (as that listed in Table 18). In Table 18, “t” stands for the reaction time in hours and “Y ml ” stands for the total yield of methyl lactate.
[0000]
TABLE 18
The reaction results of starch at 160° C. for different reaction time
t
Sn(CH 3 SO 3 ) 2
starch
CH 3 OH
EMIMC
Y ml
(h)
(g)
(g)
(mL)
(g)
(%)
2
0.20
0.20
8.0
0.50
3
4
0.20
0.20
8.0
0.50
11
6
0.20
0.20
8.0
0.50
16
8
0.20
0.20
8.0
0.50
32
10
0.20
0.20
8.0
0.50
32
12
0.20
0.20
8.0
0.50
36
15
0.20
0.20
8.0
0.50
31
Example 19
[0055] The results listed in Table 19 were obtained using 1-ethyl-3-methylimidazolium chloride (EMIMC) and Sn(CH 3 SO 3 ) 2 as catalyst. After adding EMIMC (see the amount in Table 19), Sn(CH 3 SO 3 ) 2 , starch, and methanol were added into a batch reactor (volume 15 mL), the reactor was sealed and heated to reaction temperature (listed in Table 19) under stirring to carry out the reaction for 8 hours. After reaction, the solution was analyzed on a GC to obtain the total percent yield of methyl lactate (as that listed in Table 19). In Table 19, “T” stands for the reaction temperature in degrees Celsius and “Y ml ” stands for the total yield of methyl lactate.
[0000]
TABLE 19
The reaction results of starch at different temperature
T
Sn(CH 3 SO 3 ) 2
starch
CH 3 OH
EMIMC
Y ml
(° C.)
(g)
(g)
(mL)
(g)
(%)
150
0.20
0.20
8.0
0.50
1
160
0.20
0.20
8.0
0.50
20
170
0.20
0.20
8.0
0.50
41
180
0.20
0.20
8.0
0.50
43
190
0.20
0.20
8.0
0.50
42
Example 20
[0056] The results listed in Table 20 were obtained using DMDIMDBS (see structure below) and Sn(C 6 H 5 SO 3 ) 2 as catalyst. After adding DMDIMDBS (see the amount in Table 20), Sn(C 6 H 5 SO 3 ) 2 , sweet potato, and methanol were added into a batch reactor (volume 15 mL), the reactor was sealed and heated to reaction temperature (listed in Table 20) under stirring to carry out the reaction for 8 hours. After reaction, the solution was analyzed on a GC to obtain the total percent yield of methyl lactate (as that listed in Table 20). In Table 20, “T” stands for the reaction temperature in degrees Celsius and “Y ml ” stands for the total yield of methyl lactate. DMDIMDBS stands for the following compound:
[0000]
[0000]
TABLE 20
The reaction results of sweet potato
(dry powder) at different temperature
Sweet
T
Sn(C 6 H 5 SO 3 ) 2
potato
CH 3 OH/H 2 O
DMDIMDBS
Y ml
(° C.)
(g)
(g)
(g/g)
(g)
(%)
160
0.30
0.20
6.4/0.30
0.50
34
160
0.30
0.20
4.8/0.30
0.50
37
160
0.30
0.20
3.2/0.30
0.50
28
160
0.30
0.20
1.6/0.30
0.50
21
140
0.30
0.20
6.4/0.30
0.50
17
150
0.30
0.20
6.4/0.30
0.50
23
160
0.30
0.20
6.4/0.30
0.50
34
170
0.30
0.20
6.4/0.30
0.50
38
180
0.30
0.20
6.4/0.30
0.50
36
Example 21
[0057] The results listed in Table 21 were obtained using DMDIMDBS (see structure below) and Sn(C 6 H 5 SO 3 ) 2 as catalyst. After adding DMDIMDBS (see the amount in Table 21), Sn(C 6 H 5 SO 3 ) 2 , sucrose, and methanol were added into a batch reactor (volume 15 mL), the reactor was scaled and heated to reaction temperature (listed in Table 21) under stirring to carry out the reaction for 2 hours. After reaction, the solution was analyzed on a GC to obtain the total percent yield of methyl lactate (as that listed in Table 21). In Table 21, “T” stands for the reaction temperature in degrees Celsius and “Y ml ” stands for the total yield of methyl lactate.
[0000] DMDIMDBS stands for the following compound:
[0000]
[0000]
TABLE 21
The reaction results of sucrose at different temperature
T
Sn(C 6 H 5 SO 3 ) 2
sucrose
CH 3 OH/H 2 O
DMDIMDBS
Y ml
(° C.)
(g)
(g)
(g/g)
(g)
(%)
150
0.30
0.20
6.4/0
0.50
33
130
0.30
0.20
6.4/0
0.50
25
130
0.30
0.20
4.8/0
0.50
28
130
0.30
0.20
4.8/0.20
0.50
34
120
0.30
0.20
4.8/0.20
0.50
27
130
0.30
0.20
4.8/0.20
0.50
34
140
0.30
0.20
4.8/0.20
0.50
34
150
0.30
0.20
4.8/0.20
0.50
39
160
0.30
0.20
4.8/0.20
0.50
42
Example 22
[0058] The results listed in Table 22 were obtained using DMDIMDBS (see structure below) and Sn(C 6 H 5 SO 3 ) 2 as catalyst. After adding DMDIMDBS (see the amount in Table 22), Sn(C 6 H 5 SO 3 ) 2 , starch, and methanol were added into a batch reactor (volume 15 mL), the reactor was sealed and heated to reaction temperature (listed in Table 22) under stirring to carry out the reaction for 8 hours. After reaction, the solution was analyzed on a GC to obtain the total percent yield of methyl lactate (as that listed in Table 22). In Table 22, “T” stands for the reaction temperature in degrees Celsius and “Y ml ” stands for the total yield of methyl lactate.
[0000] DMDIMDBS stands for the following compound:
[0000]
[0000]
TABLE 22
The reaction results of starch at different temperature
T
Sn(C 6 H 5 SO 3 ) 2
Starch
CH 3 OH
DMDIMDBS
Y ml
(° C.)
(g)
(g)
(mL)
(g)
(%)
140
0.282
0.20
8.0
0.50
36
150
0.282
0.20
8.0
0.50
32
160
0.282
0.20
8.0
0.50
48
170
0.282
0.20
8.0
0.50
42
180
0.282
0.20
8.0
0.50
35
160
0.282
0.20
8.0
0.50
37
160
0.282
0.20
8.0
0.50
33
160
0.282
0.20
8.0
0.50
42
160
0.282
0.20
8.0
0.50
44
160
0.282
0.20
8.0
0.50
48
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A method for synthesizing lactic acid and lactate is invented from carbohydrates, such as monosaccharides and/or polysaccharides in the presence of the catalyst that is the combinations of nitrogen-heterocycle aromatic ring cation salts and metal compounds. In the reaction, at least one alcohol and at least one solvent are used. Specifically, in the presence of [SnCl 4 -1-ethyl-3-methylimidazolium chloride ([EMIM]Cl)], SnCl 4 -1,3-dimethylimidazolium methyl sulfate ([DMIM]CH 3 SO 4 )], [SnCl 2 -1-ethyl-3-methylimidazolium chloride ([EMIM]Cl)], or SnCl 2 -1,3-dimethylimidazolium methyl sulfate ([DMIM]CH 3 SO 4 )] in methanol.
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CROSS REFERENCE TO RELATED APPLICATION
The present invention is based on provisional patent application Serial No. 60/413,813 filed Sept. 25, 2002.
BACKGROUND OF THE INVENTION
This invention relates to a novel decorative urn for storing cremation ashes in a lighted memorial display.
The devotion of a long term pet to its owner has created a corresponding interest in providing a suitable and tasteful way of keeping the memory of the departed pet fresh in the mind of the owner. While the display of a photograph serves as a reminder, it is generally limited in evoking a memory beyond that of the particular scene portrayed. A static display, such as a photograph or an artifact associated with a particular event, lacks the emotional impact of a memorial display containing the physical remains of the pet.
The retention of cremation ashes in the home environment is an ever increasing way of promoting the feeling in the owners that the pet is still with the spirit in the home. The coupling of a storage receptacle for the cremation ashes along with an active display of light is thought to broaden and enhance the impact of knowing that the remains of the pet rests therein. It is felt that the association of an active light, such as a flame, with a suitable display structure that magnifies the effect of the flame, not only draws attention to the urn but suggests life itself. As a result, the pet owner having the ashes included in an active display is continually reminded of an active pet and its activities throughout its life.
The present invention has as a significant object the use of a long-burning flame in combination with a receptacle for the ashes of a pet. A further object is the provision of a decorative urn that includes a partially-light transmissive surround. The surround has a glow imparted to it from the flame which magnifies the visual impact of the flame. A chamber is provided beneath the flame and fuel reservoir for receiving the contained ashes of the cremated pet. While the primary use for the urn is for the storage and memorialization of animals, it is to be noted that the device may be for the ashes of all animate or inanimate objects.
The subject decorative urn is a two section upright structure having a base section that is provided with a bottom surface to rest on a support such as a mantle or table. The top surface of the base section receives thereon a light-transmissive housing, which contains a fluid reservoir and the light generating flame. The housing is capable of independent use as a light source. The present invention is simple in form and attractive in appearance as befits the use for which it is intended.
SUMMARY OF THE INVENTION
The decorative urn which is the subject of this invention comprises a base section along with a housing to be supported thereon. The base section includes a cavity therein for removably receiving a receptacle dimensioned to be readily placed therein. The base section further includes a top surface that receives the housing containing a wick structure and a fluid reservoir. The base section and housing are flanged to provide engaging means for removably supporting the housing on the top surface of the base section. In the preferred embodiment, the assemblage of base section and housing thereon appear as a uniform cylinder to the observer.
The housing contains a centrally-located port which communicates with the fluid reservoir therein. A wick assembly is removably located in the port after the reservoir is filled. The wick extends into the fluid reservoir for drawing fuel therefrom and sustaining a lighted flame. The material of the housing is light-transmissive. A vertical flange extends around the periphery of the housing and aids in the glow imparted to the housing by the flame. If desired, an opaque material can be used to form the base section or, alternatively, an opaque shield can be used in the cavity in the base section so that the outline of the ash containing receptacle is not directly shown by the light transmitted through the material of the base section of the urn. Further features and advantages of the invention will become more readily apparent from the following detailed description of a specific embodiment when taken in conjunction of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in perspective of one embodiment of the invention.
FIG. 2 is a cross sectional view of the wick assembly of the embodiment of FIG. 1 .
FIG. 3 is a cross sectional view of the embodiment of FIG. 1 with the wick assembly omitted.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the decorative urn shown includes a base section 11 having an upper section 12 placed thereon. A wick assembly 14 is centrally located in the housing or upper section. The wick 15 is shown protruding therefrom. A peripheral rim 16 . extends about the outer edge of the upper surface of section 12 . In the embodiment shown, the base section 11 and the upper section 12 are formed of machined nylon to have the same diameter. Alternatively, the sections may be formed by a molding processes.
The sections comprising the urn have light-transmissive characteristics. As a result, when the wick 15 is lighted and a flame is present in the central region of the upper section 12 , the light is transmitted throughout the decorative urn. The light is brightest in the peripheral rim of the upper section and reduces in intensity in the vertical direction away from the flame. In the preferred embodiment both sections are formed of light-transmissive material, although the base section 11 may be formed by machining brass or bronze.
The upper section 12 is readily detached from the base section 11 as shown in FIG. 3 . The upper section contains a fuel reservoir 18 which is bounded by a mating threaded lid 19 . The lid is provided with a threaded opening 20 therein for receiving the wick assembly. The wick assembly 14 includes a wick holder 22 , typically formed of brass, that is threadably inserted into a machined nylon support 21 . The support has a downwardly extending threaded engaging end 24 with a central passageway therein for the wick to descend into fluid reservoir 18 . The particular embodiment shown has a large fluid reservoir to permit the wick to carry a flame for months at a time without refilling.
As shown, the base section 11 has a peripheral flange 26 which receives a mating downwardly extending flange 27 to allow the nesting of the upper section 12 upon the base section 11 . As shown in FIG. 3, the central cavity 30 contained in the base section is shown having a receptacle 31 located therein. The receptacle 31 is the container for the stored ashes and is held in position by lid 28 . In the preferred embodiment, the lid is oversize so that the edges thereof extend beyond the edge of cavity 30 . As mentioned, the device is made of light-transmissive material. However, the outline of the receptacle containing the ashes need not be directly viewed by the observer. The opaque shield 32 is positioned in slots machined into the base section segments and can be located as desired about the receptacle. If desired, the base section can be non light transmissive.
The uniform surface of the embodiment shown in FIG. 1 is especially well suited to the mounting of informational plaques containing reference material as desired. Further, the upper section can be removed and used independently as a source of light. In this situation, the base section can be utilized for the relocation of the ashes without removal of the receptacle. As shown, the receptacle is bounded by the secure nylon base section with the overlying lid 28 affixed thereto. This provides a permanent envelope for internment.
While the above description has been with reference to a particular embodiment of the invention, it is to be noted modifications and variations may be made therein without departing from the scope of the invention as claimed.
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A decorative urn for storing cremation ashes in a lighted two part container. The base section receives an ash-containing receptacle and supported thereon is a top section including a recessed wick structure and full reservoir. The sections are light transmissive so that light from the wick imparts a glow throughout the urn.
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[0001] This application is a continuation in part of application Ser. Nos. 29/566,105, 29/566,109, 29/566,110, 29/566,111 and 29/566,112, all filed May 26, 2016, all now pending.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] This invention relates generally to eating utensils and, more specifically, to Stackable Disposable Utensils.
2. Description of Related Art
[0003] Based on the shape of the handle, there are two categories of disposable plastic cutlery existing in the current market—the non-stackable and the stackable. The stackable has more advantages to reduce at least 10% raw material during production and packaging process, while over 20% of storage and transportation fees are saved.
[0004] Polypropylene or Polystyrene are the typical raw materials used for construction of disposable cutlery as the raw material, the handle of the plastic cutlery can be quite fragile and thin or sharp forms such as the blade tend to be breakable. As a reulst, the user and surrounding people are exposed to the potential safety hazard with the broken handle and fragments scattering at a high speed.
[0005] The cross-sectional structure of these products is the key to solve the issues caused by the nature of material. The strength-to-density ratio varies in different sections of the handle, affecting by its width, length, thickness and shape. The breaking points are usually located at the section with lowest ratio of strength to density.
[0006] One of the popular methods to reduce the breakage is to make the handle thicker, such as the rib reinforcement at the weak point. However, while this approach has reduced the fragility of the product, there is still a strength problem in the handle. In fact, the issue could be worsened after installing an X-shaped rib reinforcement at the rear of the handle. More stress can be produced at the rib while the surrounding areas become increasingly fragile, which might lead to more harm if broken because the rib many times will remain unbroken. Also, the problem related to the higher cost of production is not solved.
[0007] The structure of the handle plays an important role in balancing the strength, weight, brittleness as well as the stackability. Currently, there are four categories of handle cross-section on the market:
[0008] 1. Straight-Line-Shaped Cross Section.
This design is more suitable for heavy duty tableware than the plastic cutlery. The handle defines a sheet shape with low strength in the vertical direction that can be bent easily. To attempt to resolve this, the handles are either thickened or reinforced with upper and lower projecting edges along both sides. However, this design still allows the handle to be slippery. Additionally, this design does not allow the cutlery to be stacked up, and thus has higher cost of packaging and storage.
[0010] 2. n-Shaped Cross Section.
This prior design has a handle cross-section that is “N-shaped,” with the handle defining either a straight line, an -shape line or an arcuate line. Different effects will be created, due to the varied angle between the n-shaped handle's two sides and the surface. If the height of the two sides over 50 percent of the width of the surface, the strength and bending resistance of the handle will be better than the straight-line-shaped handle. However, if the handle is thin, the defects of being fragile will still exist. In order to increase its strength and elasticity, the traditional way is to sacrifice the cost of the raw material by adding a reinforcement rib with an X-shape at the rear of the handle. The contrast between the X-shaped reinforcement rib and surrounding area, leads to a more hazardous situation for breakage. The x-shaped rib would also prevent stacking.
[0012] 3. Obtuse Angle Between Handle Surface and Both Sides.
For this design, the thickness of the handle's two sides is closed to the width of its surface. If the obtuse angle is arranged properly, the cutlery can be nested and stacked high. On the other hand, the handle's strength and elasticity will decrease as the angle increases. Although this design is stackable, this advantage has been balanced out by the increased thickness and the additional cost of raw material required in order to have a strong enough handle.
[0014] 4. -Shaped or V-Shaped
This design embodies the left and right sides of the handle forming an angle of less than 180 degrees (which will make the utensil stackable). However, in order to provide sufficient strength, an x-shaped rib has also been included (which prevents stackability).
[0016] What is needed, then, is a design for disposable cutlery that is light, stackable and strong enough to inhibit breaking.
SUMMARY OF THE INVENTION
[0017] In light of the aforementioned problems associated with the prior devices, it is an object of the present invention to provide a Stackable Disposable Utensil design. The spoon, soup spoon, spork, fork and knife should all be stackable with like items so that the most compact package is provided. The handles should have a W-shaped cross-section defined by a raised peak in its center, leading to a pair of valleys adjacent thereto, and terminating in slightly raised outer edges. Furthermore, the tail end of each utensil should terminate in a downwardly-sloped portion to further add strength.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings, of which:
[0019] FIG. 1 is a perspective view of a preferred embodiment of a fork of the present invention;
[0020] FIG. 2 is a top view thereof;
[0021] FIG. 3 is a bottom view thereof;
[0022] FIG. 4 is a cutaway side view thereof;
[0023] FIG. 5 is a bottom perspective view thereof;
[0024] FIG. 6 is a side view thereof;
[0025] FIG. 7 is a cutaway transverse view of the handle of the fork of FIG. 1 ;
[0026] FIG. 8 is a cutaway transverse view of the tines of the fork of FIG. 1 ;
[0027] FIG. 9 is a perspective view of a stack of the forks of FIG. 1 ;
[0028] FIG. 10 is a cutaway transverse view of the handles of the stack of FIG. 9 ;
[0029] FIG. 11 is a perspective view of a preferred embodiment of a spoon of the present invention;
[0030] FIG. 12 is a perspective view of a preferred embodiment of a soup spoon of the present invention;
[0031] FIG. 13 is a perspective view of a preferred embodiment of a spork of the present invention; and
[0032] FIG. 14 is a perspective view of a preferred embodiment of a knife of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide Stackable Disposable Utensils.
[0034] In order to solve the above technical problems, it is necessary to introduce a novel handle design that is light, strong with low brittleness and is stably stackable, for plastic fork, spoon and knife etc.
[0035] The present design produces a novel cutlery, comprising a handle portion, and food-access or tip portion. The cutlery is further defined by a handle having a neck portion connected with the food access unit and a tail portion (handle) extending away from it.
[0036] The cross section of handle for the novel cutlery is similar to W-shape with two inner lines and two outer lines. The two inner lines are divided symmetrically by the axis of the handle with the top joined and bottom separated, which forms a -shape. Locating further along the axis, the bottom of the two outer lines are joined with the bottom of the inner lines respectively while their tops are separated and forms two small V-shapes. Additionally, the upper side of the outer line has been turned horizontally, which produces two reinforcement sheets having a polygon shape. Meanwhile, two symmetrical sections with N shape forms respectively at both sides of the axis where the inner section is higher than the outer one.
[0037] The -shape, as mentioned above, extends along the central axis until it reaches the food operational portion and forms the main handle portion, which is similar to an open triangle. This design is more advantageous with higher strength and elasticity.
[0038] The enforcement sheets, extending from the rear end to the neck portion of the handle and connecting with the food operational portion, is strong enough to share the stress on the handle. Specifically, they play an important role in preventing bending and distortion caused by pressure at both sides of the handle.
[0039] The two opposing symmetrical sections with N shape run through the handle along the axis and join with the food engagement portion, thus making the W-shape handle as a whole.
[0040] The W-shape of the handle makes it possible for the convex groove with the at the front can be nested with the V-shape notch formed on the back-side. The gap between the stacked cutlery has thus been minimized. It is a structure that largely reduces the storage requirement. In addition to this, the small V-shapes at the bottom will stabilize the stacked cutlery.
[0041] When utilized properly by users, the novel cutlery can stand the stress from all direction. The chance of bending is low, especially with the enforcement sheets sharing the pressure and avoiding the displacement of both sides of the handle.
[0042] The handle of the novel cutlery cannot be easily broken even if an extraordinary amount of pressure is placed on it to force it to bend. As there is no necessary to add the X-shape reinforcement grids, the stress will spread evenly along the handles of the cutlery, and no weak point will be formed. When the pressure is placed vertically either from the back or front of the handle, it will transfer to the top of the -shape first and then to the two inner side ridges. The outer sides and the reinforcement sheets thereon move horizontally as distortion occurs. The molecular chain of the polypropylene will be arranged to form a more unbreakable structure. Therefore, it will prevent the risk of breakage and the related hazard.
[0043] This novel cutlery also has a weight advantage. The inner sides with A-shape comprises over 70% of the total area of the W-shape handle. Therefore the weight of the handle portion will drop noticeably because the thickness of this portion can be reduced.
[0044] The handle portion and tip portion are injected into the mold as a single part with the polypropylene as the raw material. As shown by the lab data and practical usage, the novel cutlery has advantage of being lightweight, strong, and further can be nested or stacked stably. By minimizing the gap between the individual items of stacked cutlery, the cost of package and storage has been reduced tremendously while the products are much safer and more environmental friendly.
[0045] We will now reference drawing FIGS. 1, 3, 5, 6, 7 and 8 , wherein a preferred embodiment of the fork 31 is depicted. All utensils comprise the food operational portion 12 and handle portion 14 . Handle 14 includes the neck end 142 near the food operational portion 12 and the tip end 144 . The cross section of handle 14 has a W-shape as illustrated in FIG. 7 , and includes reinforcement rib 16 at the outer two edges. Reinforcement ridges 16 extending from the tip end 144 to the food operational portion 12 as shown in FIGS. 1 & 8 .
[0046] The W-shaped handle portion 14 and reinforcement rib of -shape at the back results in the fork not being prone to distortion when the food operational portion 12 is stressed during usage. With the reinforcement rib 16 of small v-shape and the structure of the handle portion 14 , it is much stronger and more comfortable for users.
[0047] Referring now to FIGS. 3 to 5 , the handle portion 14 has been strengthened by the reinforcement ridge 18 and reinforcement rib 16 as illustrated in FIG. 7 . The food operational portion is connected with the handle by the reinforcement rib formed in a small triangular shape. Comparing with the traditional fork, it is safer, lighter, as well as more comfortable and environment friendly, while the cost of production has been reduced tremendously by the reduction of raw material required.
[0048] As illustrated in FIG. 5 , the reinforcement ridge 18 of small triangle shapes extend from the neck end 142 to the tip 144 while the reinforcement rib 16 at the outer edge spreading parallel from the top 142 to 144 . It has increased the strength of convex groove 15 at the top surface and the notch 17 on the bottom. The bending stiffness of handle portion 14 has been improved without additional material being required. The food operational portion 12 and handle 14 is injected with mold as a single piece.
[0049] As claimed, the novel cutlery can be nested closely as illustrated in FIGS. 9 & 10 . It makes it possible for each pile of cutlery such as fork, spork, spoon to be stacked stably, which will reduce the storage and increase the efficiency of packaging.
[0050] This design is also practical for other types cutlery, such as the Spoon of FIG. 11 , the Soup Spoon of FIG. 12 , the Spork of FIG. 13 and the Knife of FIG. 14 . The new W-shaped handle portion design disclosed may also be embodied in other specific forms without departing from the spirit or the general characteristics, any changes and modifications which come within the meaning and range of the equivalency of the design are intended to be embraced therein.
Element Listing
[0000]
12 : Food operational and engagement portion
14 : Handle portion
15 : Handle top side ridge peak
16 : Peripheral ridge portion
17 : Handle back side ridge peak
18 : Peripheral bottom side ridge peak
22 : The notch
24 : The convex groove
32 : Spoon
33 : Soup spoon
34 : Spork
35 : Knife.
142 : handle neck end
144 : handle tip end
[0065] Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.
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Stackable Disposable Utensils. The spoon, soup spoon, spork, fork and knife are all be stackable with like items so that the most compact package is provided. The handles have a W-shaped cross-section defined by a raised peak in its center, leading to a pair of valleys adjacent thereto, and terminating in slightly raised outer edges. Furthermore, the tail end of each utensil terminates in a downwardly-sloped portion to further add strength.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to integrated circuit devices and integrated circuit device manufacturing, including manufacturing of non-volatile memory devices, and more particularly to devices and processes for protection of integrated circuitry from plasma damage during manufacture.
2. Description of Related Art
In the manufacturing of integrated circuits, the processes are utilized which utilize activated ions. For example, backend processes including metal etching, photoresist stripping, and deposition of inter-metal dielectrics, involve plasmas which induce charge on the structures being treated. These plasma induced charges may damage underlying structures in the device, including structures critical to device performance. For example, tunnel dielectrics used in flash memory devices, gate dielectrics, and inter-polysilicon dielectrics, can be damaged by plasma induced charge. Furthermore, the charge storage structure utilized in SONOS cells is particularly susceptible to damage by plasma based processes. SONOS memory devices are described in U.S. Pat. No. 6,011,725.
One characteristic of the plasma induced charge is that it may be either positive or negative, and different types of damage can occur based on the type of induced charge.
In conventional semiconductor devices, protection from plasma induced charge is provided by forming a protection diode as shown in FIGS. 1A and 1B . A protection diode between a p-type region and an n-type well is formed to release “positive” charge from a node coupled to the p-type region as illustrated in FIG. 1A . A protection diode between an n-type region and the p-type well is formed to release “negative” charge from a node coupled to the n-type region, as shown in FIG. 1B . However, the structure of FIG. 1A does not discharge negative charge until the charge buildup is negative enough for junction breakdown. Likewise, the structure of FIG. 1B does not discharge positive charge until the charge buildup is positive enough for junction breakdown. These protection devices are useful and easy to implement. However, if the plasma exposure is too high, damage continues to happen with these prior art structures.
In floating gate memory devices as shown in FIG. 2 , or other stacked gate structures, plasma charge builds up in the floating gate structure, and results in the cell threshold shifting up during the manufacturing process. Typically, the device is exposed to ultraviolet radiation after processing. The radiation causes the built up charge to be discharged to near normal conditions. However, damage to the cell structure caused by the plasma processes is not repaired.
For SONOS devices as illustrated in FIG. 3 , plasma damage is more difficult to repair. The charge buildup caused by plasma based processes cannot be neutralized by ultraviolet exposure, as used in floating gate nonvolatile memory cells. The ultraviolet radiation injects additional electrons into the nitride film shifting the threshold voltage of the memory cell. Furthermore, because the threshold voltage is increased in SONOS devices for either positive or negative charge stress, the typical junction breakdown protection device is not sufficient. Back-to-back junction diodes can be used. However, the combination does not provide sufficient protection because the cell will be damaged before the junction breakdown levels are reached.
Accordingly, it is desirable to provide a protection circuit for use in the manufacturing of integrated circuits that protect both positive and negative charge damage. Furthermore, the protection circuit should not affect device operation after manufacturing. Finally, the protection circuit should be easily manufacturable.
SUMMARY OF THE INVENTION
The present invention provides a protection device, and a method for manufacturing integrated circuit devices, for protecting against plasma charge damage, and related charge damage during manufacture. The protection device comprises a dynamic threshold, NMOS/PMOS pair having their respective gate terminals coupled to the semiconductor bulk in which the channel regions are formed. With proper metal connection, the structure protects against plasma charge damage on the integrated circuit device during manufacture, and can also be operated to protect against abnormal voltages during operation of the circuit.
In one aspect, the present invention provides an integrated circuit device, which includes a device substrate. Integrated circuitry is formed on the device substrate. The integrated circuitry is coupled to a node having voltages applied thereto during operation of integrated circuitry. A PMOS device having a gate, a source and drain, and an NMOS device having a gate, a source and drain are formed on the device substrate. One of the source and drain of the PMOS device is coupled to said node. The other of the source and drain of the PMOS device is coupled to a ground reference. One of the source and drain of the NMOS device is coupled to said node. The other of the source and drain of the NMOS device is coupled to a ground reference. The gate of the PMOS device is coupled to the bulk semiconductor in which the channel of the device is formed. Likewise, the gate of the NMOS device is coupled to the bulk semiconductor in which the channel of the device is formed. During manufacturing, the gate of the PMOS device and the gate of the NMOS device are left floating.
Thus, during manufacture, dynamic threshold MOS devices are coupled to a node in the integrated circuit, which is to be protected from plasma charge damage. The dynamic threshold MOS devices are conductive with relatively low charge on the gate. Both positive and negative charges are discharged through the devices for protecting the node of the integrated circuit from plasma charge damage. During operation of the integrated circuit, voltages are applied to the gates of the dynamic threshold MOS devices, which turn off the dynamic threshold MOS devices during normal operation. Thus, the gate of the PMOS device is connected during operation to a voltage, such as a high positive voltage greater than the supply potential on the integrated circuit, which is high enough to turn off the PMOS device when the highest operating potential is applied to the node. The gate of the NMOS device is connected to a voltage during operation, such as a negative voltage, which is low enough to turn off the NMOS device when the lowest operating potential is applied to the node.
According to another aspect of the invention, the integrated circuitry includes memory array having a word line coupled to a row of memory cells in the array. The word line is coupled to said node in the protection device to protect memory cells along the word line from plasma charge damage. In one embodiment, the memory cells comprise SONOS cells. In another embodiment, the memory cells comprise floating gate memory cells.
According to yet another embodiment, the integrated circuit device includes a non-volatile memory circuit to be protected from plasma damage during manufacture. The memory circuit has a plurality of operating modes during which operating voltages are applied to word lines in the memory array. The plurality of operating modes includes a read mode, a program mode and an erase mode. During the program mode, a programming voltage is applied to the word lines using a charge pump or other voltage generator, which generates a voltage higher than the supply potential provided to the device from an external power supply. The voltage applied to the gate of the PMOS device during the program mode is at least as high as said programming voltage. During the erase mode, an erasing voltage is applied to the word line, which is a negative voltage. The voltage applied to the gate of the NMOS device during the erase mode is at least as low as said negative voltage.
In one embodiment of the invention, the PMOS device comprises an n-type well in said substrate, which acts as the semiconductor bulk in which the channel of the PMOS device is formed, and p-type source and drain regions in the n-type well. The gate of the PMOS device is coupled to said n-type well. Also in some embodiments, the NMOS device comprises a deep n-type well in said substrate, with the p-type well within the n-type well. The p-type well acts as the semiconductor bulk in which the channel of the NMOS device is formed. N-type source and drain regions are formed within the p-type well, and the gate of the NMOS device is coupled to the p-type well.
The present invention also provides a method for manufacturing an integrated circuit device. The method includes forming integrated circuitry on a substrate, the circuitry having a node to be protected from plasma charge damage. Also, a dynamic threshold PMOS device and a dynamic threshold NMOS device are formed on the substrate. The PMOS device and the NMOS device have characteristics such as those described above, and provide protection for the integrated circuitry against plasma charge damage. Thus, the method also includes coupling one of the source and drain of the PMOS device to said node, and other of the source and drain of the PMOS device to a ground reference. Also, the method includes coupling one of the source and drain of the NMOS device to said node, and other of the source and the drain of the NMOS device to a ground reference. The method also includes floating the gate of the PMOS device and the gate of the NMOS device during manufacturing steps that exposed the integrated circuitry to plasma or other processes that may cause charge damage. Circuitry is provided on the substrate to bias the gate of the PMOS device during operation to a voltage at least as high as operating voltages applied to the node by the integrated circuitry during operation. Likewise, circuitry is provided on the substrate to bias the gate of the NMOS device during operation to a voltage at least as low as operating voltages applied to the node by the integrated circuitry during operation.
The method of manufacturing according to the present invention is applied to all kinds of integrated circuits, and particularly to non-volatile memory circuits including memory circuits based on SONOS memory cells.
Accordingly, the present invention provides a PMOS transistor and an NMOS transistor. The gates of the PMOS and NMOS transistors are floating during manufacturing, and coupled to a first voltage and a second voltage, respectively, during operation. The PMOS device protects against positive charge and the NMOS device protects against negative charge. During manufacturing, because the gates of the PMOS and NMOS devices are floating, the PMOS transistor can discharge positive charge, and the NMOS transistor can discharge negative charge. In addition, during operation, the PMOS transistor can discharge positive charge higher than operation voltages, and the NMOS transistor can discharge negative charge lower than the operation voltages.
In embodiments for which protection is desired for only one of positive and negative charge, then only one of the NMOS and PMOS transistors may be used.
Other aspects and advantages of the present invention can be seen on review of the drawings, the detailed description and the claims, which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A and FIG. 1B illustrate prior art junction based protection devices.
FIG. 2 shows exposure of a floating gate device to ultraviolet radiation as used in prior art techniques.
FIG. 3 shows exposure of a SONOS device to ultraviolet radiation.
FIG. 4 is a simplified block diagram of an integrated circuit including the protection circuit of the present invention.
FIG. 5 illustrates a cross-sectional view of one embodiment of the protection circuit according to the present invention.
FIG. 6 shows a simplified diagram of an integrated circuit memory device, including protection circuits according to the present invention.
DETAILED DESCRIPTION
A detailed description of embodiments of the present invention is provided with reference to FIGS. 4–6 . FIG. 4 illustrates an integrated circuit device 10 including a protection circuit according to the present invention. The integrated circuit device includes a device substrate 11 . Integrated circuitry 12 on the device substrate performs the “mission” operations for the device 10 . The “mission” operations may include providing memory, logic functions, processor functions, or any of a wide variety of functions provided by integrated circuitry.
A power supply provides a supply voltage VCC and a ground reference for the device substrate 11 . Voltage generator circuitry 13 on the device substrate 11 provides operational voltages for the integrated circuit 12 , including a lower operating voltage and a higher operating voltage for a node 14 .
The protection device on the device substrate includes a PMOS transistor 15 and an NMOS transistor 16 . One of the source/drain terminals of the PMOS transistor 15 is coupled to ground. The other of the source/drain terminals of the PMOS transistor 15 is coupled to the node 14 via a conductive line. The gate of the PMOS transistor 15 is coupled to the semiconductor bulk in which the channel of the transistor is formed. Also, the gate of the PMOS transistor 15 is coupled to line 17 across which the voltage generator 13 supplies during operation of the device a voltage at least as high as the higher operating voltage applied during operation to node 14 . During manufacture, the line 17 is floating.
One of the source/drain terminals of the NMOS transistor 16 is coupled to ground. The other of the source/drain terminals of the NMOS transistor 16 is coupled to the node 14 via a conductive line. The gate of the NMOS transistor 16 is coupled to the semiconductor bulk in which the channel of the transistor is formed. Also, the gate of the NMOS transistor 16 is coupled to line 18 across which the voltage generator supplies during operation of the device a voltage at least as low as the lower operating voltage applied during operation to node 14 . During manufacture, the line 18 is floating.
The structure of the protection device, according to the present invention, can be understood with reference to the example shown in FIG. 5 . FIG. 5 illustrates a semiconductor substrate 20 (PW) having an intrinsic p-type doping. A first deep n-type well 21 (NWD) and a second deep n-type well 22 (NWD) are formed by diffusion of n-type dopants into the substrate 20 . The PMOS transistor has a p-type source 23 and a p-type drain 24 formed within the first deep n-type well 21 . An n-type contact 25 is formed on the surface of the first deep n-type well 21 . The p-type contact region 26 is formed in the surface of the substrate 20 (PW), preferably adjacent to the first deep n-type well 21 . A gate 27 is formed over an insulator (not shown) between the source 23 and the drain 24 over the channel region. The first deep n-type well 21 acts as the semiconductor bulk within which the channel region is formed. The gate 27 is coupled to the first deep n-type well 21 via the contact 25 . The source 23 is coupled to the substrate 20 via the contact 26 , and to a ground reference. The drain 24 is coupled via a conductive line to a node 30 to be protected in integrated circuitry on the device. The gate 27 is also coupled to a circuit on the device which supplies the highest voltage VPCP 11 available during operation, in one embodiment. The voltage on the gate 27 is at least as high as the highest operating voltage applied to the node 30 during operation, and is high enough to bias the PMOS transistor in a normally off position during operation of the device. During manufacture, node 30 is left floating.
Within the second deep n-type well 22 , a deep p-type well 31 (PWI) is formed. The NMOS transistor has a source 32 and a drain 33 formed within the p-type well 31 (PWI). A p-type contact 34 is formed by diffusion in the surface of the p-type well 31 . Also, a p-type contact 35 is formed in the surface of the substrate 20 , preferably adjacent the second deep n-type well 22 . A gate 36 is formed over an insulator (not shown) over the channel region between the source 32 and a drain 33 of the NMOS transistor. The gate 36 is coupled to the contact 34 , so that the gate of the NMOS device is coupled to the semiconductor bulk in which the channel of the NMOS device is formed. The source 32 of the NMOS transistor is coupled to the terminal 35 and to a ground reference. The drain 33 of the NMOS transistor is coupled to the node 30 . A contact 37 is formed in the surface of the second deep n-type well 22 . The contact 37 is coupled to the highest voltage VPCP 11 generated on that chip during operation, or to another voltage level sufficient to maintain isolation of the p-type well 31 . The gate 36 of the NMOS transistor is coupled to a circuit which supplies the lowest voltage NVPP provided on the chip, at least as low as the lowest voltage applied at the node 30 during operation, or to a circuit which provides a voltage low enough to turn off the NMOS device during operation of the circuitry. During manufacturing, the gate 36 is left floating.
The gate insulator between the gate and channel of the NMOS transistor and of the PMOS transistor should be strong enough to withstand the high or low voltages applied during operation of the device. For example, the gate insulator comprises a relatively thick oxide, compared to gate oxide thicknesses for logic transistors, in one embodiment of the device.
FIG. 6 illustrates a semiconductor memory device including a protection circuit according to the present invention. The device includes a substrate 100 , a power supply terminal 101 , and a ground terminal 102 . Integrated circuitry on the device includes a memory structure 111 including an array 110 of memory cells, such as SONOS cells. The memory array 110 in various embodiments comprises DRAM cells, SRAM cells, mask ROM cells, floating gate memory cells, and other types of memory device structures. The memory structure includes the word line decoder 120 and a bit line decoder 121 and other supporting circuitry known in the art for memory devices. Supporting circuitry on the device in this example includes a read, erase and program mode control logic 122 , charge pumps 123 for supplying high positive and negative voltages supporting the operation modes of the memory array, and other supporting circuitry not shown. Within the array 110 , a word line, such as word line WL 1 , is coupled to a row of memory cells to be protected from damage by the protection circuit of the present invention.
The protection circuit on the substrate 110 includes a PMOS transistor 112 , and an NMOS transistor 113 constructed as discussed above with reference to FIG. 5 . The drains of the PMOS transistor 112 and NMOS transistor 113 are coupled to the node 115 , which is connected via a line 114 to the word line WL 1 . The sources of the PMOS transistor 112 and the NMOS transistor 113 are coupled to ground reference terminals. The gate of the PMOS transistor 112 is coupled via the line 124 to a voltage V 1 , supplied in this example by the charge pump circuitry 123 . The gate of the NMOS transistor 113 is coupled via the line 125 to the voltage V 2 , supplied in this example by the charge pump circuitry 123 .
In this embodiment, during the manufacturing process for the device 100 , the first voltage V 1 and the second voltage V 2 are floating, so that the gates as the PMOS transistor 112 and the NMOS transistor 113 are floating. Therefore, the device 100 can be protected from plasma charge having both positive and negative polarities. Negative charges are well protected by the NMOS transistor 113 by the current path L 1 . Positive charges are well protected by the PMOS transistor 112 via the current path L 2 .
During operation of the device 100 , the first voltage V 1 and the second voltage V 2 are supplied with values that depend on the operating process. In the flash memory example, different voltages are applied for the various operating modes (read, erase, program) of the memory. In the memory embodiment described, the voltages applied to word line WL 1 , the NMOS transistor 113 and the PMOS transistor 112 are shown in the following table (refer to FIG. 5 for NMOS and PMOS terminals).
PROGRAM
ERASE
READ
WORD LINE:
11.5 V
−3 V
2.6 V
NMOS:
GATE/PWI
GND
NVPP
GND
NWD
VPCP11
VCC
VCC
SOURCE/PW
GND
GND
GND
PMOS:
GATE/NWD
VPCP11
VCC
VCC
SOURCE/PW
GND
GND
GND
Within the table, the parameter VPCP 11 corresponds to the highest voltage available on the chip, or to a voltage at least as high as the highest voltage applied to the word line, and high enough to turn off the PMOS transistor during operation of the device. Also, the parameter NVPP corresponds to the lowest negative voltage available on the chip, or to a voltage at least as low as the lowest voltage applied to the word line, and low enough to turn off the NMOS transistor during operation of the device.
As can be seen, the operating voltages for the integrated circuit in the memory example are different in the different operating modes. During the programming process, the operating voltage on the word line may be, for example, 11.5 V. During erasing in reading, the operating voltages on the word line are −3 V and +2.6 V, respectively. Thus, during the programming mode, the normal operating voltage on the word line will not turn on the PMOS transistor 112 . Thus, the normal operating voltage of the word line is not disturbed. However, when an abnormal voltage, such as a voltage higher than the normal operating voltages or lower than the normal operating voltages occurs, the PMOS transistor 112 and the NMOS transistor 113 will turn on to discharge the abnormal voltage so as to protect the memory array. In this case for the programming mode, an abnormal voltage higher than 11.5 V or lower than ground can be discharged. Likewise, by setting the voltage on the gates of the protection devices properly, during erasing and reading modes, normal operating voltages are not discharged by the protection device, while abnormal voltages may be discharged to protect the device.
Thus, the present invention provides a protection circuit based on a dynamic threshold MOS pair of transistors. Positive charge is conducted to ground via the PMOS transistor, and negative charge is conducted to ground via the NMOS transistor at very low voltages. For example, the NMOS transistor will conduct at a voltage close to the junction forward turn on voltage of, for example, 0.6 V. Likewise, the PMOS transistor will conduct at a voltage close to the junction forward turn on voltage of, for example, −0.6 V. For a discussion of the operation of dynamic threshold MOS devices, see, IEEE ELECTRON DEVICES, Vol. 38, No. 11, November, 1991.
The gate oxide for the MOS pair is preferably thick enough to sustain high-voltage operation for flash memory devices or other high-voltage integrated circuits. The thick gate oxide can be easily manufactured in flash memory devices, by using the same processing step as is used to produce the thick oxides for charge pump transistors.
During manufacturing processes, plasma charge may accumulate and be conducted through the word line to the protection device. The number of protection devices used in a particular integrated circuit will depend on the manufacturing circumstances, the space available, and the needs of the particular product. There may be one protection device per word line, in some example products. In other example products, one protection device may be shared among a plurality of word lines. Other nodes in the integrated circuitry on the device can be protected as well.
While the present invention is disclosed by reference to the preferred embodiments and examples detailed above, it is to be understood that these examples are intended in an illustrative rather than in a limiting sense. It is contemplated that modifications and combinations will readily occur to those skilled in the art, which modifications and combinations will be within the spirit of the invention and the scope of the following claims.
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A protection device and a method for manufacturing integrated circuit devices protect against plasma charge damage, and related charge damage during manufacture. The protection device comprises a dynamic threshold, NMOS/PMOS pair having their respective gate terminals coupled to the semiconductor bulk in which the channel regions are formed. With proper metal connection, the structure protects against plasma charge damage on the integrated circuit device during manufacture, and can also be operated to protect against abnormal voltages during operation of the circuit.
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FIELD OF THE INVENTION
The present invention relates to a new and improved liquid dispensing system and, more particularly, to a multi-purpose liquid dispensing and/or feeding and/or medicine delivery system to facilitate not only dosage, but also the rate of delivery to the infant.
BACKGROUND OF THE INVENTION
Typically, liquid-dispensing pacifier like devices have been used for oral administration. Parents and nurses are frequently frustrated by the task of administering such liquids to infants, toddlers and other persons requiring such feeding or dosing method. The heretofore devices are not well-suited to the general and varied applications required for the daily administration of both liquid nutrient and/or medication. For example, the prior art devices do not enable the easy and constant monitoring of the dosage or liquid consumption rate. The prior art devices also do not enable the adjustment of the flow rate to provide a controlled dosage over a period of time. And the prior art devices do not enable or provide for the temporary removal of the pacifier device with fast, convenience stopping of the liquid leakage-flow to facilitate the infants other needs such as, for example, diaper replacement or burping.
Some prior art liquid dispensing pacifier devices included a sealed cartridge which is pierced to enable liquid flow and is then placed in a device having a nipple such as is described in U.S. Pat. No. 5,354,274 issued Oct. 11, 1994 to Robert J. Demeter, et al. In total contrast to the present invention, the '274 patent does not show or suggest a device to measure the mixing, for example, of a medication dosage with a host liquid such as juice or milk, and the '274 patent does not enable fluid rate control and monitoring or convenient and fast holder means.
Another prior art patent of interest is U.S. Pat. No. 5,123,915 issued Jun. 23, 1992 to Lawrence E. Miller. This patent describes a medicated pacifier having a discrete reservoir chamber 112 formed, for example, of a hard plastic onto which a discrete nipple 116 is secured. A pill or cartridge like medication dosage is placed into the reservoir chamber.
Other prior art references include, but are not limited to, Barnes U.S. Pat. No. 404,950; Spencer U.S. Pat. No. 745,920; Baer U.S. Pat. No. 4,192,307; Connelly U.S. Pat. No. 4,488,551; White U.S. Pat. No. 4,784,641; Martin U.S. Pat. No. 5,129,532 and Mailot U.S. Pat. No. 5,127,903.
SUMMARY OF THE INVENTION
Generally, speaking, and in accordance with the invention, a liquid medication and/or nutrient measuring and dispensing system is provided having particular utility for pediatric and infant medicine and nutrient dispensing, in combination, comprising:
a unitary elongated cylinder shaped container or reservoir chamber means having a plurality of circumferential measurement marking or indicia, and having a lower tapered section forming a nipple-like end portion, and having an open end portion, and being formed from a flexible resin or plastic like transparent or translucent material to enable viewing of a fluid level within said reservoir chamber means;
a circular or oval shaped disc like member affixed to the upper ridge portions of said container means to form a fluid-tight seal therebetween, said disc member having a size and shape to provide the dual function of a mounting plate and a mouth guard, and having a threaded neck like member;
a cap means having a valve member for enabling the controlled rate of air seepage into the reservoir chamber or cavity to thereby control the fluid flow rate from the opening in the nipple;
a cradle or holder means having a base plate dimensioned for providing a stable support, said base plate includes a surface designed to engage with and depress the end portion of the nipple to provide a sealing or closing effect to the nipple opening with the dispenser being placed in cradle, a circular transparent plastic or glass container having an internal cavity for receiving said reservoir chamber means therein, and a top rim portion dimensioned for supporting said disc member thereon.
OBJECTS OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a new and improved liquid dispensing device for the administration of oral medicine and/or nutrients and/or fluids at a more controllable rate of flow to an infant.
It is yet a further object of this invention to provide a unitary liquid reservoir and nipple means.
Another object of this invention is to provide a reservoir means having measuring indicia for facilitating the desired amount or dosage of a medicine or fluid to an infant.
Another object of this invention is to provide a holder means for holding the dispenser during non-feeding periods.
Another object of this invention is to provide a means to facilitate the temporary cessation of dispensing without spilling the fluid or medication on undesired surfaces such as furniture, etc.
Another object of this invention is to provide a warming container for the fluid within the dispensing device.
Another object of this invention is to provide a virtual turnoff valve to enable the stopping of the fluid flow from the dispensing device without requiring the removal of the nipple section from the infant's mouth.
Another object of the present invention is to facilitate the mixing of various fluids and medicines at measured amounts directly within the dispensing device.
Yet another object of the present invention is to provide a liquid dispenser having a design and shape to enable it to be hand held by an infant or toddler.
And another object of the present invention is to provide a fluid flow stoppage means such that the fluid is trapped within the reservoir chamber even when the valve means is not shut off, for example, in the event the mother or nurse inadvertently forgets to shut off the valve means when burping the infant.
Another object of the present invention is to provide a multi-function cradle means for providing storage to the dispenser device, a clean environment for the nipple, a fluid chamber for maintaining the dispenser device at a selected temperature and for stopping fluid out flow from the dispenser unit.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will be more clearly seen when viewed in conjunction with the accompanying drawings. Like numerals refer to like parts throughout.
FIG. 1 is a perspective view of the liquid dispenser in accordance with the present invention;
FIG. 2 is an exploded view of the dispenser illustrated in FIG. 1;
FIG. 3 is a side view of the dispenser placed in a holder in accordance with one feature of the present invention;
FIG. 4 is a side view of the dispenser being partially submerged in a fluid within the holder in accordance with another feature of the present invention; and
FIG. 5 is an exploded view of an alternative embodiment of the dispenser unit in accordance with the present invention;
FIG. 6 is a perspective view of an alternative liquid dispenser in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1 and 2 of the drawings, a new and improved liquid dispenser 10 in accordance with a preferred embodiment of the invention is illustrated. Briefly stated, the dispenser 10 comprises a main body portion 11, a nipple section 12, an upper flange or rim member 13, a mouth guard ring and holder cover 14, an upper cap 15 and a valve member 16.
The main body portion 11 and nipple section 12 may be integrally formed of any suitable material such as, for example, a flexible latex rubber like material. The end of the nipple section 12 is provided with one or more apertures or holes 17 which extend through the nipple rubber like material into the inner fluid reservoir chamber 40. The main body portion 11 and preferably also the nipple section 12 are formed of semitransparent or opaque material to enable a person to visually determine the level or amount of fluid and/or medication 19 within the nipple 12 and main body portion 11 of dispenser 10. Preferably, the annular side wall 20 of main body portion 11 is made or molded to be thicker and more rigid than nipple section 12 which has an axially inwardly converging conical annular wall 21.
In this manner, a desired rigidity is incorporated into the main body portion 11 to facilitate handling and to resist squeezing pressure from the infant's hands (not shown). A plurality of measurement lines 22 are provided about the peripheral surface of the main body portion 11 and nipple section 12. Measurement markings or indicia 23 may also be provided to facilitate the accurate measurement of the liquid medication and/or nutrient within dispenser 10. The measurement lines 22 and indicia may be integrally formed in the molding process. In accordance with another feature of the invention, metric and English measurement indicia 23, 24 are provided to facilitate the mixing of a dosage of a liquid medicament with a desired flavorful liquid such as juice or to enable the mixing of a desired liquid formulation. In this manner, a dispenser 10 is provided having greater flexibility of use and enabling improved medicament and nutrient dosage delivery than heretofore possible.
In accordance with the present preferred embodiment, the main body portion 11 is formed in a molding process to include an upper annular flange 13. Flange 13 is affixed in any conventional manner, for example, epoxy glued to the lower surface 26 of the mouth guard 14 to form a fluid-tight seal therebetween.
Mouth guard 14 may be formed of any suitable material such as a rigid plastic. Mouth guard 14 is integrally formed to have a pipe shaped upwardly projecting cap mounting member 30. Cap mounting member 30 includes a plurality of circumferential male threads 31 and a central hole or aperture 32 which extends through mouth guard 14. Aperture 32 is medially located on the circular or oval shaped mouth guard disc 14 for being in alignment with cavity mouth opening 18. The diameter or size of cap mounting member 30 and aperture 32 are predetermined to facilitate easy pouring/filling of liquid medicament, nutrient fluids and other liquids into aperture 32 and, thereby, to fill the nipple 12 and main body portion 11 with the liquid formulation to a selected measurement.
It should be recognized at this time, that in contrast to the prior art, a substantially precise formulation may be achieved by first filling the nipple 12 to the graduated metric measurement level and then adding a liquid transfer fluid such as juice or other medicinal to a desired formulation. With cap 15 and air valve member 16 in closed position, the formulation may be mixed simply by turning dispenser 10 upside down.
An air valve member 16 is provided to enable the controlled flow of air into cavity 40 and, thereby, substantially control the rate of fluid flow from nipple opening 17. In this manner, the oral administration of medicament or nutrient formulation may be dispensed to the infant, toddler or patient at a slow to fast rate of flow.
Although it is recognized that various valve means may be designed, it is a feature of the present invention to utilize a valve member 16 to enable selective adjustment of the medicament flow-rate from an infant's bottle or pacifier.
One preferred embodiment of valve member 16 consists of a cap 41 having female internal threads 42 designed to matingly engage with the male threads 43 located on cap nipple 44. Cap nipple 44 may be integrally formed with cap 15. A plurality of holes or apertures 45 are provided in cap nipple 44, which communicates into reservoir chamber 40.
Cap 15 comprises a generally round bottle like cap shape and having internal female threads 46 designed to mate with the male threads 31 on cap mounting member 30.
Thus, important features of the present invention are to provide an oral medicament dispenser 10 having means for measuring the formulations of medicament and other liquids and to dispense such formulation at a relatively controllable fluid flow rate.
For example, with tightly screwing cap 41 down onto cap nipple 44, and thereby sealing all the nipple air ports 45, a vacuum air lock is established to retard, reduce or virtually cease any liquid flow from the nipple 12 hole 17.
With reference now to FIG. 3, another important feature of the present invention will now be described.
Typically, infant bottles or pacifiers are simply placed on a counter top or other surface which may be unclean. It is noted that from time to time, during the administration of a medicament, the dispensing must be interrupted to perform other functions such as, for example, changing of a diaper or burping of an infant. During such interruptions, the dispenser heretofore was placed on its side on a bed or counter top or other surface which may result in leaking of the medicament formulation from the dispenser.
In accordance with the present dispenser system invention, a holder or container 50 is provided for temporary and longer term storage of dispenser 10. In the preferred embodiment, holder 50 comprises a glass or plastic container having a jar shape. The dimensions of holder 50 are predetermined to enable the up-right vertical mounting of dispenser 10 as illustrated in FIGS. 3 and 4. The height 52 of holder 50 and the length of the body portion 11 and nipple 12 are selected such that the tip of nipple 12 abuts the bottom surface 53 of holder 50 and, thereby, provides a means of closing or plugging nipple hole or aperture 17. Nipple 12 as noted above is formed of a flexible rubber or latex material which deforms slightly when compressed against bottom wall 53 to urge aperture 17 to close. In this manner, the medicament formulation is substantially maintained within dispenser 10 during such periods of temporary interruption of feeding of the infant or patient.
The diameter dimension 55 of mouth guard 14 is designed to extend beyond the upper rim 57 of holder 50. Accordingly, the diameter 56 of holder 50 is less than the diameter 55 of mouth guard 14.
Holder 50 is preferably transparent to facilitate the care taker's observation of the liquid formulation level within dispenser 10. Another beneficial advantage and feature of the present system is that if any leakage does occur from dispenser 10, such leaked fluid is captured within holder 50 and can be reintroduced back into dispenser 10. In this manner, expensive medications are not lost and more precise dosage amounts may be delivered to the infant or patient.
With reference now to FIG. 4, an alternative embodiment of a mouth guard disc 60 and its cooperation with holder 50 to effect a more positive closure therebetween is depicted. Basically speaking, mouth guard 60 is similar to mouth guard 14 with the exception of a sealing/locking circular O-ring 61. O-ring 61 may be formed of any suitable material such as a flexible plastic, rubber or caulk like material. O-ring 61 is designed to have an outer diameter 62 equal to or slightly greater than the inner diameter of holder 50 such that a force fit or snug fit may be established between O-ring 61 and holder 51. In this manner, dispenser 10 may be securely maintained in holder 50 until manually removed by a person for intended use.
An advantageous feature of this embodiment contemplates the use of a warming and/or sterilization fluid 66 in holder 50. It should also be recognized that with the warming/sterilizing solution being maintained at or slightly below the level of the formulation in holder 10, a further hydraulic effect is created to virtually eliminate outflow of the formulation from outlet aperture 17.
With O-ring 61 snugly abutting against the side walls 68 of holder 50, spillage by accidental knocking over of holder 50 is substantially eliminated.
With reference now to FIG. 5, an alternative embodiment of a dispenser in accordance with the present invention will now be described.
Basically speaking, the dispenser comprises a nipple member 71, a tubular body member 72, a mounting unit 73 and a cap member 74. Nipple member 71 includes a flexible rubber like nipple 12 having an outlet fluid port or hole 17. The upper circumferential ridge 75 is affixed and fluid-tight sealed to a lower cap member 76. Lower cap member 76 may be formed of any suitable material such as plastic. Cap member 76 has a cavity 77 which communicates with nipple reservoir chamber 40. A plurality of female threads 78 are provided for mating with male threads 79 found on body member 72.
Tubular body member 72 may be formed of any suitable material such as plastic or glass and includes a plurality of measurement lines or markings 22. A plurality of male threads 80 are provided at the top end of tubular body member 72 for matingly screw engagement with female threads 81 located about the inner circumferential wall of mounting unit 73. Mounting unit 73 also includes a mounting disc 14 and an upper tubular shaped cap mounting and liquid inlet port member 30. Inlet port member 30 includes a plurality of male threads designed for mating engagement with female threads of cap 74.
Cap 74 may also include an air inlet valve means to regulate the liquid dispensing flow rate from outlet port 17 of nipple 12. As with the dispenser 10 described above, cap 74 may be removed for filling the nipple 12 and body member 72 to the desired medicament and nutrient formulation desired.
It should now be recognized that the present invention incorporates several structural and functional advantageous features, such as, but not limited to:
a medicament/nutrient dispenser and holder system;
a medicament dispenser having measurement indicia;
a dispenser having means for regulating flow rate;
a dispenser type pacifier having a dual function mouthguard and mounting platform;
a holder means for holding and retarding outlet flow/leaking from a nipple during storage;
a holder means for heating the dispenser formulation.
a liquid dispensing system having a holder means to facilitate the filling of a dispenser device with a medicament/nutrient formulation and to substantially eliminate leakage and loss of such formulation from the nipple aperture/hole during such filling or formulation process. In this manner the prior art long recognized but heretofore not solved problem of leakage/loss/fluid dripping from the nipple during the filling process is substantially eliminated. Such leakage/loss/fluid dripping was a substantial problem because it represented an unmeasured loss of a medication which may require very precise dosage to be effective.
It should be recognized that the synergistic structural and functional advantageous features of the present invention as highlighted above are distinguishing features of the invention which are incorporated into the claims without specifically being stated therein.
With reference now to FIG. 6, an alternative embodiment 90 of holder 50 will now be described. Basically speaking, holder 90 comprises a base unit comprising a base member 91 having a bottom floor section 97 and a plurality of, for example, five, upwardly projecting and spaced apart column like members 92-96. Holder 90 functions in similar manner to holder 50 illustrated in FIG. 3, with the exception that holder 90 is not used to contain a warming fluid 66 as demonstrated in FIG. 4. The mounting disc 14 is dimensioned to fit atop of the columns 92-96 so as to mount the dispenser 10 in a stand-up position similar to that illustrated in FIG. 3.
While there has been shown and described what is considered to be the preferred embodiments of the invention, it is desired to secure in the appended claims all modifications as fall within the true spirit and scope of the invention.
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A liquid dispensing device which allows oral ingestion of a liquid at a desired or controlled rate to, for example, an infant. A holder is provided to enable the placement of the dispenser during periods when dispensing and/or feeding is interrupted or suspended. The dispenser basically comprises a transparent or semi-transparent flexible rubber like elongated cylinder having measurement markings on or about the peripheral surface. An upper flange member supports the dispenser in an upright position when placed in the holder unit. A cap is provided having means for controlling the fluid flow rate. A fluid flow blocking means is provided at the bottom of the holder unit.
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[0001] This application is a continuation of U.S. patent application Ser. No. 10/635,679, entitled “Non Clogging Screen,” filed Aug. 7, 2003, the entirety of which is incorporated herein by reference, and claims priority to Provisional Patent Application No. 60/401,781 filed Aug. 8, 2002.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to composite screen or perforated surface and filtering membranes.
[0004] 2. Related Prior Art
[0005] Various gutter anti-clogging devices are known in the art and some are described in issued patents.
[0006] In my U.S. Pat. No. 6,598,352, incorporated herein by reference, I disclose a filter configuration comprised of a debris repelling membrane, overlying a skeletal structure of ellipsoid rods spaced and resting on vertical planes that serve to break the forward flow of water and to channel water onto and through its integral perforated horizontal plane. Included herein is product literature for LEAFFILTER™, a gutter guard patterned after designs disclosed in U.S. Pat. No. 6,598,352. To date, LEAFFILTER™ has been noted to remain free enough of debris clogs and/or coatings of scum, oil, and pollutants so as to disallow gutter clogs in every known instance of it's installation onto rain gutter systems attached to at least eight thousand residential homes. The LEAFFILTER™ system, however, is costly to manufacture in comparison to other gutter guard systems.
[0007] U.S. Pat. No. 6,463,700 to Davis teaches a composite gutter guard, marketed as Sheer Flo®, comprising a polymer coated fiberglass mesh filter cloth overlying and sonic welded to an underlying perforated plane, disclosed in claims 1 and 4 . Davis specifically teaches employment of a medium filter opening fiberglass mesh rather than a fine metal or polymer mesh cloth, disclosed in Column 1 lines 19-35. Such fiberglass mesh of medium openings can be shown to allow the lodging of pine needle tips and to be subject to water-proofing due to oil leaching from roofing shingles. This may cause permanent accumulation of debris upon the composite gutter guard and water-proofing may allow forward, rather than downward flow of water to occur. In instances of high ambient temperatures sonic welded fiberglass has been shown to break free of the underlying polymer plane and the composite gutter guard has been shown to warp and wave due to heat deformation. Davis teaches a mostly single planar composite gutter guard that allows much forward underflow of water to occur on the underside of the disclosed invention and such underflow acts to oppose downward flow of water through perforations.
[0008] U.S. Pat. No. 6,164,020 to Nitch teaches a gutter screen for preventing the accumulation of debris within a gutter. Nitch teaches a gutter screen that has a plurality of v-shaped bars positioned to run above and generally parallel to the gutter. Nitch teaches that the unique shape of the bars minimize the surface area of the underside of the screen decreases water tension on the underside of the screen and postulates that this decreases the ability of water to accumulate on the underside of the screen which promotes the pulling of water into the gutter, disclosed in Col. 2 lines 45 through 50. Such a device can be shown to eventually allow debris to accumulate within the spaces between v-shaped bars. Such a device can additionally be shown to allow the forward channeling of water to occur as an underflow from tip to tip of the downward most portion of the v-shaped bars due to their close spacing and lack of a length of downward extension that would provide a greater directed downward flow of water into the underlying gutter. This and other prior art do not recognize that water adhesion surfaces extending downward from a planar surface into a rain gutter in a height staggered manner or that are separated by a minimum of one inch provide greater siphoning action and are less likely to be overcome by a forward channeling of under flowing water on the underside of surfaces that receive water through perforations or open channels than is reliance on a lesser amount of water adhesion on the underside of perforated surfaces or screens with bottom most water dispersing areas that are closely spaced and follow mostly horizontally linear or follow a linear path that angles downward from the rear most portion of a gutter guard to the front lip of a rain gutter. Allowing for greater spacing of rods or fins or water channeling paths or staggering and/or extending the height of rods or fins so that they extend to a depth that the volume of water they channel downward overcomes by sheer weight and gravity an opposing underflow and continues a downward flow into an underlying gutter has not been found to be a simple matter of anticipation, or design choice by those skilled in the arts. Rather, it has proved to be unclaimed in disclosed prior art and untested in the field with the exception of the LEAFFILTER™ gutter guard which has proved to be very efficient at channeling water downward into a rain gutter while disallowing either the rain gutter or the gutter guard to clog or exhibit an overflow of water. Nitch teaches that fine screens allow for water run-off and are less capable of receiving water than other structural components such as bars or ribs, disclosed in Col. I lines 33-35. This and other prior art such as U.S. Pat. No. 6,463,700 to Davis do not recognize that fine screens can be shown to exhibit great water permeability and downward water channeling properties when contacting ovaled or angled edged surfaces resting on downward extending legs as is disclosed in U.S. Pat. No. 6,598,352 to Higginbotham, Col. 18 lines 26-67, Col. 19 lines 1-54.
[0009] U.S. Pat. No. 5,755,061 to Chen teaches a rain cover that includes pairs of adjacent fins separated by a uniform traverse gap that significantly increases the return of water to the gutter by surface tension with the fin walls, disclosed in the ABSTRACT. As occurs with U.S. Pat. No. 6,146,020, copious amounts of roof runoff may negate the intended effect of water returning to the gutter allowing for forward flow of water past the gutter. The bottom terminal points of the fin walls Chen teaches exist in the same linear plane as do the bottom terminal points of the rods Nitch teaches in U.S. Pat. No. 6,146,020. This allows a forward underflow (beneath the topmost surface of a perforated or open channeled plane) of water to occur. In my U.S. Pat. No. 6,598,352 it is disclosed that such forward rather than downward flow of water has been shown to cease if downward extending planes or rods of varying heights, disallowing a linear channeling path for water to follow, and sufficiently spaced are employed beneath the top most surface of water receiving areas but the disclosed preferred embodiment has been shown costly to manufacture.
[0010] U.S. Pat. No. 5,557,891 to Albracht teaches a gutter protection system for preventing entrance of debris into a rain gutter. Albracht teaches a gutter protection system to include a single continuous two sided well with angled sides and perforated bottom shelf 9 into which rainwater will flow and empty into the rain gutter below. The well is of a depth, which is capable of receiving a filter mesh material. However, attempts to insert or cover such open channels of “reverse-curve” devices with filter meshes or cloths is known to prevent rainwater from entering the water receiving channels. This occurrence exists because of the tendency of such membranes, (unsupported by a proper skeletal structure), to channel water, by means of water adhesion along the interconnected paths existing in the filter membranes (and in the enclosures they may be contained by or in), past the intended water-receiving channel and to the ground. This occurrence also exists because of the tendency of filter mediums of any present known design or structure to quickly waterproof or clog when inserted into such channels creating even greater channeling of rainwater forward into a spill past an underlying rain gutter. Filtering of such open, recessed, channels existing in Albracht's invention as well as in U.S. Pat. No. 5,010,696, to Knittel, U.S. Pat. No. 2,672,832 to Goetz, U.S. Pat. Nos. 5,459,965, & 5,181,350 to Meckstroth, U.S. Pat. No. 5,491,998 to Hansen, U.S. Pat. No. 4,757,649 to Vahldieck and in similar “reverse-curved” inventions that rely on “reverse-curved” surfaces channeling water into an open channel have been known to disallow entrance of rainwater into the water-receiving channels. Albracht's as well as previous and succeeding similar inventions have therefore notably avoided the utilization of filter insertions. What may appear as a logical anticipation by such inventions at first glance, (inserting of a filter mesh or material into the channel), has been shown to be undesirable and ineffective across a broad spectrum of filtering materials: Employing insertable filters into such inventions has not been found to be a simple matter of anticipation, or design choice of filter medium by those skilled in the arts. Rather, it has proved to be an ineffective option, with any known filter medium, when attempted in the field. Such attempts, in the field, have demonstrated that the filter mediums will eventually require manual cleaning.
[0011] German Patent 5,905,961 teaches a gutter protection system for preventing the entrance of debris into a rain gutter. The German patent teaches a gutter protection system to include a single continuous two sided well 7 with angled sides and perforated bottom shelf which rainwater will flow and empty into the rain gutter below. The well is recessed beneath and between two solid lateral same plane shelves close to the front of the system for water passage near and nearly level with the front top lip of the gutter. The well is of a depth, which is capable of receiving a filter mesh material. However, for the reasons described in the preceding paragraphs, an ability to attach a medium to an invention, not specifically designed to utilize such a medium, may not result in an effective anticipation by an invention. Rather, the result may be a diminishing of the invention and its improvements as is the case in Albracht's U.S. Pat. No. 5,557,891, the German Patent, and similar inventions employing recessed wells or channels between adjoining planes or curvatures.
[0012] U.S. Pat. No. 5,595,027 to Vail teaches a continuous opening 24A between the two top shelves. Vail teaches a gutter protection system having a single continuous well 25, the well having a depth allowing insertion and retention of filter mesh material 26 (a top portion of the filler mesh material capable of being fully exposed at the holes). Vail does teach a gutter protection system designed to incorporate an insertable filter material into a recessed well. However, Vail notably names and intends the filter medium to be a tangled mesh fiberglass five times the thickness of the invention body. This type of filtration medium, also claimed in U.S. Pat. No. 4,841,686 to Rees, and in prior art currently marketed as FLO-FREE™ is known to trap and hold debris within itself which, by design, most filter mediums are intended to do, i.e.: trap and hold debris. Vail's invention does initially prevent some debris from entering an underlying rain gutter but gradually becomes ineffective at channeling water into a rain gutter due to the propensity of their claimed filter mediums to clog with debris. Though Vail's invention embodies an insertable filter, such filter is not readily accessible for cleaning when such cleaning is necessitated. The gutter cover must be removed and uplifted for cleaning and, the filter medium is not easily and readily inserted replaced into its longitudinal containing channel extending three or more feet. It is often noted, in the field, that these and similar inventions hold fast pine needles in great numbers which presents an unsightly appearance as well as create debris dams behind the upwardly extended and trapped pine needles. Such filter meshes and non-woven lofty fiber mesh materials, even when composed of finer micro-porous materials, additionally tend to clog and fill with oak tassels and other smaller organic debris because they are not resting, by design, on a skeletal structure that encourages greater water flow through its overlying filter membrane than exists when such filter meshes or membranes contact planar continuously-connected surfaces. Known filter mediums of larger openings tend to trap and hold debris. Known filter mediums smaller openings clog or “heal over” with pollen and dirt that becomes embedded and remains in the finer micro-porous filter mediums. There had not been found, as a matter of common knowledge or anticipation, an effective water-permeable, non-clogging “medium-of-choice” that can be chosen, in lieu of claimed or illustrated filter mediums in prior art, that is able to overcome the inherent tendencies of any known filter mediums to clog when applied to or inserted within the types of water receiving wells and channels noted in prior art until such a medium of inter connected centered threads was disclosed in my U.S. Pat. No. 6,598,352 Col. 22 lines 47-50. The present invention will employ such medium and utilize such in an embodiment less costly to manufacture while remaining effective.
[0013] Vail also discloses that filter mesh material 26 is recessed beneath a planar surface that utilizes perforations in the plane to direct water to the filter medium beneath. Such perforated planar surfaces as utilized by Vail, by Sweers U.S. Pat. No. 5,555,680, by Morin U.S. Pat. No. 5,842,311 and by similar prior art are known to only be partially effective at channeling water downward through the open apertures rather than forward across the body of the invention and to the ground. This occurs because of the principal of water adhesion: rainwater tends to flow around perforations as much as downward through them, and miss the rain gutter entirely. Also, in observing perforated planes such as utilized by Vail and similar inventions (where rainwater experiences its first contact with a perforated plane) it is apparent that they present much surface area impervious to downward water flow disallowing such inventions from receiving much of the rainwater contacting them.
[0014] A simple design choice or anticipation of multiplying the perforations can result in a weakened body subject to deformity when exposed to the weight of snow and/or debris or when, in the case of polymer bodies, exposed to summer temperatures and sunlight.
[0015] U.S. Pat. No. 5,406,754 to Cosby teaches a gutter guard comprising a fine screen supported by a structural stiffening matrix support that prevents the penetration of even fine debris from entering a gutter. When lesser amounts of water flow are present such a device will allow water flow through its combination of screens downward into the gutter. However, during heavy rainfall, roof runoff is known to simply travel over the top most surface of such a device past an underlying gutter rather that downward into the gutter. As with other devices aforementioned in preceding paragraphs, this may occur due to a forward moving underflow of water that can occur beneath the top most surface of nearly planar gutter guards that do not incorporate downward extending planes that break forward flow of water.
[0016] U.S. Pat. No. 4,841,686 to Rees teaches an improvement for rain gutters comprising a filter attachment, which is constructed to fit over the open end of a gutter. The filter attachment comprised an elongated screen to the underside of which is clamped a fibrous material such as fiberglass. Rees teaches in the Background of The Invention that many devices, such as slotted or perforated metal sheets, or screens of wire or other material, or plastic foam, have been used in prior art to cover the open tops of gutters to filter out foreign material. He states that success with such devices has been limited because small debris and pine needles still may enter through them into a rain gutter and clog its downspout opening and or lodge in and clog the devices themselves. Rees teaches that his use of a finer opening tangled fiberglass filter sandwiched between two lateral screens will eliminate such clogging of the device by smaller debris. However, in practice it is known that such devices as is disclosed by Rees are only partially effective at shedding debris while channeling rainwater into an underlying gutter. Shingle oil leaching off of certain roof coverings, pollen, dust, dirt, and other fine debris are known to “heal over” such devices clogging and/or effectively “water-proofing” them and necessitate the manual cleaning they seek to eliminate. (If not because of the larger debris, because of the fine debris and pollutants). Additionally, again as with other prior art that seeks to employ filter medium screening of debris; the filter medium utilized by Rees rests on an inter-connected planar surface which provides non-broken continuous paths over and under which water will flow, by means of water adhesion, to the front of a gutter and spill to the ground rather than drop downward into an underlying rain gutter. Whether filter medium is “sandwiched” between perforated planes or screens as in Rees' invention, or such filter medium exists below perforated planes or screens and is contained in a well or channel, water will tend to flow forward along continuous paths through cur as well as downward into an underlying rain gutter achieving less than desirable water-channeling into a rain gutter.
[0017] U.S. Pat. No. 5,956,904 to Gentry teaches a first fine screen having mesh openings affixed to an underlying screen of larger openings. Both screens are elastically deformable to permit a user to compress the invention for insertion into a rain gutter. Gentry, as Rees, recognizes the inability of prior art to prevent entrance of finer debris into a rain gutter, and Gentry, as Rees, relies on a much finer screen mesh than is employed by prior art to achieve prevention of finer debris entrance into a rain gutter. In both the Gentry and Rees prior art, and their improvements over less effective filter mediums of previous prior art, it becomes apparent that anticipation of improved filter medium or configurations is not viewed as a matter of simple anticipation of prior art which has, or could, employ filter medium. It becomes apparent that improved filtering methods may be viewed as patentable unique inventions in and of themselves and not necessarily an anticipation or matter of design choice of a better filter medium or method being applied to or substituted within prior art that does or could employ filter medium. However, though Rees and Gentry did achieve finer filtration over filter medium utilized in prior art, their inventions also exhibit a tendency to channel water past an underlying gutter and/or to heal over with finer dirt, pollen, and other pollutants and clog thereby requiring manual cleaning. Additionally, when filter medium is applied to or rested upon planar perforated or screen meshed surfaces, there is a notable tendency for the underlying perforated plane or screen to channel water past the gutter where it will then spill to the ground. It has also been noted that prior art listed herein exhibits a tendency to allow filter cloth mediums to sag into the opening of their underlying supporting structures. To compensate for forward channeling of water, prior art embodies open apertures spaced too distantly, or allows the apertures themselves to encompass too large an area, thereby allowing the sagging of overlying filter membranes and cloths. Such sagging creates pockets wherein debris tends to settle and enmesh.
[0018] U.S. Pat. No. 3,855,132 to Dugan teaches a porous solid material which is installed in the gutter to form an upper barrier surface (against debris entrance into a rain gutter). Though Dugan anticipates that any debris gathered on the upper barrier surface will dry and blow away, that is not always the case with this or similar devices. In practice, such devices are known to “heal over” with pollen, oil, and other pollutants and effectively waterproof or clog the device rendering it ineffective in that they prevent both debris and water from entering a rain gutter. Pollen may actually cement debris to the top surface of such devices and fail to allow wash-off even after repeated rains. U.S. Pat. No. 4,949,514 to Weller sought to present more water receiving top surface of a similar solid porous device by undulating the top surface but, in fact, effectively created debris “traps” with the peak and valley undulation. As with other prior art, such devices may work effectively for a period of time but tend to eventually channel water past a rain gutter, due to eventual clogging of the device itself.
[0019] There are several commercial filtering products designed to prevent foreign matter buildup in gutters. For example the FLO-FREE™ gutter protection system sold by DCI of Clifton Heights, Pa. comprises a 0.75-inch thick nylon mesh material designed to fit within 5-inch K-type gutters to seal the gutters and downspout systems from debris and snow buildup. The FLO-FREE™ device fits over the hanging brackets of the gutters and one side extends to the bottom of the gutter to prevent the collapse into the gutter. However, as in other filtering attempts, shingle material and pine needles can become trapped in the coarse nylon mesh and must be periodically cleaned.
[0020] U.S. Pat. No. 6,134,843 to Tregear teaches a gutter device that has an elongated matting having a plurality of open cones arranged in transverse and longitudinal rows, the base of the cones defining a lower first plane and the apexes of the cones defining an upper second plane Col. 5 lines 16-25. Although the Tregear device overcomes the eventual trapping of larger debris within a filtering mesh composed of fabric sufficiently smooth to prevent the trapping of debris he notes in prior art, the Tregear device tends to eventually allow pollen, oil which may leach from asphalt shingles, oak tassels, and finer seeds and debris to coat and heal over a top-most matting screen it employs to disallow larger debris from becoming entangled in the larger aperatured filtering medium it covers. Filtering mediums (exhibiting tightly woven, knitted, or tangled mesh threads to achieve density or “smoothness”) disclosed in Tregear and other prior art have been unable to achieve imperviousness to waterproofing and clogging effects caused by a healing or pasting over of such surfaces by pollen, fine dirt, scum, oils, and air and water pollutants. Tregear indicates that filtered configurations such as a commercially available attic ventilation system known as Roll Vent® manufactured by Benjamin Obdyke, Inc. Warminster, Pa. is suitable, with modifications that accommodate its fitting into a rain gutter. However, such a device has been noted, even in its original intended application, to require cleaning (as do most attic screens and filters) to remove dust, dirt, and pollen that combine with moisture to form adhesive coatings that can scum or heal over such attic filters. Additionally, referring again to Tregear's device, a lower first plane tends to channel water toward the front lip of a rain gutter, rather than allowing it's free passage downward, and allow the feeding and spilling of water up and over the front lip of a rain gutter by means of water-adhesion channels created in the lower first plane.
[0021] Prior art has employed filter cloths over underlying mesh, screens, cones, longitudinal rods, however such prior art has eventually been realized as unable to prevent an eventual clogging of their finer filtering membranes by pollen, dirt, oak tassels, and finer debris. Such prior art has been noted to succumb to eventual clogging by the healing over of debris which adheres itself to surfaces when intermingled with organic oils, oily pollen, and shingle oil that act as an adhesive. The hoped for cleaning of leaves, pine needles, seed pods and other debris by water flow or wind, envisioned by Tregear and other prior art, is often not realized due to their adherence to surfaces by pollen, oils, pollutants, and silica dusts and water mists. The cleaning of adhesive oils, fine dirt, and particularly of the scum and paste formed by pollen and silica dust (common in many soil types) by flowing water or wind is almost never realized in prior art.
[0022] Prior art that has relied on reverse curved surfaces channeling water inside a rain gutter due to surface tension, of varied configurations and pluralities, arranged longitudinally, have been noted to lose their surface tension feature as pollen, oil, scum, Eventually adhere to them. Additionally, multi-channeled embodiments of longitudinal reverse curve prior art have been noted to allow their water receiving channels to become packed with pine needles, oak tassels, other debris, and eventually clog disallowing the free passage of water into a rain gutter. Examples of such prior art are seen in the commercial product GUTTER HELMET® manufactured by American Metal Products. In this and similar commercial products, dirt and mildew build up on the bull-nose of the curve preventing water from entering the gutter. Also ENGLERT'S LEAFGUARD®, manufactured and distributed by Englert Inc. of Perthamboy N.J., and K-GUARD®, manufactured and distributed by Knudson Inc. of Colorado, are similarly noted to lose their water-channeling properties due to dirt buildup. These commercial products state such, in literature to homeowners that advises them on the proper method of cleaning and maintaining their products.
[0023] None of theses above-described systems keep all debris out of a gutter system allowing water alone to enter, for an extended length of time. Some allow lodging and embedding of pine needles and other debris within their open water receiving areas causing them to channel water past a rain gutter. Others allow such debris to enter and clog a rain gutter's downspout opening. Still others, particularly those employing filter membranes, succumb to a paste and or scum-like healing over and clogging of their filtration membranes over time rendering them unable to channel water into a rain gutter. Pollen and silica dirt, particularly, are noted to cement even larger debris to the filter, screen, mesh, perforated opening, and/or reverse curved surfaces of prior art, adhering debris to prior art in a manner that was not envisioned.
BRIEF SUMMARY OF THE INVENTION
[0024] A filter assembly is provided that has a filtering screen and a skeletal structure, the skeletal structure being attached to the filtering screen. At least one of the filtering screen and the skeletal structure form a plurality of downward extending channels. The invention employs a filtering membrane and underlying skeletal support system applicable for disallowing small twigs, leaves, pine needles, pollen, and other debris larger than 100 microns from entering the gutter while directing rain water roof run off into an underlying rain gutter in the presence of such debris. The invention employs downward extending planes underside the filtering membrane and supporting skeletal structure that break the forward flow of water.
[0025] Unlike some prior art gutter guards which have a relatively fine-mesh polymer, fiberglass, or metal layer overlying a perforated panel that exhibits no downward water channeling planes, the gutter guard of the present invention includes a filtering screen integrally joined to a perforated expanded metal panel forming a lateral plane with downward extending water channeling paths. The absence of effective downward extending water channeling paths exhibited in prior art that employs filtering methods often allows for the forward channeling of water past rather than downward into an underlying rain gutter. Unlike prior art that does employ effective downward extending water channeling paths in a polymer body, notably LEAFFILTER™, the present invention has been demonstrated to achieve similar properties through a design more readily accomplished at lower cost of manufacture.
[0026] Accordingly, it is an object of the present invention to provide a gutter shield that permits drainage of water runoff into the gutter trench without debris becoming entrenched or embedded within the surface of the device itself and that employs a filtration membrane configuration that possesses sufficient self-cleaning properties that prevent the buildup of scum, oil, dirt, pollen, and pollutants that necessitate eventual manual cleaning as is almost always the case with prior art.
[0027] Another object of the present invention is to provide a gutter shield that redirects water and self-cleans as effectively as the LEAFFILTER™ gutter shield has been shown to do but do so at a lower cost of manufacture.
[0028] Another object of the present invention is to provide a gutter shield that will accept more water run-off into a five inch K-style rain gutter than such a gutter's downspout opening is able to drain before allowing the rain gutter to overflow (in instances where a single three-inch by five-inch downspout is installed to service 600 square feet of roofing surface).
[0029] Other objects will appear hereinafter.
[0030] It has now been discovered that the above and other objects of the present invention may be accomplished in the following manner. Specifically, the present invention provides a gutter screen for use with gutters having an elongated opening. Normally the gutters are attached to or suspended from a building.
[0031] An important feature of the present invention is to capture and redirect water flow across it's filtering membrane downward through the underlying skeletal support of expanded metal and into an underlying rain gutter as effectively as, and at a lower cost of manufacture, than does the LEAFFILTER™ gutter guard.
[0032] Another important feature of the present invention is to redirect downward flow of water rearward to the rear most portion of a rain gutter by means of angled walls comprising diamond shaped openings present in the underlying skeletal support of expanded metal whereby a forward underflow of water on the bottom surfaces of the gutter screen is greatly diminished.
[0033] The gutter shield device includes a first connecting plane of roll formed metal, a second filtering plane of roll formed metal and metallic or polymer cloth, and a third connecting plane of roll formed metal roll formed into an integral unit. The gutter shield device is adapted for being positioned in a longitudinally extending k-style gutter used for capturing rainwater runoff from roof structures.
[0034] According to another preferred embodiment of the invention, the first plane comprises an angled z-shaped connecting member for securing the gutter shield device to an inwardly extending flange of a k-style gutter to hold the gutter shield in place during use. According to another preferred embodiment of the invention, the first plane is fastened longitudinally along the first edge of the second plane by means of roll formed crimps. According to another preferred embodiment of the invention, the second plane comprises a combined fine filtering membrane with an underlying skeletal support of expanded metal support that may be assembled together as an integral unit.
[0035] According to another preferred embodiment of the invention, the filtering membrane has mesh openings not greater than 80 microns, top and bottom surfaces, first and second opposing edges, two opposing ends and an elongated axis extending between opposing ends. Adjacent the filtering membrane is the expanded metal support having diamond shaped openings, each wall of the opening angled downward at approximately 30 degrees, top and bottom surfaces, first and second opposing edges and two opposing ends.
[0036] According to another preferred embodiment of the invention, the first opposing edge of the expanded metal is fastened and crimped by means of roll forming to the first opposing edge of the filtering membrane to form a fast edge portion.
[0037] According to another preferred embodiment of the invention, the second opposing edge of the expanded metal is fastened and crimped by means of roll forming to the second opposing edge of the filtering membrane to form a second edge portion. The expanded metal support and filtering membrane, so joined as an integral plane, are then roll-formed to create two or more v-shaped downward extending longitudinal channels within the integral plane that transverse the length of the invention parallel to the first and second edge portions for redirecting water flow downward into the gutter.
[0038] According to another preferred embodiment of the invention, the third plane comprises a lateral connecting plane longitudinally fastened to the second edge of the second plane for securing the gutter shield device beneath the shingles of a roof. The first and third connecting planes provide a fastening method for securing the gutter shield device in place over a gutter.
[0039] In another embodiment, the third plane comprises a rear vertical leg fastened to and perpendicular to the second plane for resting on a gutter spike or gutter hangar for securing the gutter shield within the open lateral top of a rain gutter.
OBJECTS AND ADVANTAGES
[0040] Of the above described systems, the LEAFFILTER™ self cleaning gutter guard is known to have demonstrated an ability to, in almost every circumstance and over a period of years, prevent either a rain gutter or the gutter guard itself from clogging, or failing to direct water into a gutters downspout, due to debris lodging, or pollen or scum or oil accumulation. Of the remainder of the above described systems it has been noted that a buildup or coating of debris, pollutants, and oils either cause water adhesion properties to be lost or cause blockage of water receiving openings resulting in rain water roof run-off to flow past, rather than into, an underlying rain gutter.
[0041] An object of the present invention is to provide the above noted advantages, accomplished in the LEAFFILTER™ gutter guard, at a reduced cost to manufacturer and consumer. Additional objects of the present invention are to provide a gutter shield device that employs a fine filtration combination that is not subject to gumming or healing over by pollen, silica dust, oils, and other very fine debris, as well as to provide a filtration configuration and encompassing body that eliminates any forward channeling of rain water on surfaces or undersurfaces as is noted in prior art.
[0042] Another object of the present invention is to provide a filtration configuration that does not allow its filter cloth or membrane to sag and develop debris catching pockets. Another object of the present invention is to provide the noted advantages, accomplished in the LEAFFILTER™ gutter guard, at a reduced cost to manufacturer and consumer. Another object of the present invention is to provide the above advantages in a readily roll-formed gutter guard that may be manufactured on-site, via mobile roll-forming machines, at residential locations allowing for custom fitting of different rain gutters present on residential homes.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0043] FIG. 1 is a top view of a wire screen which is a component of the present invention.
[0044] FIG. 2 is a top view of a filter membrane which is a component of the present invention.
[0045] FIG. 3 is a top view of the filter membrane illustrating 3 applied adhesive strips.
[0046] FIG. 4 is a top view illustrating the filter membrane applied and resting on an underlying support screen of expanded metal, both being components of the present invention.
[0047] FIG. 5 is a top view of components of the present invention generally shown in FIG. 4 , that introduces two fastening sleeve components of the present invention.
[0048] FIG. 6 is a top view of components of the present invention illustrating an alternate embodiment of securing the filter membrane and underlying screen components of the present invention.
[0049] FIG. 7 is a top view of the present invention that illustrates a filter membrane of greater width than an underlying screen.
[0050] FIG. 8 is a top view of two components of the present invention merged by lapping a wider filtering membrane around lateral edges of an underlying screen and crimping both filter membrane and screen together along their respective lateral edges.
[0051] FIG. 9 is an exploded view of lateral edges of components of the present invention.
[0052] FIG. 10 is top view of components of the present invention generally shown in FIG. 4 .
[0053] FIG. 11 is an exploded view of a water directing channel component of the present invention.
[0054] FIG. 12 is an exploded view of a water directing channel component of the present invention exhibiting walls of the channel crimped together.
[0055] FIG. 13 is a top view of the present invention illustrating a rear attaching component.
[0056] FIG. 14 is an exploded view of the rear attaching component generally shown in FIG. 13 .
[0057] FIG. 15 is a top view of the present invention illustrating a rear attaching component unlike the rear attaching component shown in FIG. 13 .
[0058] FIG. 16 is an exploded view of the rear attaching component shown in FIG. 15 .
[0059] FIGS. 17 & 18 are top views of a preferred embodiment of the present invention.
[0060] FIG. 19 is a cross sectional view of an assembling line.
[0061] FIG. 20 is an exploded view of a roller component of the assembling line.
[0062] FIG. 21 is an exploded view of a tensioned roller component of the assembling line.
[0063] FIG. 22 is a cross sectional view of an assembling line generally shown in FIG. 20 .
[0064] FIG. 23 is a general pictorial view, partial in cross section, illustrating a gutter cover according to the present invention and installed above a conventional gutter adjacent to a conventional building.
[0065] FIG. 24 is a general pictorial view of the present invention generally shown in FIG. 23 , illustrating a different rear attaching member than is shown as employed by the present invention in FIG. 23 .
REFERENCE NUMERALS IN DRAWINGS
[0066]
1
Expanded metal screen
1a
width of expanded metal screen
2
downward extending channels
2a
gap between walls of downward extending channels
3
fine mesh membrane
3a
width of fine mesh membrane
4
glue strips
5
sprayed liquid adhesive
6
metal z-shaped sleeve
7
metal u-shaped sleeve 8 crimps
9
rear connecting sleeve
10
width of top plane of rear connecting sleeve
11
recessed channel
12
opening
13
gripping tooth
14
width of recessed channel
15
lower plane of rear connecting sleeve
16
lower plane of rear connecting sleeve
17
lower plane of rear connecting sleeve
18
width of first segment of top plane of rear
connecting sleeve
19
width of second segment of top plane of rear
connecting sleeve
20
width of third segment of top plane of rear
connecting sleeve
21
top horizontal plane of rear connecting member
22
top angled plane of rear connecting member
23
vertical rear leg of rear connecting member
24
height of lower segment of vertical rear leg
of rear connecting member
25a-c
decoiling cylinder
26
rolling assembly cylinder
26a, b, c
rolling assembly cylinders
27, 27a-e
shaping and crimping cylinders
28
roofing shingles
29
rain gutter
30
front lip of k-style gutter
31
subroof
32
preferred embodiments of present invention
33
fascia board
DETAILED DESCRIPTION OF THE INVENTION
[0067] Referring now specifically to the drawings, in FIG. 1 a gutter screen (protector) is illustrated 1 with downward extending water receiving channels 2 . The preferred gauge of the gutter screen wire is approximately 0.035 to 0.055 inch, which is suitably thick to maintain it's shape and not deform or dip under load bearing weight of snow and ice. The preferred gauge of the gutter screen wire is also of a narrow enough diameter (0.035 to 0.055) to allow the screen 1 sufficient flexibility to be wrapped around a spindle 25 and later unrolled in a manufacturing process as illustrated in FIG. 19 .
[0068] Referring now to FIG. 1 the gutter screen 1 presents a horizontal surface which extrudes downward into channels 2 , which act to inhibit the forward flow of rainwater off a roof structure by means of their open-air areas 2 a , having no greater than ¼ inch width of open air, which interrupt or inhibit some amount of forward water flow. The forward flow of water is further inhibited by being encouraged to flow downward into an underlying gutter due to a downward flowing water path created by the water tension that exists on the wire surfaces of 1 and 2 as they extend downward into any underlying rain gutter. This is an improvement over gutter screens presented in prior art which tend to channel water forward along their single plane or near single plane wire structures, around open air space apertures present in the same plane of the screen, and past, rather than into, a rain gutter. The side walls of channels 2 are crimped closely together contacting each other creating a honey combed wall that has demonstrated an ability to channel greater volumes of water than a solid plane or fin of the same dimensions that would extend downward. Such fins or planes have been utilized in prior art.
[0069] The downward crimped extensions 2 occurring in the horizontal plane of screen 1 also offer an improvement over prior art that employs fine screen or mesh placed over a perforated undulating or wavy support skeleton: Such prior art exhibits lateral weakness, tending to concave, and also provides fewer contact points between fine screen mesh and larger underlying support screen allowing for sagging of the supported mesh to occur. It has also been observed that sequential “waves” or undulations separated by open air space, channel a lesser volume of water downward and allow more to channel forward than does the compressed or crimped channels 2 of the present invention. Prior art that employs waves or undulations as a supporting skeleton for an overlying finer mesh, if constructed of identical material as the present invention, incurs greater cost of manufacture, as more material is required for prior art to cover the same amount of open gutter the present invention would cover.
[0070] Referring now to FIG. 2 : a filtering membrane 3 is illustrated that is comprised of warp-knit or “junctured” (threads not crossing over and under each other but, rather, passing through or adjoining each other) metal or polymer threads that form a fabric or mesh with air space between threads of approximately ≦80 microns. This particular method of fabric or mesh construction prevents the smallest of debris from “catching” and then lodging in the membrane itself as is common with filter methods, cloth, and membranes presented in prior art. Testing has shown that filtering membranes and screens so constructed, and made to contact each other in as many points as possible, as illustrated in FIG. 10 , (with the points of contact being limited to no greater widths than 0.03 inches) exhibit great resistance to clogging or matting due to pollen, oil that leaches from shingles, and other pollutants that commonly coat prior art and eventually lead to the loss of water permeability and water adhesion. A particular test of the invention involved immersing the invention in 30 wt oil: within 10 seconds water permeability of the invention was regained. Prior art so tested: filters, perforated planes, fins, curved surfaces, tangled mesh, louvers, multi-channeled curved surfaces, filtering membranes over planar perforated surfaces, filtering membranes over undulating or wavy surfaces, demonstrated significant loss of water adhesion and siphoning abilities for hours and, in some instances, days.
[0071] Limiting the space between threads to approximately 80 microns, does allow sufficient water permeability, approximately 75%, to accommodate rainfall run-off if the threads are warp-knit or “junctured”. Tests have shown that when such cloth is tilted at angles greater than 20 degrees, forward flow of water begins and water permeability of the filtering cloth is significantly reduced. When, however, such cloth or membrane 3 is made to contact underlying planes that extend downward, additional surface tension is created at the points of contact and the siphoning ability of the filtering membrane is regained. When such downward extending planes are composed of porous sidewalls that contact each other, the siphoning ability of the filtering membrane is not only regained, but improved and water permeability (or the ability to siphon water downward through the membrane) of filtering membranes will increase and remain as high as 97% even when such membrane is tilted at angles of 50 degrees (referenced to a horizontal plane).
[0072] Referring to FIG. 3 , adhesive strips 4 are applied at each edge and at an approximate center location on the underside of filter membrane 3 . This process may be accomplished at a fabric mill at the time of cloth manufacture and is one method of affixing filtering membrane 3 to underlying screen 1 .
[0073] Referring to FIG. 4 liquefied adhesive paths 5 are sprayed or otherwise applied to the top surface of screen 1 where they then are made to contact the underside of filter membrane 3 as an alternate method (to adhesive strips) of affixing filter membrane 3 to underling screen 1 . The spraying would be accomplished at the site of the roll forming merger of membrane 3 to underlying screen 1 as is illustrated in FIG. 19 : spraying head 41 spraying liquefied adhesive 5 to the top surface of screen 1 .
[0074] Referring to FIG. 22 the filter membrane 3 wound on a spool 25 a , may be unwound and applied and pressed onto the top surface of gutter screen 1 , by tensioning roller bars 26 a , 26 b , and 26 c as is illustrated. The tensioning bars are intended to position the filter membrane 3 in place as the adhesive strips (or narrow paths of adhesive spray) temporarily secure the filter membrane to the gutter screen 1 allowing permanent securing sleeves 6 and 7 (supplied by decoiling cylinders 25 b , 25 c ) to be roll formed and crimped on to sides of filter screen 1 and membrane 3 by tooled dies 27 , 27 a , 27 b , 27 c , 27 d , & 27 e.
[0075] Referring to FIG. 4 it is illustrated that the adhesive strips or spray 5 , which join filter membrane 3 to screen 1 are not positioned over downward extending channels 2 . Doing so may create a “bridging effect” that would encourage forward water flow across the glue paths or strips rather than encourage the downward siphoning effect on water the channels 2 exhibit. The adhesive strips 4 do, however, act to impede the forward flow of water and when positioned away from channels 2 : The adhesive strips or spray paths 5 indirectly allow the downward extensions 2 to more effectively siphon water downward and into the rain gutter beneath by slowing the water flow entering the downward extensions as well as slowing the lesser amounts of water that falls through the remaining non-channeled portions of screen 1 .
[0076] This unique dual use of the adhesive strips or stray paths is an improvement over filtered gutter cover methods presented in prior art that tend to channel water by surface tension along single planed horizontal surfaces past the top opening of a rain gutter. This dual use of the adhesive strips or spray paths also offers an improvement over prior art that employs fine mesh over undulating or wavy support skeletons that may glue filtering mesh to the underlying skeleton along the top of undulations or waves, encouraging forward flow water paths and/or no glue paths whatsoever exist to inhibit forward water flow.
[0077] Referring to FIG. 5 , sleeve 6 is a metal or polymer “z” shaped length, approximately ½″ to 1″ in width, that will be crimped 8 onto the left edge of gutter screen 1 and filter membrane 3 permanently fastening them together as illustrated in FIG. 6 . Sleeve 6 of FIG. 5 provides a means of fastening the left (or forward facing) edge of the invention to the top lip of a K-style rain gutter. Sleeve 7 is a metal or polymer “u” or “v” shaped length approximately ½″ to 1″ in width that will be crimped 8 onto the rear (or right) edge of gutter screen 1 and filter membrane 3 permanently fastening them together.
[0078] The invention offers improvement over prior art in that the junctured or warp-knit construction of both screen 1 and membrane 2 , when joined and achieving as many points of contact as possible exhibits greater water permeability than has been seen in prior art employing fine filtration membrane or cloths whose thread pattern is not so constructed: The invention also offers improvement over prior art that employs filtering screens or cloths, in different embodiments, in that the present invention exposes greater surface area, per rear to forward lateral inch, of water permeable membrane (that is able to effectively direct water flow) to oncoming rain water roof run-off by means of the present invention's downward extensions 2 .
[0079] The invention, FIG. 6 , additionally offers improvement over prior inventions in that it demonstrates great resistance to residual organic buildup which has been demonstrated to clog, and render ineffective, prior art over time. The combination of the particular type of a “warp-knit” or “junctured” filtration cloth or fine mesh over a screen mesh or hardware cloth with diamond shaped openings (that also employs wires junctured together on an equal plane (rather than woven up and under one another) creates a stronger downward siphoning action than is exhibited in prior art that utilizes fine or medium filter membranes or cloth fastened over underlying screens or perforated surface. The strong siphoning action, downward water channeling, and water permeability of the invention is due, in part, to the myriad of “blocks” to forward water flow presented by warp knit or “junctured” mesh or cloth: each thread intersects or abuts another causing water flow to “brake”, then climb up and over a new thread, time and time again at each thread intersection, without being able to follow a more continuous and unobstructed flow path available with other threading methods such as under and over, or knotted thread weaving, or knitting, or non-woven lofty fiber methods. Gravity is then able to exhibit more force on any water, present on the invention, than does the momentum of forward water flow.
[0080] Referring to FIG. 19 , a spray jet 41 spraying a quick drying weak adhesive 5 onto the top surface of gutter screen 1 is shown as an alternative way of temporarily fastening and holding in place the filter cloth membrane 3 until sleeves 6 and 7 are crimped onto the edges of filter cloth membrane 3 and gutter screen 1 achieving a permanent fastening of the filter membrane to the gutter screen.
[0081] Referring to FIG. 7 , there is illustrated a filter membrane 3 slit to a width wider than the underlying skeleton 1 it will attach to.
[0082] Referring to FIG. 9 , it is illustrated that a metal wire cloth membrane of junctured or warp-knit construction, with thread per inch counts of 100 or more, is wrapped around and under a side edge of a supporting skeleton 1 . The wire cloth is then crimped 8 onto the underlying support screen. This method of securing a screening element to an underlying support structure offers an improvement over prior art in that such a securing method is easily accomplished, economical, and does not require a third additional fastening element or material.
[0083] Referring to FIGS. 10, 11 , & 12 it is illustrated that membrane 3 a is roll formed down into channel 2 , (illustrated in the exploded view of FIG. 11 ). FIG. 12 illustrates that channel 2 is then crimped together so that membrane 3 and screen 1 contact each other within the well of channel 2 . This embodiment of channel 2 is another, less costly, method of achieving “downward extending legs”, disclosed in U.S. Pat. No. 6,598,352, column 13, lines 40-47, that break the forward flow of water and redirect water away from an overlying filtering membrane and also serves to further secure membrane 3 to underlying screen 1 . A downward curve of the combined screen 1 and membrane 3 is created at the top of each “leg” of channel 2 and is another, less costly, method of achieving “oval ellipses”, disclosed in U.S. Pat. No. 6,598,352, column 13, lines 47-51, that redirect water away from an overlying filtering membrane to underlying “downward extending legs”. This embodiment of channel 2 additionally creates a honey-combed porous plane that presents a great number of downward flow paths to water which is traveling the surface of an upper plane the channels 2 are connected to.
[0084] The greater number of flow paths presented by this honey-combed embodiment of channels 2 , over prior art that employs downward extending fins, or open air apertures in a singular plane, or curved surfaces, or singular filters, or filtering membranes over planar surfaces, or filtering membranes over undulating or wavy surfaces, offers improved siphoning ability and water re-direction into an underlying gutter.
[0085] Channel 2 should leave an open air space 2 a of no greater width than ⅛ inch. FIGS. 10, 11 , & 12 demonstrate the preferred securing of membrane 3 a to underlying support skeleton 1 . The roll forming of 3 a down into channels 2 illustrates the most effective embodiment of channels 2 of the present invention: this embodiment best redirects water flow into an underlying gutter while presenting only minute areas, 2 a , where debris may tend to gather.
[0086] FIG. 13 and FIG. 15 illustrate two interchangeable rear attachments: 9 and 14 . The attachments have a forward securing configuration 13 , 15 , 16 , and 17 that allow the attachments to interchangeably clip onto main body 1 a . Rear attachment 9 may be utilized in instances where it may be advantageous to install the rear of the gutter cover onto, or sandwiched between, a roof membrane and underlying sub roof as is illustrated in FIG. 24 . Rear attachment 14 may be utilized in instances where it is desirable to allow the gutter cover to rest wholly inside the top open end of a rain gutter and not have any part of the gutter cover extend up onto a roof as is illustrated in FIG. 23 .
[0087] Referring to FIG. 14 it is illustrated that two indented channels 40 lie in plane 10 of rear channel 9 . These channels may serve to act as flex or adjusting points and to enable heating cables to be inserted into them, if desired.
[0088] Referring to FIG. 16 an exploded view of rear attachment 14 is seen. Plane 22 of rear attachment 14 can contact a fascia board and create a rear to forward tension to secure the present invention into the top open end of a rain gutter.
[0089] FIGS. 14 and 17 illustrate a preferred embodiment of the present invention: A cloth filtering membrane 3 , with openings limited to no larger than 80 microns and of junctured or warp knit construction, is roll formed onto the top surface of supporting screen 1 and down into channels 2 and then roll formed around the lateral edges of support screen 1 and subsequently crimped in place near the later edges of supporting screen 1 and filtering membrane 3 , (as illustrated in FIG. 10 ). Channels 2 extend to lengths not less than ¾ inch and are crimped tightly together so that each side wall of the channels physically contact each other creating a micro-porous honey-combed downward extending plane. Testing has indicated that channels 2 begin to forward channel water on the underside of supporting screen 1 when their length is less than ¾ inch. A z-shaped roll-formed strip 6 is then crimped onto the forward lateral edge of the present invention: strip 6 will act to secure membrane 3 to underlying support skeleton 1 as well as serve to secure the gutter screen (the present invention) to the forward top lip of a k-style gutter. A choice of rear attachments 14 and 9 may then act to further secure membrane 3 to screen 1 . Additionally, the attachments allow the present invention 32 to act as a rain gutter screen that may be inserted wholly into the top of a rain gutter, resting on securing spikes or gutter hangars, and held in place by rear to forward tension (when 14 is chosen as the rear attachment) as is illustrated in FIG. 23 , or to serve as a gutter screen that allows for the insertion of it's rear attachment 9 beneath a roofing membrane or shingles to secure the present invention in place as is illustrated in FIG. 24 .
[0090] An improvement if offered over prior art in that the interchangeability of rear attachments 9 and 14 offer a configurable gutter cover that may be adjusted for installation in a wider array of circumstances existing in the field than is offered by prior art, which are known to be limited to the single choice of either “under the shingle” installation or to “wholly inside the gutter” installation.
Operation
[0091] Referring to FIGS. 23 and 24 , rain water will flow from a roof structure 28 onto the filtering membrane and screened plane 32 of the invention. The filtering membrane and screen combination 32 will redirect water flow downward into an underlying rain gutter. Testing has shown that 32, absent channels 2 , is able to redirect approximately 50% of rainfall that contacts 32 when rainfalls of 3 to 5 inches per hour occur over roofs with 32 foot rafter spans and slopes greater than 3/12 pitch. Testing further indicates that, when plane 32 incorporates channels 2 , the invention is able to redirect approximately 97% of rainfall into an underlying rain gutter (when rainfalls of 3-5 inches per hour occur over roofs with 32 foot rafter spans and slopes greater than 3/12 pitch.) Testing of the invention, in it's preferred embodiment, indicate that the invention is capable of redirecting approximately 90% of rain fall into an underlying rain gutter when rainfalls of 8-10 inches per hour occur over roofs with 32 foot rafter spans and slopes greater than 3/12 pitch. Significant water run-off or over shoot has been noted when the invention is installed on rain gutters that service roofs with pitches less than 3/12 and at “inside valleys” of hip valley roofs.
[0092] Debris, that may accompany rainfall runoff or that may, by other means, contact the invention will not lodge within or cling to plane 32 . Prior art commonly allows shingle grit, oak tassels, fir needles, and other small debris to enter a rain gutter or to become within the prior art itself. Testing has indicated the present invention makes this occurrence nearly impossible. Gravity or water adhesion may temporarily cause debris to rest on top of plane 32 , but it has been noted that water from roof run-off will travel beneath such debris and contact plane 32 and be directed into the underlying rain gutter 29 . Debris has been noted to rest or lodge on or within prior art and cause a bridging effect which channels water past the water receiving areas of prior art and onto the ground.
[0093] It has been noted that pollen has the capacity to “cement” debris to prior art, and to the present invention. Testing has shown that pollen may coat 32 but will wash through as soon as water from roof run-off contacts it. Testing has shown this is not the case with prior art: pollen tends to remain on prior art and require physical removal for restoration of water adhesion and/or permeability.
[0094] It is illustrated in FIG. 23 that the present invention may be inserted or snapped into the top open end of a rain gutter and remain in place by a rear to forward tension existing across plane 32 that is created by attachment 14 contacting fascia board 33 and z-shaped roll-formed strip 6 contacting the top upper lip 30 of a k-style gutter. Attachment 14 rests on an underlying hangar or spike and may be notched out to fit over them if necessary to maintain a constant level plane across sections of the invention as it is installed. Many building owners prefer that shingles or roof membranes not be lifted and disturbed due to the possible voiding of shingle warranties, and also prefer a gutter guard to install in a fashion that does not allow it to contact a building's sub roof: much prior art requires such installation.
[0095] Also, many homeowners find the appearance of a gutter guard covering the fast row of shingles on their home to be unattractive. In these instances, an installer in the field may snap attachment 14 onto the rear edge of plane 32 .
[0096] In some instances, a home or building owner may desire a “wholly inside the gutter” installation as is illustrated in FIG. 23 , but certain sections of a rain gutter may have shingles extending down into a gutter, or straps that extend from a subroof down into the gutter or onto it's top front lip, or the gutter may have a cable or other wire directly over it and passing thought the fascia board 33 it is attached to, or a drip edge may extend down into a gutter making the installation of a “wholly inside the gutter” gutter guard difficult or impossible. In these instances, an installer may opt to snap or place attachment 9 onto the rear lateral plane of 32 and continue installation with a matched product.
[0097] The invention will be manufactured in lengths that simply butt together at installation. Either rear attachment allows for quick installation and provides a gutter guard that ensures debris as small as 80 microns, or a grain of shingle grit, will not enter a gutter, and additionally ensures the gutter guard itself will remain water permeable and effective at channeling water into a rain gutter.
[0098] The embodiments illustrated and discussed in this specification are intended only to teach those skilled in the art the best way known to the inventors to make and use the invention. Nothing in this specification should be considered as limiting the scope of the present invention. All examples presented are representative and non-limiting. The above-described embodiments of the invention may be modified or varied, without departing from the invention, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that, within the scope of the claims and their equivalents, the invention may be practiced otherwise than as specifically described.
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A filter assembly is provided that has a filtering screen and a skeletal structure, the skeletal structure being attached to the filtering screen. At least one of the filtering screen and the skeletal structure form a plurality of downward extending channels.
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BACKGROUND OF THE INVENTION
This application is a continuation of copending application U.S. Ser. No. 485,434 filed Feb. 23, 1990, now abandoned.
The present invention relates generally to the manufacture of directed-fiber composite materials either of preformed or nonformed configurations. A preformed material is formed over a foraminous mold in the shape of the ultimate product to be formed. A nonformed material is deposited over a flat foraminous surface and results in a sheet which can ultimately be molded to a desired shape.
PRIOR ART
Directed-fiber preforms and sheets are a well known intermediate material used in the making of various finished products. These materials are made by forming a substantially open, three dimensional matrices of structural fibers and water based binder either into a shape resembling the finished product or as a sheet for subsequent forming. The structural fibers are commonly glass fibers. These glass fibers are bound together into either preformed or sheet shapes by the binder which is commonly a water borne adhesive material. The material is then additionally processed, by applying heat to drive off the water and set the binder. The intermediate material is then soaked in a resin, and subsequently finish molded into a final product.
One method and apparatus for making directed-fiber preforms using a horizontally translated shuttle is described in applicant's application Ser. No. 07/413,463, filed Sep. 27, 1989, which is herein incorporated by reference.
In a known method of making of directed-fiber preforms illustrated in Reinforcement Digest pg. 18, Vol. 46, Jan. 1989; glass fiber roving is chopped to short fiber lengths by an electrically powered chopping apparatus. The glass fiber is then fed through a hopper to a venturi in a tube connected at one end to a high powered fan. A spray head is suspended at the opposite, opened end of the tube for directing a binder liquid. The apparatus directs the glass fibers and binder liquid onto a rotating foraminous mold, or screen, in the shape of the preform to be made. Because the gun is fixed, rotation of the mold is required to cover the mold with fibers. A partial vacuum located behind the mold holds the fibers in place on the mold. The preform is then heated to drive off the water of the binder and activate the binder to set the glass into a matting.
This method results in large amounts of particulate emissions due to "splash-back" from the binder liquid/glass mixture hitting the rotating mold, resulting in material waste, operator health risks, and added labor expense in clean up. Contamination of the environment also results from a binder liquid which commonly contains isocyanates and/or formaldehydes which are released to the atmosphere upon drying and curing the preform.
Further, the preform manufacture process is slowed by the time needed to drive off the water from the binder in the wet preform, and is made more expensive by the heat required to do so.
Also, by using an aqueous binder, such as the commonly used latex slurry, the binder, when heated, will tend to fuse and run in the matrix of the preform. Thus, a webbing or lamination is formed in the matrix which blocks the efficient flow of resins therethrough in the subsequent finishing steps.
U.S. Pat. No. 3,328,383 ('383) illustrates another method and apparatus of applying fibers to a flat foraminous surface to provide the intermediate material in sheet form. The '383 patent discloses a substantially "Dry" method of fiber deposition which forms frangible binder filaments from a resinous binder melt immediately prior to their mixing with the glass fibers. The glass fibers are cut from roving and the binder filaments are shattered when the glass and binder are simultaneously fed through a chopping mechanism from whence they are fed to a chamber having a mold therein. An airstream is directed against the flow of fiber particles to distribute them throughout the chamber. The fibers are then deposited onto the foraminous flat mold or surface.
In such a process many independent variables must be controlled to ensure the correct ratio of binder filament-to-glass fiber. For example, in such a system, diameter of the binder filaments is dependent upon the pressure applied to the resin melting tank, the heat of the melt tank, the diameter of the orifice plate holes which extrude the binder filament, and the pressure and rotation speed of the binder filament take up rollers. Further, the heavier glass fibers and lighter binder filaments may separate upon contact with the opposing airstream, causing an uneven distribution of binder fibers through the preform. The agglomerated binder fibers will then fuse and form globules upon curing, resulting in a weakened preform structure. Also changeover of machine use from one type of binder filament to another is not quickly accomplished in the '383 apparatus.
There is, therefore, need for a composite fiber delivery device which minimizes waste material, reduces environmental contamination, is fast and efficient, and is simple and reliable to use with a variety of different structural fiber and binder filament types. Further, this fiber delivery system should create a fibrous composite comprising an evenly distributed three dimensional matrix of randomly oriented preform fibers in which massing, or agglutination of binder material is minimized. The composite matrix created should further be able to be quickly and efficiently set. The present invention provides a device having the above-cited advantages over the prior art.
SUMMARY OF THE INVENTION
The present invention provides an apparatus for the delivery of fibers to a foraminous mold or surface, comprising:
(a) a substantially tubular chute having:
(1) a first end having an opening for receiving an airstream,
(2) a second end having an opening for discharging a fiber mixture, and
(3) an opening in the chute for admitting fibers into the chute;
(b) means for attaching a binder fiber chopper in proximity to the chute;
(c) means for attaching a structural fiber chopper in proximity to the chute; and
(d) an air nozzle for directing an airstream through the chute in a direction from the first chute and to the second chute end
Attached to the chute are binder fiber and structural fiber choppers, which serve to chop, or cut, the binder and structural fibers, which are supplied in strands. Once the fibers, i.e., binder and structural fibers, are cut into short lengths, the choppers also entrain the cut fibers into the chute.
The binder fiber chopper is located upstream on the chute. By "upstream" it is meant proximal to the chute first end, which is upstream on the longitudinal airstream supplied by the nozzle. As the cut binder fiber is entrained into the longitudinal airstream the binder fiber is separated into longitudinal binder filaments. These individual binder filaments are carried downstream within the chute by the longitudinal air stream.
The structural fiber chopper is located downstream of the binder fiber chopper. The cut structural fiber lengths are entrained into the longitudinal airstream, which is carrying the binder filaments. Any residual clumps of binder filaments are separated into individual filaments upon collision with the heavier structural fiber lengths, which do not separate out into individual filaments. The mixture of binder filaments and structural fiber lengths is carried by the longitudinal airstream out the second end of the tube. The dispersal pattern of the fibers coming out of the chute may be modified at the chute second end by additional airstreams, or mechanical baffles, or like means, impinging upon the fiber mixture.
The fiber mixture is then deposited upon a foraminous mold or surface in an evenly distributed, three dimensional matrix of randomly oriented mixture of fibers. This matrix is then set by heat. In the matrix, the structural fiber lengths will be bound by numerous individual and separate binder filaments. Because the binder filaments do not agglomerate they will not run or form globules, i.e., agglutinate; in the matrix when heated, which would lead to a weakened intermediate structure and/or subsequent finishing problems, as previously said. Instead, the filaments stay elongated and bound to the structural fibers in a strong interlaced structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an environmental view of an apparatus embodying the present invention.
FIG. 2 is a second environmental view.
FIG. 3 is a front view of an apparatus embodying the present invention.
FIG. 4 is a cross sectional view taken along line IV--IV of FIG. 3 and disclosing operational details of the present invention.
FIGS. 5a and 5b are graphic aids to understanding fiber distribution.
FIGS. 6a-6d illustrates in enlarged detail the various forms taken by the preform fibers as seen in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As hereinafter used "mold" may refer to a contoured shape as shown in the drawings, or a flat surface the latter of which results in a sheet form composite. As seen in FIG. 1 an apparatus 10 comprises a mold control apparatus 12 previously disclosed by the applicant in Ser. No. 07/413,463, now U.S. Pat. No. 5,034,181, and a fiber delivery device 14. The mold control apparatus 12 horizontally translates a foraminous mold 16 over a vacuum source 18 during which the constituent fibers, i.e., the mixture of structural and binder fibers of the preform is deposited on the mold 16.
The activation of the fiber delivery device 14 is controlled by a control unit 70 which controls the shuttle movement so as to activate the fiber delivery device 14 is controlled by a control unit 70 which controls the shuttle movement so as to activate the fiber delivery device 14 when the mold 16 is in the proper position to receive fiber from the delivery device 14.
As seen in FIGS. 3 and 4, the fiber delivery device 14 comprises a substantially tubular chute 20 made of steel or other suitably surface-hard material so as to withstand impingement thereon of glass fiber, or other structural fibers as may be found desirable to use as further explained below.
The chute 20 has a substantially open first end 22 for receiving an airstream from a directed fluid source, such as delivery nozzle 24, as further explained below. The chute has a substantially open second end 26, opposite the first open end 22, through which the fiber mixture 72 exits the chute 20.
A side opening 28 is formed longitudinally in the chute 20 to allow the fibers 72 to be entrained into the interior of the chute 20. The side opening 28 does not run the entire longitudinal length of the chute 20 in the preferred embodiment, but stops short of the chute second end 26 to leave an enclosed cylindrical portion 30 of the chute 20 proximal to the chute second end 26 to provide a choke or other directing means on the dispersal of the filaments/fibers as further explained below.
The airstream delivery nozzle 24 is preferably attached to a wall of the chute 20 proximal to the chute first end 22. The nozzle 24 is positioned to provide a longitudinal airstream 71 through the chute 20 from first chute end 22 to second chute end 26. As shown, the nozzle 24 is affixed within the interior of the chute 20 to a chute wall 32 opposite the side opening 28 by means of a clamp 34 comprising a metal strap 33 fitted over the nozzle 24 and held by pop rivets 35a, 35b. Alternatively, the nozzle 24 may be affixed by adhesives, welding, etc. within or without the chute 20 so long as the proper airstream is achieved as further explained below. The nozzle 24 receives pressurized air from an air line 36 attached to the nozzle 24, in a known manner, and conveys the pressurized air from a compressor (not shown) or the like.
A rectangular mounting plate 38, providing means for attaching first and second fiber choppers 40, 42 respectively, is affixed to the chute 20 by retaining a chute side flange 39 at one longitudinal side of the side opening 28, and positioning the side flange 39 between the mounting plate 38 and an opposing plate 37. The plates 37, 38 are attached to the side flange by an appropriate fasteners, such as by a rivet 91, screw, bolt, or the like. The mounting plate 38 carries thereon the first and second fiber chopper/entraining means 40, 42 respectively as further explained below. The mounting plate 38 also has formed therein throughholes 43a and 43b for receiving therein means 44 for suspending the chute 20 above the preform mold 16 such as a suspender rod 46. A suspender rod 46, as shown, may be affixed at one end to the mounting plate 38 by a clamp 45 comprising a metal strap 47 surrounding the rod 46 and affixed to the mounting plate 38 by screws 49 held in the throughholes 43a, 43b. Alternatively, the rod may be attached to the chute 20 by other means such as a threaded receptacle (not shown) pivotally affixed to the mounting plate 38 and receiving a threaded end (not shown) of the rod 46 therein. The rod 46 is attached, at the other end thereof, to the overhead support rack 60 by suitable means as known in the art. Provision is preferably made for suitable adjustability of the chute position in any such suspension arrangement.
The first and second fiber chopper/entraining means 40, 42 respectfully, are commercially available fiber strand choppers such as Model B-410 Choppers from Glass-Craft, Inc. of Indianapolis, Ind. The fiber choppers 40, 42 are air-powered devices which chop, or cut, fiber strands 48, 52 into short lengths 74, 78 and blow these short lengths of fiber away from the chopper with a directed airstream 84, 86. Such choppers as are utilized with the present invention will preferably have separate motor speed and blower controls, as well as adjustable cutting lengths.
Separate choppers are needed for each fiber-type to adequately maintain consistent cutting results on the various types of fibers as may be used with the preform apparatus 10. Additional choppers may be supplied as needed for different fiber types or increased capacity.
The first fiber chopper/entraining means 40 is attached by conventional means, such as, through bolts (not shown) to the mounting plate 38 proximal to the chute first end 22 so as to be located upstream of the second fiber chopper 42 on a longitudinal airstream 71 supplied by the nozzle 24. A fibrous binder material strand 48, or strands, enter that side 50 of the first fiber chopper 40 distal to the chute 20 during operation of the manufacturing apparatus 10. The first chopper 40 is powered by directed air through an airline 41 attached to first chopper 40 at a nipple 41a. While other thermoplastic materials may be used, the binder material strand 48 currently used is a low molecular weight variety of KODEL (Trademark) polyester type fiber manufactured by Eastman Chemical Products, Inc. of Kingsport, Tenn. and Wellman, Inc. of Johnsonville, S.C. The binder fiber strand currently used is supplied in the form of tow; i.e., a strand without definite twist collected in loose, rope-like form. It is envisioned that a variety of binder fiber strands may be suitably employed by those skilled in the art dependent upon the binder characteristics desired and the chopper/entraining means available to the artisan.
The second fiber chopper/entraining means 42 is attached to the mounting plate 38 by conventional means such as throughbolts (not shown) downstream of the first chopper 40. Glass fiber roving 52 of a known type enters that side 54 of the second fiber chopper 42 distal to the chute 20 during operation of the preform manufacture apparatus 10. The second chopper is powered by directed air through an airline 43 attached to the second chopper at a nipple 43a.
A mechanical baffle 56, or baffles, may be attached by known means such has pop rivets 57a, 57b or the like, onto or proximal to the chute 20 longitudinally downstream of the second chopper 42 to vary the fan, or dispersal pattern, of the fiber mixture 72 exiting the chute second end 26. Alternatively or cooperatively with baffle 56, an oblique airstream 88 may be supplied through a second nozzle 58 to alter the dispersal pattern of the exiting fiber mixture 72. The second nozzle 58 is preferably located longitudinally downstream of the second chopper 42 and will direct the airstream 88 obliquely downstream of the longitudinal axis of the chute 20. Alternatively, the enclosed cylindrical portion 30 of the chute 20 may be formed to provide dispersal, or fanning, means.
In use, as seen in FIGS. 1 and 2, the fiber delivery device 14 is suspended by rod 46 from a support rack 60, or otherwise suitably affixed thereto. The delivery system 14 is placed such that the chute second end 26 is pointed toward the foraminous mold 16 when the mold 16 is in a position to have fibers 72 applied thereto.
A fibrous binder strand 48, is fed from its spool 62 through a strand guide 64 attached to the support rack 60. From there, the binder strand 48 is fed to the first chopper 40 which takes up the binder strand 48 as needed during operations. A strand of glass fiber roving 52 is likewise fed from its spool 64 into the second chopper 42. It will be appreciated that each chopper 40, 42 may handle a plurality of strands of fiber. Apparatus 10 is activated so as to translate the mold 16 in the horizontal plane beneath the fiber delivery system 14.
In the preferred embodiment, the fiber delivery system 14 is activated by a position indicator 66 read by a sensor unit 68 which, in turn, communicates with a control unit 70 for the apparatus 10. The airline 36 to the nozzle 24 is activated to provide the longitudinal air stream 71 down one side of the chute 20. The first chopper 40 is activated to take up the binder strand 48 and cut it to the desired lengths. The desired length of cut is determined by the need to separate the binder fiber 48 completely into individual filaments and how the particular binder fiber being used is held together. For example, if the binder filaments 76 are formed into a strand by turning or crimping the filaments three times per inch, the chopper 40 will be set to cut the strand at one-third inch intervals. This length of cut ensures that no cut length 74 of binder fiber will have its filaments 76 held together by more than one turn or crimp. Thus, the binder filaments within each cut length 74 can be easily separated. Alternatively, untangled or loosely held strands of filaments may be cut to any desired length.
The first chopper 40, after cutting the binder fiber strand 48 into cut lengths 74, entrains the cut lengths 74, by means of an airstream 84, transversely into chute 20 through side opening 28 and thereby into the longitudinal airstream 71. It will be appreciated that either chopper 40, 42 may entrain its cut fibers 74, 78 into the chute 20 without additional thrust from a chopper supplied airstream 84, 86 if such an arrangement is adequate for the size of chute being used.
As the cut lengths 74 of binder fiber impinge upon the longitudinal airstream the filaments 76 therein are blown apart from each other. At this point approximately ninety-five percent of the filaments are separated out from the cut lengths 74.
The second chopper 42 is activated an instant after the first chopper 40 to entrain cut bundles 78 of glass fiber from the glass fiber roving 52 into the chute 20. The length of the glass bundles 78 is largely determined by the physical properties desired in the final product. The glass bundles 78 have more mass than the cut binder lengths 74 and therefore will travel through the longitudinal airstream and rebound off the chute wall 32.
As seen in FIG. 4, the glass bundles 78 will substantially retain their original physical form and will not be separated into individual filaments 80 by the longitudinal airstream or by contact with the chute wall 32. Mixing of the binder filaments 76 and the glass bundles 78 occurs in the glass-bundle rebound area 82 of the chute. Impingement of the glass bundles 78 on the binder filaments 76 will substantially complete the remaining five percent of binder filament 76 separation. In that case where the composite part is to be subsequently liquid cast, i.e., impregnated with a liquid resin for final molding, the mixture of fibers 72 is approximately ninety-five percent structural to five percent binder. In such case, the resin binder fibers are in an amount sufficient to hold the composite material together until final liquid casting A higher percentage of binder fibers will be used in the case where these fibers are to provide the final product binding matrix. In the latter case the structural fibers may be as low as seventy percent and the binder fibers as high as thirty percent of the composite mixture.
Finally, the fiber mixture 72 is directed out of the chute second end 26 onto the foraminous mold or surface 16. The resultant composite fiber material will contain individual binder filaments 76 substantially surrounding and contacting the glass bundles 78 in an evenly distributed three dimensional matrix of randomly oriented fibers.
Upon heating, the binder filaments 76 will adhere to the glass bundles 78 and to each other thereby knitting together the entire structure and producing a composite material capable of further processing into a finished part. It will be appreciated that this dry matrix of fibers 72 will require substantially less heat to set than the known preforms using an aqueous binder. Thus, a savings in time and energy costs is obtained.
As seen in FIG. 2, should the width of the mold require more than one fiber delivery device 14 for necessary fiber coverage, a plurality of fiber delivery devices 14 may easily be arranged over the mold 16 in a variety of arrays.
As graphically illustrated in FIGS. 5a and 5b, without any baffling, the natural distribution of the fibers from the chute 20 onto the mold 16 is heavily center-weighted under the diameter of the chute. In other words, the amount of fiber deposited at, or beyond, the edges of the chute 20 drops off rapidly, as represented by the steep bell curves 90.
In order to alleviate the undesired areas of sparse fiber deposition on those parts of a mold which may lie beneath or beyond the edges of the chute 20, a mechanical baffle 56 of an oblique airstream 88, or both, may be utilized as means for fanning the standard fiber distribution and thereby substantially evenly spreading the fiber mixture 72 over the mold 16. Alternatively, the enclosed chute cylindrical portion 30 may be shaped to provide the necessary mechanical baffling.
In use of the illustrated embodiment the stream of fibers emitted from the chute is compressed on each of two opposing sides by the mechanical baffle 56, and the oblique airstream 88 from the additional nozzle 58, respectively, to broaden the stream, thereby changing the distribution pattern from a circle to an eclipse as graphically represented by the flattened curves 92.
Care must be taken in the placement and operation of the additional fan elements 56, 58 so as to not separate or stratify the heavy glass bundles 78 and light individual binder filaments 76 from their well-mixed condition in the longitudinal airstream 71.
Thus it will be seen that the present invention provides a clean and efficient method of delivering fibers to a foraminous mold in a well distributed matrix of individual binder filaments and glass fiber bundles.
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A method and apparatus for applying fibers to a foraminous mold or surface using strands of binder and glass fibers is disclosed. A strand of binder fiber is chopped and entrained into a chute. The chute has a longitudinal airstream directed therethrough toward the foraminous surface. The binder fiber is separated into filaments by the airstream. The glass fiber strand is chopped and entrained into the chute downstream of the filaments. The chopped glass and the binder filaments mix within the chute and are then directed by the airstream onto the foraminous mold or surface. The mixture may be fanned out from the chute to provide more even coverage of large sized molds or surfaces.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a divisional of co-pending U.S. patent application Ser. No. 12/946,990, filed on Nov. 16, 2010, which is a divisional of Ser. No. 10/459,895, filed Jun. 12, 2003, which claims priority to and the benefit of provisional U.S. patent application Ser. No. 60/388,446, which was filed on Jun. 12, 2002, all of which are incorporated by reference in their entireties herein.
TECHNICAL FIELD
The invention relates generally to the treatment of mammalian tissue through the process of bulking, and more specifically to the injection of bulking particles into a treatment region of a mammal.
BACKGROUND
Urinary incontinence, vesicourethral reflux, fecal incontinence, and intrinsic sphincter deficiency (USD), for example, are disorders that have responded to treatments with augmentative materials. Such disorders occur when the resistance to flow of bodily discharges decreases to the point where the resistance can no longer overcome the intra-abdominal pressure. Nearly all procedures developed to restore continence are based on restoring the lost resistance.
Surgical implantation of artificial sphincters has often been employed to treat patients suffering from urinary incontinence. The surgical implantation of the artificial sphincter commonly requires hospitalization, is relatively complex and expensive, and will usually require six to eight weeks of recovery time. Moreover, the procedure may be unsuccessful if the artificial sphincter malfunctions. As a result, additional surgery is required to adjust, repair, or replace the implant.
Urinary incontinence can also be treated using nonsurgical means. A common method to treat patients with urinary incontinence is periurethral injection of a bulking material. One such bulking composition is a Teflon® paste known commercially as “Polytef” or “Urethrin.” This paste is comprised of a fifty-fifty (50-50) by weight mixture of a glycerin liquid with Teflon® (polytetrafluoroethylene (PTFE)) brand particles sold by DuPont. The glycerin is biodegradable, however, and over a period of time the glycerin dissipates into the body and is then metabolized or eliminated leaving only about fifty percent (50%) of the injected mixture (i.e., the Teflon® particles) at the injection site. Consequently, to achieve the desired result, the surgeon typically overcompensate for the anticipated loss of bulking material by injecting a significantly larger amount of material than initially required. At the extreme, this overcompensation can lead to complete closure of the urethra, which could put the patient into temporary urinary retention. Additionally, the eventual dissipation of the glycerin complicates the surgeon's ability to visually gauge the appropriate amount of bulking material to inject. To avoid these over-bulking side effects, the surgeon may ultimately not inject enough bulking mixture, leading to the likelihood of a second or even a third procedure to inject additional material.
Further, the particle size in the Teflon® paste bulking material if sufficiently small may allow the particles to migrate to other locations of the body, such as the lungs, brain, etc. Teflon® particles have been known to induce undesirable tissue reaction and form Teflon® induced granulomas in certain individuals.
In addition, the Teflon® paste is typically highly viscous and can only be injected using a hypodermic needle held by an injection assist device. Use of an injection assist device may be required, because a surgeon would likely not have sufficient strength to force the highly viscous Teflon® paste through a needle of any acceptable size.
Two alternatives to the Teflon® paste are a collagen gel and carbon coated zirconium beads. One such commercially available product includes Contigen®, available from CR Bard. The collagen gel is injected in the same manner as the Teflon® paste and forms a fibrous mass of tissue around the augmentation site. This fibrous mass created by the collagen injection, however, also dissipates over time and is eventually eliminated by the patient's body. As a result, additional injections are periodically required.
Yet another bulking procedure includes the injection of swollen hydrogel particles. The swollen hydrogel particles exhibit relatively low injection forces by incorporating low molecular weight water-soluble organic compounds, along with water, in the particles. See, for example, U.S. Pat. Nos. 5,813,411 and 5,902,832 to Van Bladel et al., and U.S. Pat. No. 5,855,615 to Bley et al., the disclosures of which are hereby incorporated herein by reference in their entireties.
Another alternative to the Teflon paste is a hard particle suspension. One such commercially available product is Durasphere® available from Carbon Medical Technologies. These hard particles, for example carbon coated zirconium beads, are injected in a beta-glucan carrier. The beta-glucan is eliminated by the patient's body over time. As a result, additional injections may be required. Furthermore, hard particle suspensions, depending on the size of the particle, may tend not to be easily dispensed without clogging smaller gauge injection needles.
Furthermore, available methods of injecting bulking agents require the placement of a needle at a treatment region, for example, peri-urethrally or transperenially. Assisted by visual aids, the bulking agent is injected into a plurality of locations, causing the urethral lining to coapt. In cases where additional applications of bulking agent are required (e.g., when bulking agents are dissipated within the body), the newly added bulking agent may need to be injected at a higher pressure than the pressure at which the initial bulking agent was injected. The higher pressure requirements for subsequent injections may result from the effect of closing off the treatment region by the initial bulking agent, thereby creating backpressure when attempting to insert additional hulking agent(s). Typically, the bulking agent is injected at multiple locations to cause the uretheral lining to coapt with a higher opening pressure than the patient had prior to injection of the bulking agent.
Bulking agent delivery methods have attempted to address the issue of subsequent injection requirements. One method that has been employed is hydrodissection of tissue in the vicinity of the treatment region, thereby creating tissue voids designed to decrease the injection pressure required when adding additional bulking agent to the voids. Another method used to reduce injection pressures is the Urovive™ device available from American Medical Systems. Urovive™ utilizes a plurality of silicone balloons that are inserted into the treatment region, specifically, the periphery of the sphincter. The balloons are then filled with a hydrogel to effect tissue coaptation.
SUMMARY OF THE INVENTION
The invention generally relates to an injectable bulking composition that does not degrade or dissipate in the body, has sufficiently low viscosity such that it is easily administered via injection, and will not migrate from the site of injection, thereby enabling the affected tissue to maintain the desired constriction without causing undesirable side effects. In addition, the invention generally relates to an injection method that reduces the injection pressure required to place the bulking agents.
In one aspect the invention relates to the use of polymeric particles to facilitate bulking in a treatment region of a mammal's body through injection of the particles into the treatment region. The particles are compliant enough to be delivered through a relatively small gauge injection device. Generally, the invention is employed in the treatment of diseases requiring sphincter bulking, e.g., for treating urinary or fecal incontinence; however, the bulking method described herein can also be used for soft tissue bulking for use during, for example, plastic surgery.
In another aspect the invention relates to a bulking agent for medical applications. The bulking agent includes a carrier and a plurality of substantially spherical polyvinyl alcohol particles dispersed within the carrier. The carrier aids the delivery of the substantially spherical polyvinyl alcohol particles to a site to be bulked.
In yet another aspect, the invention relates to a method for bulking mammalian tissue. The method includes the steps of introducing a bulking agent to the mammalian tissue to coapt the mammalian tissue with the bulking agent. The bulking agent includes a carrier and a plurality of substantially spherical polyvinyl alcohol particles dispersed within the carrier. The carrier aids the delivery of the substantially spherical polyvinyl alcohol particles to a site to be bulked.
In various embodiments of the foregoing aspects, the bulking agent comprises a volume. The volume could be, for example, from about 1 ml to about 30 ml, from about 20 ml to about 30 ml, or from about 2 ml to about 16 ml. In additional embodiments, the substantially spherical polyvinyl alcohol particles are sized from about 40 micron to about 1500 microns in diameter, preferably from about 150 micron to about 1100 microns in diameter, and more preferably from about 500 micron to about 900 microns in diameter. Further, the substantially spherical polyvinyl alcohol particles can comprise pores and/or bioreactive agents, such as drugs, proteins, genes, chemo-therapeutic agents, and growth factors. In other embodiments, the substantially spherical polyvinyl alcohol particles can be compressible and/or substantially dimensionally stable.
In additional embodiments, the carrier can be a water-based solution, such as saline solution. In addition, the carrier can include at least one of a lubricant, a biocompatible thickening agent, or a color. Furthermore, the bulking agent can be delivered through a needle and/or a catheter. In one embodiment, the bulking agent is delivered transuretherally. In addition, the bulking agent can be delivered while viewing the tissue to be bulked with a cytoscope.
In still another aspect, the invention relates to an apparatus for bulking mammalian tissue. The apparatus includes a needle defining a lumen, an inflation device adapted to advance through the lumen of the needle, and a bulking agent insertable via the lumen of the needle. The needle is adapted to penetrate the mammalian tissue. The inflation device is disposed adjacent to the mammalian tissue after being advanced through the needle. The inflation device is inflatable and subsequently deflatable to create a void in the mammalian tissue. The bulking agent is inserted to fill at least partially the void in the tissue, the bulking agent coapting the mammalian tissue.
In various embodiments of the foregoing aspect of the invention, the inflation device can include a biocompatible balloon, and/or a color coating for visualization made from at least one of a silicone, an ethylene vinyl alcohol, a polypropylene, a latex rubber, a polyurethane, a polyester, a nylon, or a thermoplastic rubber. Additionally, the inflation device can have a shape selected from the group consisting of substantially round, oval, hemi spherical, spherical, or oblong. In one embodiment, the needle is sized from 16 gauge to 24 gauge, preferably from 18 gauge to 22 gauge.
In additional embodiments, the bulking agent comprises a plurality of polymeric particles and can be injected into the void by a syringe. In one embodiment, the bulking agent includes a carrier and a plurality of substantially spherical polyvinyl alcohol particles dispersed within the carrier. The carrier aids the delivery of the substantially spherical polyvinyl alcohol particles to a site to be bulked. The bulking agent can further include a color.
In yet another aspect, the invention relates to a method for bulking mammalian tissue. The method includes the steps of inserting an inflation device within a portion of a mammal, inflating the inflation device to compress the mammalian tissue surrounding the inflated inflation device, thereby creating a void in the tissue, deflating the inflation device, removing the inflation device from the mammal, and providing a bulking agent to at least partially fill the void, the bulking agent coapting the mammalian tissue.
In various embodiments of this aspect of the invention, the method includes the steps of inserting a needle with a penetration device into the mammalian tissue, removing the penetration device while retaining the inserted needle, and advancing the inflation device through the needle. The needle can be sized from 16 gauge to 24 gauge, preferably 18 gauge to 22 gauge. The method can also include the step of viewing the tissue to be bulked with a cytoscope. In one embodiment, the inflation device can include a biocompatible balloon, and/or a color coating for visualization made from at least one of a silicone, an ethylene vinyl alcohol, a polypropylene, a latex rubber, a polyurethane, a polyester, a nylon and a thermoplastic rubber. Additionally, the inflation device can have a shape selected from the group consisting of substantially round, oval, hemi spherical, spherical, or oblong.
In additional embodiments, the bulking agent comprises a plurality of polymeric particles and can be injected into the void by a syringe. In another embodiment, the substantially spherical polyvinyl alcohol particles are coated, embedded, or filled with a material that will aid the delivery of the particles to a site to be bulked. In one embodiment, the bulking agent includes a carrier and a plurality of substantially spherical polyvinyl alcohol particles dispersed within the carrier. The carrier aids the delivery of the substantially spherical polyvinyl alcohol particles to a site to be bulked. The bulking agent can further include a color.
These and other objects, along with advantages and features of the present invention, will become apparent through reference to the following description, the accompanying drawings, and the claims. Furthermore, it is to be understood that the features of the various embodiments described herein are not mutually exclusive and can exist in various combinations and permutations.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, like reference characters generally refer to the same parts throughout the different views. Also, the drawings are not necessarily to scale, emphasis generally being placed upon illustrating the principles of the invention. In the following description, various embodiments of the present invention are described with reference to the following drawings, in which:
FIG. 1 depicts a side view of a tissue structure with an enlarged lumen surrounded by muscle tissue;
FIG. 2 depicts the tissue structure of FIG. 1 immediately after a bulking agent in accordance with the invention has been injected around the enlarged lumen of the tissue;
FIG. 3 depicts the tissue structure of FIG. 1 immediately after a bulking agent in accordance with the invention has been injected around the enlarged lumen of the tissue utilizing a cystoscope-aided injection method;
FIG. 4 is a schematic plan view of a needle assembly in accordance with the invention;
FIG. 5 is a schematic plan view of the needle assembly of FIG. 4 with the trocar/obtuator assembly being removed;
FIG. 6 is a schematic plan view of the needle assembly of FIG. 4 with a balloon assembly being inserted into the needle assembly;
FIG. 7 is a schematic plan view of the needle assembly of FIG. 4 with a syringe attached to the needle assembly for inflating the balloon;
FIG. 8 is a schematic plan view of the assembly of FIG. 7 with the syringe and balloon assembly being removed;
FIG. 9 is a schematic plan view of the assembly of FIG. 4 with another syringe attached to the needle assembly for injecting a bulking agent into tissue;
FIG. 10 is a pictorial representation of a method of creating a void within a patient's tissue by inserting and inflating a balloon; and
FIG. 11 is a pictorial representation of a method of filling the void within the patient's tissue with a bulking agent.
DESCRIPTION
Embodiments of the present invention are described below. The invention is not limited, however, to these embodiments. For example, various embodiments of the invention are described in terms of treating incontinence; however, embodiments of the invention may be used in other applications, such as cosmetic reconstruction.
Referring to FIG. 1 , a tissue structure, more specifically a urethra/ureter 10 , having a wall 20 and an enlarged lumen 30 surrounded by muscle tissue 40 is shown in side view. Before the enlarged lumen 30 is constricted with the bulking composition, a cystoscope 50 comprising a fiberoptic light transmitting element 60 , a working channel 70 and a viewing element 80 encased in a sheath 90 may be inserted in the urethra/ureter 10 to a distance close to the enlarged lumen 30 . The close distance is selected to allow a clear view of the enlarged lumen 30 .
Referring to FIG. 2 , the urethra/ureter 10 is shown immediately after a bulking agent in accordance with the invention has been injected around the enlarged lumen 30 of the tissue. Once the enlarged lumen 30 is readily in view, a hypodermic needle 100 is inserted through the tissue 40 , preferably over the enlarged lumen 30 , stopping near the wall 20 of the enlarged lumen 30 . Thereafter, a bulking agent 110 including polymeric particles 120 is injected via the hypodeimic needle 100 into the tissue 40 adjacent the wall 20 . The result is a constricted region 130 located in the vicinity of the accumulation of the bulking agent 110 .
Alternatively, referring to FIG. 3 , the urethra/ureter 10 is shown immediately after the bulking agent 110 of the present invention has been injected around the enlarged lumen 30 of the tissue 40 utilizing a cystoscope 50 aided injection method in accordance with another embodiment of the invention. An elongate needle 140 may be inserted through the working channel 70 into the urethra/ureter 10 and the surrounding tissue 40 and the injection can be completed operating solely through the cystoscope 50 . This is generally the preferred method of operation on male patients for the area surrounding the urethra/ureter and is the preferred method for female patients for the area surrounding the ureter.
Furthermore, the present invention relates to a bulking agent including substantially spherical polyvinyl alcohol particles used to facilitate hulking in a region of the human body through injection of the particles into the treatment region. The particles are compliant enough to be delivered through a substantially small-gauge injection device. In one embodiment, the particles are 50% compressible. This is accomplished through the use of particles that are adapted to compress as they pass through the small gauge injection device. In one embodiment, a 16 to 24 gauge needle is used to dispense the bulking composition without clogging. In other applications, other size needles may be preferred, for example 18-22 gauge.
Filling the space surrounding the urethra/ureter allows the sphincter to be more readily coapted by the patient to maintain continence. Generally, the present invention is employed in the treatment of diseases requiring bulking, e.g., urinary or fecal incontinence. Some examples of conditions that can be treated by way of the present invention include urinary incontinence, vesicourethral reflux, fecal incontinence and intrinsic sphincter deficiency or ISD. However, the bulking method described herein can also be used for soft tissue bulking for use during, for example, plastic surgery.
In greater detail, the method of providing a bulking agent to the human body includes using polymeric particles, such as polyvinyl alcohol, as a bulking agent and injecting the particles into the treatment region of the human body. An advantage of the present invention is that the particles are substantially non-biodegradable, thereby virtually eliminating the need for replenishing the particles to maintain efficacy. A further advantage of the present invention is that the substantially spherical size and shape of the particles allows for close packing of the particles in the treatment space.
In one embodiment, the particles are made of a water and polyvinyl alcohol mixture. For a description of particles contemplated for use with the present invention, see U.S. patent application Ser. Nos. 10/232,265, 10/215,594, 10/116,330, 10/109,966, 10/231,664, the disclosures of which are hereby incorporated by reference herein in their entirety. Generally, water, polyvinyl alcohol, and alginate are combined and pumped through a nozzle under pressure, generating substantially spherically-shaped droplets. The substantially spherically-shaped droplets encounter a solution that promotes cross-linking of the polyvinyl alcohol. Subsequently, the alginate is removed from the outer surface. The result is a substantially spherically-shaped particle that is substantially all polyvinyl alcohol.
To facilitate other treatments, dosages of bio-active agents can be added to the particles. For example, substances, such as drugs, growth factors, proteins, genes, and chemo-therapeutic agents can be added to the particles to enhance localized treatments while still providing significant bulking benefits. The particles themselves are substantially inert in that they do not tend to react with body fluids and/or tissue. For example, many other types of bulking particles swell in use. In contrast thereto, the substantially spherical polyvinyl alcohol particles are substantially dimensionally stable. Some tissue growth on, near, or around the particle surface may occur, but no biological interaction between the tissue and the particles is expected.
In one embodiment, the particles are substantially solid. In a particular embodiment, the particles are substantially spherically-shaped and are sized in a range of about 40 microns to about 1500 microns in diameter, preferably about 150 microns to about 1100 microns in diameter, and more preferably about 500 microns to about 900 microns in diameter. The size of the particles chosen for a particular application will be determined by a number of factors. Smaller particles are easier to inject with a smaller gauge size needle; however, embolization due to migration of the particles is a concern with the smaller particle sizes. The size of the particles used in a particular procedure will include consideration of the procedure employed, disease progression, the degree of degradation of the affected region, patient size, the disposition of the patient, and the preferences and techniques of the doctor performing the procedure. Similarly, such factors must be considered when determining the proper volume of bulking agent to inject into a patient. In one embodiment of the invention, the volume of bulking compositions about 1 ml to about 30 ml, and preferably about 20 ml to about 30 ml. In another embodiment, the volume of bulking composition injected into a patient is about 2 ml to about 16 ml. However, these amounts can vary significantly based on the doctor's determination as to when the target region is sufficiently bulked up.
To vary compressibility, provide for absorption of medications, or for the purpose of incorporating the particles into the surrounding tissue, the porosity of the particles may be modified. These effects, if desired, can be enhanced by increasing pore size. For example, tissue in-growth can be encouraged by increasing pore size. Preferably, pore sizes are within a range of about 4 microns to about 5 microns up to about 30 microns to about 50 microns. In one embodiment, the pores cover up to 80% of the surface area of the particle.
In one embodiment, the bulking particles are injected through a needle. In other embodiments, a cystoscope is used to allow for viewing the injection area. The bulking particles can be supplemented with a contrast agent to enhance their appearance as an aid to the doctor performing the procedure. Other methods of visual enhancement to assist in viewing of the bulking agent can also be employed. Injection of the particles can also be accomplished transuretherally by, for example, using a catheter.
In another embodiment, the method of providing the bulking agent to the human body further includes mixing the bulking particles with a carrier such that the particles are suspended in the carrier, and then injecting the particles-carrier mix into the treatment portion of the human body. The carrier serves as a lubricant for the particles thereby increasing the ease with which the particles move into the body. In another embodiment, the carrier is a saline solution. In other embodiments bio-compatible thickening agents such as alginate, beta-glucan, glycerin, cellulose, or collagen are added to the carrier or serve as the carrier themselves to modify the viscosity of the carrier. By varying the carrier viscosity, proper disbursement of the bulking particles can be accomplished; however, carriers must not be so viscous that their passage through an injection device is inhibited. In yet another embodiment, the carrier may be bio-active, that is the carrier includes an anti-microbial agent, or the like.
The present invention also relates to a method used to dilate tissue within a treatment tissue region to facilitate injection of the bulking agent. The method includes: inserting a needle with a penetration device (e.g., a taper point obtuator or trocar) into the treatment region (e.g., the sphincter region) ( FIG. 4 ); removing the penetration device while retaining the inserted needle ( FIG. 5 ); advancing a balloon through the needle ( FIG. 6 ); inflating the balloon, thereby creating a void in the treatment region ( FIG. 7 ); deflating and removing the balloon from the treatment region ( FIG. 8 ); affixing a syringe with a bulking agent to the needle and injecting the bulking agent into the tissue void ( FIG. 9 ). This procedure can be repeated as necessary in order to maximize the effectiveness of the bulking agent and to achieve the desired results.
The method and apparatus for carrying out the method in a method to treat urinary incontinence by bulking the urethral tissue is described generally with reference to FIGS. 4-11 . A needle 400 , such as a blunt-end hypotube or hypodermic needle having a first end and a second end, is adapted to accept a penetration device 404 , such as a taper point obtuator or a trocar, at the first end of the needle 400 ( FIG. 4 ). The needle 400 may range in size from about 18 gauge to about 22 gauge, and preferably about 20 gauge to about 22 gauge. The penetration device 404 is attached to the needle 400 to enable penetration of the needle 400 into the tissue. The penetration device 404 may be adapted to the needle 400 by way of a luer hub or fitting, and in one embodiment, a male luer hub is used. The needle 400 is inserted with the penetration device 404 into the treatment region 420 (e.g., the sphincter region) ( FIG. 10 ) to the desired depth. In one embodiment, desired penetration depth can be determined by striping 406 located on the penetration device 404 . In one embodiment, the amount of penetration of the penetration device 404 ranges from about 2 cm to about 2.5 cm ( FIG. 4 ). In one embodiment, the amount of tissue penetration of the needle 400 ranges from about 0.5 cm to about 1 cm beyond the tissue line 407 ( FIG. 5 ). The penetration device 404 is removed while retaining the inserted needle 400 ( FIG. 6 ).
A luer hub 402 or fitting, or in one embodiment a female luer hub, may be adapted to the second end of the needle 400 , to which a syringe 412 , 418 ( FIGS. 7-9 ) is adapted. Referring to FIG. 4 , the luer hub 402 is depicted in its locked position, and in FIG. 5 the luer hub 402 is depicted in its unlocked position. In the locked position, the luer hub 402 can be positioned for inflating the balloon 408 or injecting a bulking agent 416 . In the unlocked position, the luer hub 402 can be positioned for accepting the balloon 408 for insertion or for removal of the balloon 408 after dilation.
The balloon 408 is adapted to advance through a lumen of the needle 400 , and an adapter on the balloon 408 provides a means to lock the balloon 408 to the luer hub 402 , which in turn adapts to the syringe 412 ( FIG. 6 ). The balloon 408 may have no tip or, alternatively, the balloon 408 may have a small stump appendage, which may remain from processing of the balloon. In one embodiment, the balloon 408 is affixed to an end of a plastic tube 410 ( FIG. 6 ). In another embodiment, the tip for the balloon 408 is integral with a shaft. In yet another embodiment, balloon 408 includes at least one fill and/or evacuation port.
In one embodiment, the balloon is a colored balloon (e.g., blue) to facilitate remote visualization of the procedure and proper placement of the balloon. Alternatively, the balloon could be clear to transparent and the inflation media could be colored, for example, a colored saline solution. The balloon may be semi-compliant or non-compliant. The balloon may be manufactured from any suitable material, for example, a polymer. Some examples of suitable balloon materials include: silicone, ethylene vinyl acetate (EVA), polypropylene, latex rubber, polyurethane, polyester, nylon and thermoplastic rubber. In one embodiment, the balloon is inflated to, for example, about 3 cm to about 5 cm in diameter. The balloon may assume a variety of shapes. Some shapes that may be considered, depending upon the attendant requirements of the procedure, include substantially round, oval, hemi spherical, and oblong. The length of the balloon may vary depending upon the procedure. In one embodiment, the inflated balloon may have a length in the range of, for example, about 3 cm to about 10 cm. Other balloon configurations may be employed, and the types and methods used to employ the most suitable balloon configurations for a particular application of this invention will be obvious to those skilled in the art.
The balloon 408 is then inflated using an inflation device, such as the syringe 412 , creating avoid in the treatment region ( FIGS. 7 and 8 ). The balloon may be colored (i.e. blue) to aid in visibility through the tissue. As the balloon 408 expands, the balloon 408 becomes visible to aid in proper balloon placement. For example, the expanding balloon 408 may become visible under the urethra as it thins. In one embodiment, the balloon 408 inflates to a volume of about 1 cc to about 1.5 cc, although such volumes may vary depending upon many factors inherent in the characteristics of the particular application, some of which were discussed previously. In another embodiment, saline is used to inflate the balloon 408 . In yet another embodiment, about 3 cc of saline is placed in the syringe 412 and injected into the balloon 408 for inflation.
The balloon 408 is then deflated and removed from the treatment region, resulting in a tissue void 414 where the inflated balloon 408 previously resided ( FIGS. 8 and 10 ). The balloon 408 is removable through the lumen of the needle 400 . In one embodiment, a plastic tube or other tip 410 is used to aid in removal of the balloon 408 .
A syringe or other injection device 418 containing the bulking agent 416 is then affixed to the needle 400 by way of the luer hub 402 . The plunger of the syringe 418 is then depressed, thereby injecting the bulking agent 416 into the tissue void 414 ( FIGS. 9 and 11 ).
While the invention has been shown and described with reference to specific embodiments, it should be understood by those skilled in the art that various changes in foil and detail may be made therein without departing from the spirit and scope of the invention.
Having thus described certain embodiments of the present invention, various alterations, modifications, and improvements will be apparent to those of ordinary skill. Such alterations, modifications, and improvements are within the spirit and scope of the invention, and the foregoing description of certain embodiments is not exhaustive or limiting.
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The invention relates to bulking agents and apparatus and methods for using the disclosed bulking agents. The bulking agents can be used to treat such conditions as urinary and fecal incontinence, gastro-esophageal reflux, aneurismal blockages, and cosmetic deformities. The invention also relates to an injection method that reduces the injection pressure required to place the bulking agents.
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FIELD OF INVENTION
The present invention relates to sand-control apparatus and methods in a subterranean hydrocarbon well. More particularly, the present invention relates to methods and apparatus for using an expandable sand control device in conjunction with a specialized gravel pack fluid system.
BACKGROUND
The control of the movement of sand and gravel into a wellbore and production string has been the subject of much importance in the oil production industry. Gravel pack operations are typically performed in subterranean wells to prevent fine particles of sand or other debris from being produced along with valuable fluids extracted from a geological formation. If produced, the fine sand tends to erode production equipment, clog filters, and present disposal problems. It is therefore economically and environmentally advantageous to ensure that the fine sand is not produced. During gravel packing, the annulus between the well bore wall and the production tubing, which can include a screen or slotted liner assembly, is filled with selected natural or man-made packing material, or “gravel.” Such packing materials can include naturally occurring or man-made materials such as sand, gravel, glass, metal or ceramic beads, sintered bauxite and other packing materials known in the art. The gravel prevents the fine sand from the formation from packing off around the production tubing and screen, and the screen prevents the large grain sand from entering the production tubing.
One difficulty in packing operations, especially in open-hole wellbores, is completely filling the often irregular annular space between the production tubing and the wellbore wall. Where packing is incomplete, “voids” are left around the production tubing. These voids, or areas which are incompletely packed with gravel, allow sand fines to be produced along the area of sand screen or slotted liner. The fines can clog the production assembly or erode production equipment.
Consequently, a more effective method of packing a wellbore is needed.
SUMMARY
In general, a method is provided for completing a subterranean wellbore, and an apparatus for using the method. The method comprises positioning an expandable sand-control device in the wellbore thereby forming an annulus between the sand-control device and the wellbore; depositing a filter media in the annulus; and after the depositing step, radially expanding the sand-control device to decrease the volume of the annulus. The sand control device can be a sand screen or slotted or perforated liner having radially extending passageways in the walls thereof, the passageways designed to substantially prevent movement of the particulate material through the passageways and into the sand control device. Where a slotted liner is desired, the passageways can be plugged during positioning and later unplugged for production.
The filter media is typically a particulate material and can be deposited as a slurry comprising liquid material and particulate material, or as a cement slurry. The step of expanding the sand-control device further includes squeezing at least a portion of the liquid of the slurry through the sand-control device passageways thereby forming a pack in the wellbore annulus. The liquid material can be water-based, oil-based or emulsified and can include gelling agents. Further, the particulate can be resin coated with a delayed activation of the resin. The filter media can also be a solids-free or particulate-bearing foam system. The foam system can include particulate material. The foam can also include decomposable material which can be decomposed after placement of the foam in the annulus.
Another embodiment of the method and apparatus presented herein comprises positioning a well-completion device into the wellbore, thereby forming an annulus between the well-completion device and the wellbore, the well-completion device having a flexible, permeable membrane sleeve surrounding an expandable sand-control device; and thereafter radially expanding the sand-control device to decrease the volume of the annulus, thereby also expanding the membrane sleeve. The well-completion device can further include a layer of filter media encased between the membrane sleeve and the sand-control device. The filter media may be of any type known in the industry. Preferably, the membrane sleeve, when expanded, substantially fills the annular space extending between the wellbore and the sand-control device by deforming to substantially contour the wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
Drawings of the preferred embodiment of the invention are attached hereto, so that the invention may be better and more fully understood, in which:
FIG. 1 is a schematic elevational cross-sectional view of a typical subterranean well and tool string utilizing the invention;
FIG. 2 is a schematic elevational detail, in cross-section, of the depositing the filter media and expanding the expandable sand-control device of the invention:
FIG. 3 is a detail of a slotted or perforated liner which can be used with the invention; and
FIGS. 4A and 4B are views of alternate embodiments of the invention.
Numeral references are employed to designate like parts throughout the various figures of the drawing. Terms such as “left,” “right,” “clockwise,” “counter-clockwise,” horizontal,” “vertical,” “up” and “down” when used in reference to the drawings, generally refer to orientation of the parts in the illustrated embodiment and not necessarily during use. The terms used herein are meant only to refer to the relative positions and/or orientations, for convenience, and are not meant to be understood to be in any manner otherwise limiting. Further, dimensions specified herein are intended to provide examples and should not be considered limiting.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a tubing string 10 is shown run in well 16 at least to the zone of interest 12 of the formation 14 . The well 16 can be on-shore or off-shore, vertical or horizontal, consolidated or unconsolidated and can be cased or an open-hole. It is expected that the invention will be primarily utilized in open-hole horizontal wells, but it is not limited to such use. The tubing string 10 extends from the well surface 18 into the well bore 20 . The well bore 20 extends from the surface 18 into the subterranean formation 14 . The well bore 20 , having well bore wall 26 , extends through a cased portion 22 and into an un-cased open-hole portion 24 which includes the zone of interest 12 which is to be produced.
In the cased portion 22 of the well, the well bore 20 is supported by a casing 26 . The well bore typically is cased, as shown, continuously from the well surface but can also be intermittently cased as circumstances require, including casing portions of the wellbore downhole from the zone of interest 12 . The well is illustrated for convenience as vertical, but as explained above, it is anticipated that the invention may be utilized in a horizontal well.
The tubing string 10 extends longitudinally into the well bore 20 and through the cased portion 22 . The tubing string can carry packers, circulating and multi-position valves, cross-over assemblies, centralizers and the like to control the flow of fluids through the tubing string and placement of the string in the well bore.
Adjacent the lower end 28 of the tubing string 10 a sand control device 30 is connected. The sand control device 30 can be of many types which are generally known in the art, including one or more sand screens. Preferably POROPLUS (a trademark) sand screens are used and reusable, retrievable screens are preferred. Apparatus and methods for constructing and deploying screens are used in conjunction with the invention. Exemplary sand-control screens and methods of deployment are disclosed in U.S. Patent Nos. 5,931,232 and 5,850,875, and in U.S. patent application No. 09/627,196 filed Jul. 27, 2000, all of which are assigned to the assignee of this application and are incorporated herein by reference for all purposes.
The sand control device 30 can also be a slotted or perforated liner or sleeve, as seen in FIG. 3, and such as are known in the art, having radially extending passageways 31 to fluidly connect the interior of the slotted liner 30 with the formation. In the case of a slotted or perforated liner it may be desirable to plug the passageways 31 in the liner with plugs 33 during run-in of the tools and completion of the packing procedure. The passageways 31 can later be unplugged, or the plugs 33 removed, to allow fluid flow into the tubing string. Removal of the plugs 33 can be accomplished mechanically or chemically as is known in the art.
Mounted on the tubing string 10 are a hanger 32 and an open-hole packer 34 . The packers are shown in their expanded or “set” positions. The packers are run into the hole in a retracted or unexpanded condition. The hanger 32 engages the casing 26 of the cased portion 22 of the well and typically provides a seal through which fluids and particulate cannot pass. The hanger 32 can be a retrievable direct hydraulic hanger with a control line access feature 36 . The hanger can be of any type generally known in the art and can be an inflatable, compression or other type of hanger, and can be actuated hydraulically, by wireline or otherwise as will be evident to those of ordinary skill in the art. Similarly, the open-hole packer 34 may be of any type known in the art such as a “hook wall” packer or a non-rotating inflatable packer. The packer can be retrievable if desired. Additional or fewer packers and hangers can be employed without departing from the spirit of the invention. A lower packer 34 may only be necessary when it is desired to seal off a non-producing zone downhole from the zone of interest 12 .
The tubing string 10 , as shown in FIG. 1, can additionally carry other drill string tools for controlling and measuring fluid flow and well characteristics and for manipulating the tubing string. Illustrated are a valve 40 , a cross-over kit 42 having a control line 36 , and disconnects 44 and 46 . These tools are generally known in the art and additional tools, such as collars, measuring devices, and samplers can be added to the tool string as desired.
The tubing string 10 or work string 50 also carries an expansion tool assembly 52 . The expansion tool assembly is run into the well in a retracted position so as not to interfere with movement of the tubing and work strings, as seen in FIG. 1 . The expansion tool is activated to an expanded position 54 , as seen in FIG. 2, and drawn through the expandable sand-control device 30 . The expansion cone, or other expansion device, such as is known in the art, can be hydraulically actuated by a downhole force generator or can be forced along the tubing string by weight applied to the work string. The expansion of the expandable sand-control device can occur from top-down or from bottom-up, as desired. Preferably the expansion tool assembly is retrievable.
The tubing string preferably carries centralizers 48 which act to maintain the tubing string in a spaced relation with the well bore wall 26 . This is of particular importance where the well bore is horizontal. The details of construction of the centralizers 48 varies according to the requirements of the application and include segmented “fin” devices, round disks as well as the centralizers shown. The centralizers aid in cuttings removal and protect the expandable sand-control device 30 during run-in and drilling operations, as well.
A working string 50 can be deployed interior of the tubing string 10 and sand-control device 30 . Working string 50 can carry a plurality of well tools as are known in the art. Such tools can include a measuring while drilling assembly 62 , a shoe 64 , a downhole motor 66 , a drill bit 68 and a receptacle 70 for the downhole motor and bit, as shown. Preferably these tools are retrievable. Additional tools and types of tools can be utilized as well without departing from the spirit of the invention. Those skilled in the art will recognize a vast choice of tool combinations depending on the requirements of the formation and desires of the practitioner.
The measuring while drilling assembly 62 preferably includes a logging while drilling function and may include an acoustic telemetry system to provide real-time data acquisition of well characteristics. Other data acquisition instruments can also be employed.
Disconnects 44 allow sections of the tubing and work strings to be released for retrieval to the surface for reuse. Additionally the disconnects can allow portions of the strings, such as downhole motor 66 and drill bit assembly 68 to be retracted into receptacle 70 used for that purpose. Disconnects 44 are of types generally known in the art and may be mechanically, hydraulically or explosively actuated.
A tool assembly, such as the one shown in FIGS. 1 and 2, is drilled into place in formation 14 using a downhole motor 66 and drill bit 68 assembly. The tool assembly can include a downhole motor 66 with bit 68 , a measuring while drilling tool assembly 62 , a receptacle housing 70 , an expanding screen or slotted liner device 30 , blank tubing 72 and an expansion tool assembly 52 . Depending on the tool assembly configuration, the expansion tool 52 can be run-in as part of the assembly or on a separate trip. Also depending on the configuration, an inner tubing string, or work string 50 or the tubing string 10 with expandable sand-control device 30 can be used as the fluid conduit during drilling, wellbore fluid placement and filter media placement.
The bottom hole assembly is made up and run in the wellbore 20 . The open-hole portion 24 will be drilled with the downhole motor 66 and drill bit 68 assembly along the desired well bore trajectory and to the desired depth. Once the zone of interest 12 is passed or reached, the wellbore can be cleaned to remove cuttings, as is known in the art. Once cleaned, a wellbore fluid can be placed in the well bore annulus 72 between the tubing string 10 and the well bore wall 26 . The use of well bore fluids is well known in the art. Preferably the hanger 32 is set in the cased portion 22 of the well, as shown. Alternately, a packer may be used. The hanger anchors the sand-control device 30 in place.
The work string 50 can be released at a disconnect 44 to allow recovery of the measurement while drilling tool 62 and latching of the downhole motor 66 and drill bit 68 assembly into the receptacle housing 70 . The receptacle housing 70 seals the motor 66 from the sand-control device 30 if desired. The recovery of the work string may occur before or after insertion of the filter media 74 into the annulus 72 depending on the system configuration.
The filter media 74 is placed across the annulus 72 , particularly along the length of the annulus surrounding the sand-control device 30 . The filter media 74 can be inserted into the annulus 72 by any method known in the art, such as pumping the filter media 74 from the surface 18 through the annulus 76 between the work string 50 and the tubing string 10 and thereafter through ports 80 into annulus 72 . The ports may be located at various places along the tubing string. Alternately, the filter media can be pumped out of the shoe 64 at the lower end of the hole. In such a case, the lower isolation packer 34 would be unnecessary. In cases where the tubing string 10 is run in on a separate trip from the drilling string 30 , the filter media 74 can be pumped into the annulus 72 during run in of the tubing string 10 or after the desired depth is reached by the string. Further, the filter media 74 can be pumped in as the welbore fluid is removed. The method and direction of pumping, or inserting, the filter media 74 is not critical to the invention. Various methods of placing the filter media 74 into the annulus 72 will be readily apparent to those of skill in the art. Preferably, the drilling operation, filter pumping operation and sand-control device expansion operation can be accomplished with a single trip of the combined tubing string and concentric work string. However, multiple trips may be necessary or desired depending on the configuration employed.
The filter media 74 of the process can take several forms. Some of the fluids covered by the invention are a suspension of particulates in fluid, a particulate slurry and foamed systems.
The filter media 74 can be a suspension of particulates in fluid. The particulates in this application could be of any size appropriate for controlling sand production from the reservoir. In addition, the proppant, or particulate, specific gravity preferably ranges from 1.1 to 2.8. The specific gravity and other characteristics of the particulate will vary, however, and are determined by the required downhole hydrostatic pressure. The use of lightweight particulate is preferable where the major mechanism for inducing a squeezing of the void filling fluid, or filter media, is caused by expansion of the sand-control device. Particulate, or proppant, loading preferably ranges between 0.1 to 20 ppg, but is not limited to this range. The carrier fluid for the particulate can be water-based, hydrocarbon-based, or an emulsified system. Examples of water-based systems include, but are not limited to, clear brines or those that include the use of gelling agents such as HEC, xanthan, viscous surfactant gel or synthetic polymers. In addition, the water-based system bay be weighted by the addition of salts such as calcium chloride or other conventional brines as used in the oil field. Examples of hydrocarbon based systems include, but are not limited to, the use of gelled oils and drill-in fluids. Emulsified systems (water external or oil external) can also be used.
Another filter media system 74 that can be applied is a solid particulate/cement slurry mixture that after liquid removal by the squeezing action of the expansion of the sand-control device, and after the passage of time, creates a porous media through which hydrocarbons and other fluids can be produced while controlling fines migration. Particulate concentrations can range from 5 to 22 ppg, but will vary based on application conditions. The density of the particulates can range from 1.1 to 2.8, but may also vary. Testing with such a system containing 20/40 sized sand indicated that a permeability of 40 Darcy and an unconfined compressive strength of 900 psi could be developed with this system. Such a system, with these permeability and strength factors, is desirable in most well formations.
A system in which a particulate coated with a resin material is also covered by this invention. The resin material may be activated by well temperature, time, stress induced by liquid removal, or through the use of an activator that is injected after the liquid removal process. Resins and activators are well known in the art.
The filter media can be a foamed system, with or without particulates, that creates an open-faced permeable foam after liquid removal. A chemical treatment, after dehydration, may be necessary to enhance the permeability of the foam. A typical system for this application could be a foamed cement to which a mixture of crosslinked-gel particulate and carbonate particles of appropriate size have been added to the slurry. The crosslinked gel particles have a chemical breaker added to them. After liquid removal the crosslinked gel particles are broken by the in-situ breaker leading to the creation of a porous media. The permeability of the porous media can be further enhanced by pumping an acid to dissolve the crosslinked gel and the calcium carbonate particles. This invention also covers the use of alternative materials that can decompose by contact with conventional brines or oil soluble systems such as oil soluble resin or gilsonite that can be dissolved by contact with hydrocarbons. Degradable semi-solid gel particulate material can also be used in the filter system to act as a means to increase the porosity of the filter media after the carrier fluid is removed by squeezing. This will enhance the permeability and prevent excessive losses in permeability caused by the dehydration process. Various types of foam and particulate mixtures, and methods for improving permeability and porosity, will be recognized by those of skill in the art.
Surface modifying agents can be added to the particulate material in the filtration media. These surface modifying agents can improve the filtration properties of the particulate material by stopping fines migration at the open hole, filter interface and prevent plugging of the filter media itself. Surface modifying agents can also be added to the particulate material in the filtration media to provide cohesive bonds between particles when the suspending fluid is at least partially removed by the squeezing effect of the sand-control device expansion. The cohesive strength in the pack will prevent movement of particles in the pack during production operations which will reduce any chance for well tool erosion.
Alternately, the permeable filter media is placed external of the sand-control device 30 prior to running and expanding in the subterranean wellbore. An open-cell, permeable, expandable, foamed material is molded or cast into a cylinder shape 90 , sleeve or jacket. This foamed sleeve 90 is then slid over the expandable sand-control device 30 to encapsulate its outer wall before its downhole placement. The wall thickness of the sleeve is preferably from ¼ inch to 1 inch, depending on the diameters of the screen and wellbore. The permeable sleeve 90 can be tightly fit or glued to the device surface to prevent it from sliding off of the device during operation. The outer surface of the foamed sleeve 90 can be coated with high tensile strength “film” 92 or material to protect the sleeve from tearing or ripping during handling and installation of the expandable screen downhole.
The deformability of the foam allows it to fill up the void space or gaps between the screen and the formation as the screen is expanded against the open-hole wall 26 . The foamed sleeve 90 can also be impregnated with synthetic beads, sands or proppant, to maintain permeability of the porous medium under compression.
The foamed sleeve 90 can also be impregnated with treatment chemical that can be slowly released, such as a breaker that can break up or dissolve the filter cake remaining after drilling operation. The treatment chemical can be mud breakers, such as oxidizers, enzymes or hydrolysable esters that are capable of producing a pH change in the fluid, scale inhibitors, biocides, corrosion inhibitors, and paraffin inhibitors that can be slowly released during production.
Another concept includes the use of a flexible, expandable, and permeable membrane 94 , which is prepared in the shape of a sleeve or jacket to provide similar function as described in the above concept. The permeable sleeve, which can be pulled over the expandable screen covering its outer wall, acts as pouch containing the filter medium 74 (i.e. lightweight beads, sands, proppant, etc.). As the screen is expanded, the filter medium in the deformable membrane fills up the annulus space 72 . This permeable membrane can be prepared from materials such as metals, polymers, or composites, so that it can tolerate both physical and chemical requirements of downhole conditions.
After placement of the filter media 74 in the wellbore annulus 72 , the sand-control device 30 is expanded. As shown in FIG. 2, wherein the work string 50 has already been retrieved, the sand-control device 30 can be expanded from bottom-up. The expansion can occur top-down as well depending on the well tool configuration.
The sand-control device 30 is adjacent the zone of interest 12 . The retractable expansion tool 52 is activated to its expanded position, as seen in FIG. 2, to expand the sand-control device. The sand-control device 30 is radially expanded from its unexpanded, or initial position or radial size 80 , to its expanded position 82 . During expansion, liquid L from the filter media 74 flows along lines F into the sand-control device 30 and then into the tubing string 10 . If the expansion assembly is operated from the top-down, it may be desirable for the expansion assembly to have a bypass port through which the fluid F may travel up into the tubing string 10 . As at least a portion of the fluid F is squeezed from the filter media 74 , the particulate material P is tightly packed into the annulus 72 . The filter media particulate P cannot flow into the sand control device 30 . The screen or slotted holes of the sand-control device 30 are selectively sized and shaped to prevent migration of the particulate P into the device 30 . The filter media particulate P remaining in the annulus 72 acts as a filter during production of hydrocarbons H from the well formation 14 . Fines, or small sand particles S, are trapped or filtered by the remaining media and prevented from flowing into the sand-control device 30 .
The filter media is pumped into the annulus 72 to fill up the annular space. However, conventional methods of packing often leave undesirable voids, or areas which are not filled with packing media. Preferably, in the current invention, as the filter media is squeezed between the wellbore wall 26 and the tubing string 10 during expansion of the sand-control device 30 , any voids not previously filled are eliminated and filled-in with the filter media.
The filter media can prevent fines from migrating to the sand-control device, thereby preventing clogging and erosion of the well tools and sand-control device, and can prevent the formation from collapsing thereby reducing the production of fines. The tight packing of the media against the wellbore wall can also prevent shale spalling. Shale spalling could result in plugging of the media and sand-control device.
Preferably, when the filter media 74 is pumped into the annulus 72 , the filter media fills the annulus at least a set distance into the cased portion 22 of the well as shown.
It will be seen therefore, that the apparatus and method addressed herein are well-adapted for use in flow testing an unconsolidated well formation. After careful consideration of the specific and exemplary embodiments of the present invention described herein, a person of skill in the art will appreciate that certain modifications, substitutions and other changes may be made without substantially deviating from the principles of the present invention. The detailed description is illustrative, the spirit and scope of the invention being limited only by the appended claims.
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In general, a method is provided for completing a subterranean wellbore, and an apparatus for using the method. The method comprises positioning an expandable sand-control device in the wellbore thereby forming an annulus between the sand-control device and the wellbore; depositing a filter media in the annulus; and after the depositing step, radially expanding the sand-control device to decrease the volume of the annulus. The sand control device can be a sand screen or slotted or perforated liner having radially extending passageways in the walls thereof, the passageways designed to substantially prevent movement of the particulate material through the passageways and into the sand-control device. Where a slotted liner is desired, the passageways can be plugged during positioning and later unplugged for production. The filter media is typically a particulate material and can be deposited as a slurry comprising liquid material and particulate material, or as a cement slurry. The step of expanding the sand-control device further includes squeezing at least a portion of the liquid of the slurry through the sand-control device passageways thereby forming a pack in the wellbore annulus. The liquid material can be water-based, oil-based or emulsified and can include gelling agents. Further, the particulate can be resin coated with a delayed activation of the resin. The filter media can also be a foam system. The foam can also include decomposable material which can be decomposed after placement of the foam in the annulus.
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[0001] This application claims priority from U.S. application No. 60/805,776, which application is incorporated herein by reference for all purposes.
BACKGROUND
[0002] It is not easy to design systems using RF-linked tags to achieve visibility. It would be desirable to have systems that permit day-to-day functions to be achieved without the need for communications back to a central server to facilitate seemingly simple tasks. It would be desirable to have systems that scale well, and that work even with steel and water nearby. For many visibility tasks it would be very helpful to have system structure permitting knowledge of types of products or product taxonomy.
[0003] Staggering amounts of money and toil have been devoted to efforts to devise such systems. Despite this, no present-day system of RF tags has come anywhere close to satisfying such goals.
[0004] Both passive and active RF-ID tags now on the market use non-radiating backscattered mode, and all work as transponders, i.e they all need a carrier and do not work well around steel or water and cannot be networked.
[0005] The current standard EPC RFID tags all have a pre-assigned or assigned fixed ID serial number with some data encoded. It may include a header. Different formats are allowed, for example the DoD has 256 bits to define its UID (Universal Identification) versus 96 bits for all consumer goods. The CG scheme after the 8 bit header follows the current Global Trade Identification Number format of country code (2 digits); Manufacturer code 4 or 5 digits; Product Code 5 digits; and finally a serial number of 30 bits. There are possible categories for manufacturer's name but none for types of products or for product taxonomy.
[0006] Often, this serial number is created when the tag itself is manufactured. With other tag technologies the serial number is written when the product is packaged. In either case, it will be appreciated that with current RFID tags and tag networks that meet EPC global standards, the systems depend on addressing schemes based on fixed arbitrary numbers often 96-128 bits long. This also requires that key product data and information be stored in remote IT systems. An analogy is shown in FIG. 1 , part A. Packages are be identified and encoded with a unique number with all information about “ship to”, “ship from”, and “packing slip” encoded in (and pointed to by) a number. Such systems generally require that all detailed data may be contained on a server with a key or pointer based on the encoded number.
[0007] Such systems have many drawbacks. Chief among the many drawbacks is that the system requires message-passing back to a central server and from the central server back to the user location, for even the simplest visibility task. The message passing requires bandwidth, sometimes a lot of bandwidth, both in the communications channels and in the central database, to keep up with system activity. Disruption of the communications channels brings the entire system grinding to a halt.
SUMMARY OF THE INVENTION
[0008] A system has tags communicating by means of low frequency (below 1 megahertz) with routers which in turn communicate with nameservers. The tags have IP addresses, either explicitly programmed into the tags or associated in a virtual way with the tags. Lookups analogous to domain lookups permit human-friendly inquiries of tag status and location. Static (battery-backed) RAM in a tag permits great versatility in the localized function of the tag.
DESCRIPTION OF THE DRAWING
[0009] FIG. 1 shows a conventional RF-ID tag that uses a license-plate fixed or assignable ID. It also shows a proposed system that includes as much information as possible on the package with the item.
[0010] FIG. 2 shows steps required with a prior-art system to discover a tag.
[0011] FIG. 3 shows the system according to an embodiment of the invention, using IP addresses and subnet addresses and holding most of the critical information in memory itself.
[0012] FIG. 4 shows a “Tag Taxonomy” according to the invention.
[0013] FIG. 5 shows a tag being given a new IP address from a remote IP authority, or from a block of IP addresses contained in the router.
[0014] FIG. 6 shows a tag being programmed with a unique IP address once it is placed with a network and is discovered.
[0015] FIG. 7 shows a tag accessed with either a special IPv4 address or a standard IPv6 address.
[0016] FIGS. 8-10 show a tag being moved from one subnet to another, and being discovered by an RARP.
[0017] FIG. 11 shows a user searching the Web for a specific tag.
[0018] FIG. 12 shows an example of a display of data from a tag, as if on a web page.
DETAILED DESCRIPTION
[0019] As mentioned above, tags according to one embodiment of the invention work in water and near steel, in part due to their use of relatively low radio frequencies.
[0020] The tags according to one embodiment of the invention employ a full active, transmit/receive transceiver protocol with peer-to-peer, client server, IP networking. The system uses Long Wave (LW) for data communication so it can achieve low cost (less cost than many passive RF-ID tags and all active RF-ID tags), can have long battery life (10-15 years), and can work in harsh environments. The protocol is a pending IEEE standard known as P1902.1. LW tags according to the invention have achieved long-range area reads (100′×100′) based on novel tunable antenna and tag designs. Tags according to the invention may be credit-card thin or just a few mm thick, and can be as small as a dime. Also, since tags have batteries, static RAM (sRAM) may be added at low cost, as well as sensors, LEDs, and displays. The chief disadvantage of the present protocol has over other systems is the data rates will always be limited to under 9,600 baud and in most case they will run at 1,200 baud. In contrast the same information can also be contained on the package itself either as human legible or machine-readable data. The “B” approach in FIG. 1 is far too expensive with current passive RFID tags since they use EEPROM to store any read/write data and the read write cycles for EEPROM are both slow and power hungry.
[0021] The tags employed can be those described in US 2007/0115132, published May 24, 2007, and incorporated herein by reference for all purposes. The RF technology can be that described in US 2007/0063895, published Mar. 22, 2007 and, incorporated herein by reference for all purposes. The tag technology can be that described in U.S. Pat. No. 7,049,963, issued May 23, 2006, and incorporated herein by reference for all purposes. The transceiver communicating with the tags can be that described in US 2007/0120649, published May 31, 2007, and incorporated herein by reference for all purposes.
[0022] The tags described herein use low-cost static memory (sRAM at 6 transistors/bit). On a bit-by-bit comparison, batteries and static memory are 100,000 times faster, 1,000 times lower write power and lower cost than EEPROM. Batteries and sRAM are used for example for critical BIOS and date time storage on PC's and laptops. The ability to use sRAM in tags as described herein opens many other unexpected opportunities. It is, for example, possible to use assignable addresses consistent with IP addresses that have become the standard under LAN and TCP/IP protocols. Turning to FIG. 1 , what is shown at “A” is a conventional RF-ID system 109 using a license-plate style fixed or assignable ID 103 . A good analogy would be to use a fixed ID on a package. This requires an IT system 102 to look up the name, address, and content. In contrast the proposed system “B” (item 110 ) includes as much information as possible 108 , 105 , 106 , 107 on the package 104 with the item, to minimize IT costs.
[0023] In FIG. 2 , what can be seen is that the existing approach needs several steps to discover a tag 111 and to figure out to what the tag is attached. The system has to read the assigned ID 112 from a tag with a reader 110 , and has to pass that ID from the reader to the reader controller to the internet, to the ONS 113 which points to the server/database where the information about that fixed ID is stored. The information returns along the same path. A data request 116 from a user at 115 requires the steps shown.
[0024] As shown in FIG. 3 , in an embodiment of the invention, the system uses IP addresses and subnet addresses 130 and holds most of the critical information 120 in memory itself. The LW tags used in this system can do this at a much lower cost than the passive ID tags since passive RF-ID tags use more expensive EEPROM or similar non-volatile memory for storage. What's more, if a higher frequency were employed this would use up battery power much more quickly, by orders of magnitude. A battery and static memory in the tags according to this embodiment is less costly than EEPROM. Such tags are manufactured with a standard or default IP address such as 11.11.11.1 and a standard or default subnet 130 . They may be programmed with data when the tag is attached to a product as shown in FIG. 3 .
[0025] As shown in FIG. 4 , the subnet address is based on a “Tag Taxonomy”, this is a binary tree 123 of categories into which the product or person might be classified. For example a medical device has a different subnet address than a doctor or a patient. A beef cow has a different subnet address than a dairy cow. This means that many subnet addresses may coexist within a network. For example, a router can ping a room to see if any doctors are in the room and not have to talk to 200-300 stents that may also be stored in the same room. A user may ask hundreds of routers that are online to ping hip implants made by one manufacturer. This permits a distributed processing that can accumulate a lot of information in a very short time. In a prior-art system, on the other hand, achieving a census of hip implants would require as many lookups (in the central database) as there are tags in the universe being interrogated.
[0026] As shown in FIG. 5 , after the tag 128 has been programmed with a serial number (the same as a Mac address, or NIC number) as well as other data including the subnet address 129 , it is placed into a network. The router 127 detects that the tag 128 has the 11.11.11.1 address and provides a new IP address from a remote IP authority, or from a block of IP addresses contained in the router. This is analogous to DHCP used in most networks having ISO layers 2 and 3 , such as an IP network overlaid upon a number of ethernet networks.
[0027] As shown in FIG. 6 , the tag 133 may be programmed with a unique IP address 134 once it is placed with a network and is discovered by a router 132 .
[0028] As shown in FIG. 7 , once programmed the tag maybe accessed with either a special IPv4 address 135 or a standard IPv6 address by the Router 132 .
[0029] FIG. 8-10 show a process of a tag 146 moving from one subnet 147 to the next. Tags as they are moved from one network 147 to another 152 , 153 are discovered by an RARP in the router 141 , 142 , 143 so they always have a unique IP address and can be localized within any network. Using the addressing approaches described in one embodiment herein, the limit is 4.2 billion tags with 4.2 billion different subnets for a total or 1.8×10 19 per local network. The Router itself (local network) may be IPv4 or IPv6 multiplying this another 1.8×10 19 times (264×264) or a full address space of 2128 bits.
[0030] As depicted in FIG. 11 , a user 169 may search the web for a specific tag 163 . The Tag 163 may be given a name in the same manner that any web site is given a name through a Domain Name System. An optional Tag Name Server 165 translates this name into an IPv6 address and finds the tag 163 on the web. The user may also simply enter the IP address of the tag 166 .
[0031] As depicted in FIG. 12 , the result for a user 169 is the data contained in the tag 163 displayed at 168 similarly to what might be viewed on a web page. The RF-IP Tag 163 thus becomes a web server. Such tags can be addressed by domain names allocated in a suitable Top Level Domain name, and domain names in this name space can be used for manual or automated searches started by middleware.
[0032] It will thus be appreciated that the embodiment just described makes it possible to search all suitable routers that are connected to the Internet, and to find any tag anywhere in the world, using the existing World Wide Web and DNS resolution infrastructure. This can be achieved with either the IPv4 or the IPv6 standard. Worldwide search schemes are proved and tested. It is likewise possible to create Virtual Private Networks (VPNs), with same security now used by major financial institutions, governments, and even the CIA—security and security levels being the customer's choice.
[0033] Because the low-frequency tags discussed here work in harsh environments near steel or water, they have applications in many different industries. Some examples are: medical devices, pharmaceuticals, asset tracking in healthcare, asset tracking in business, records tracking, tools, aircraft parts, livestock, retail visibility at item level, and airline baggage. The network can transparently provide visibility at a low cost to many of these industries.
[0034] As mentioned above, the tags in this embodiment have IP addresses which are manufactured as a standard or default 11.11.11.1 form. Such values are used for discovery when a new tag is introduced into a network. The system has an Address Resolution Protocol (ARP) as well as a Reverse Address Resolution Protocol (RARP) for new members of a radio tag net. This means a router can discover all tag's NICs and assign an IP in about a second per tag when it is introduced within an RF area. The tags all work within the Top Level Domain (TLD) using a suitable top-level domain or second-level domain. Word-based names may be registered for individual tags (for example www.drjacksmith.tag) or groups of tags (www.Medco.tag), and these maybe accessed through a name server we call the Tag Name Server (TNS), analogous to a domain name server.
[0035] The subnet address is for example 32 bits and similar to a domain or sub-domain network. It is used in each tag as an added address to classify the tag's item type, or Tag Taxonomy. For example all tags used to identify doctors in a hospital have a unique subnet address, patients another subnet, tools used in surgery another subnet. This is a binary tree and searchable. Thus, in effect doctors have their own private network within any IP subnet. When tags are used for livestock many subcategories may be assigned. Each tag has 32 bits of subnet or about 4.2 billion separate possible categories. The major advantage of the subnet is that a router can quickly discover entries (e.g can ping or use ARP) within an area. It can find all doctors, nurses, patients, devices, tools, cows, airline baggage) and rapidly discover new members of an active subnet.
[0036] TCP/IP and four ISO layers are used to manage and create any application. TCP/IP is the most widely accepted communication standard on the planet. It is also the most widely used and tested set of standards for identifying, naming and managing the largest shared network and most used database in history—the worldwide web. It seems likely that adoption of the same standard in “RF-IP” tags as described here will provide the most rapid and lowest-cost developmental vector for any asset visibility network. Also, almost any other standard may be synthetically used in any application layer, including local databases, or on-line reports of events, activity and pedigree with independent audit trails. 21CFRPart11 audit trail standards may be met with a device as described here.
[0037] Thus, the tag itself has an address space of 264 32 bit IP address and 32 bit subnet. The router according to the invention than manages the local net may be IPv4 or IPv6 so may have an additional 264 bits of address space. This any tag may have full address ability to 2128 bits. In practice, since address space and data space are not intermixed due to a large RAM budget, a local 32 bit address within any regional network is sufficient (4 billion tags per local net).
[0038] It will be appreciated that employing the teachings herein, it is possible to provide a system comprising a plurality of routers communicatively coupled with each other, each router in turn communicatively coupled via RF communication below 1 megahertz to a plurality of tags, each tag having a battery and a static RAM powered by the battery, each tag having a radio transceiver and controller, the controller of the tag controlling the transceiver and disposed to read and write information to and from the static RAM of the tag and to communicate said information via the transceiver to and from the router, each tag having a unique hardware address independent of the static RAM and independent of the battery, said unique hardware address communicable by the controller and the transceiver to and from a router, a portion of said information defining for at least one tag an address independent of the hardware address of the tag, said address stored within the static RAM, each router characterized in having routing means for routing data packets among the routers to the at least one tag with reference to the address independent of the hardware address of the tag, wherein the information stored in the static RAM further comprises a portion thereof defining a subnet mask, the subnet mask for a particular tag identifying a placement of the particular tag in a predefined taxonomy.
[0039] In such a system it is possible to interrogate the plurality of routers with respect to a particular subnet value. At each router, tags can be interrogated with respect to the particular subnet value. Responses can be received from two or more tags each having its subnet mask containing the particular subnet value. In such a case it may turn out that the responses from the plurality of routers constitute responses from more than one but less than all of the tags. A second interrogation could come a year or more after the first interrogation, with at least two of the responsive tags each powered with the same battery as at the time of the first interrogation.
[0040] The exemplary system in summary has:
1. Address space is up to 2128 bits (2×IPv6). Local tags may be addressed and discovered with a local 232-bit word.
2. Address space and address logic have been separated from data space and data logic.
3. Data and data logic (e.g. for binary searches using tags) is stored in sRAM, thus providing full flexibility to meet any past or future data standard.
[0041] Current EPCglobal and other data ANSI standards may be required for seamless integration into existing systems. These data standards may be maintained as a data register within tag memory. Thus, the system can transparently support old and new data standards as they are created. However, the system can also be used in many vertical applications that may not be standard-critical, while requiring only minimal IT. The raw data normally stored in a remote database is simply placed in the tag. This direct storage approach offers major cost reductions. It is possible to discover and read such tags within a local network, and provide full physical inventory, pedigree and asset status, with no external IT systems. These functions are provided within the Router and the tag systems that generate both 21CFRPat11 and SOX Logs within a remote server.
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A system has tags communicating by means of low frequency (below 1 megahertz) with routers which in turn communicate with nameservers. The tags have IP addresses, either explicitly programmed into the tags or associated in a virtual way with the tags. Lookups analogous to domain lookups permit human-friendly inquiries of tag status and location. Static (battery-backed) RAM in a tag permits great versatility in the localized function of the tag.
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This non-provisional patent application claims priority to provisional Ser. No. 60/446,016 filed Feb. 8, 2003.
BACKGROUND OF THE INVENTION
The present invention relates to a portable container for holding and dispensing wipes, for example, baby wipes, hand wipes, and the like. Of particular interest in respect to the present invention are moistened baby wipes made of soft cloths or paper towels and used to clean infants. Baby wipes are typically supplied in bulk in packaging designed to both protect the wipes from damage by contamination and avoid loss of the fluid(s) used to moisten and/or medicate the wipes. This packaging is generally intended to be inexpensive and consequently removing individual wipes from the packaging can be difficult, especially for a person who holds a baby in one hand whiles removing a wipe from the container with the other. Existing containers do not facilitate ease of removal of individual or small numbers of wipes with one hand, especially in travel situations.
In addition, existing containers do not provide for reliable heating of wipes to a controlled range of temperatures. It is desirable, especially for wipes which are being transported, to have warm wipes available for cleaning infants. Often parents will remove a wipe from the package and warm it against their skin before using the wipe to clean the infant. This process is time consuming, annoying to the parent because of the cold wipe against the skin, and inconvenient because of the difficulty in retrieving a wipe from the package. Additionally, it is desirable to carry, keep clean and accessible and warm other articles, for example, baby bottles, pacifiers, diapers, clothing, and the like.
Others in the art have recognized some of the above needs and deficiencies and have attempted to provide solutions thereto. U.S. Pat. No. 5,738,082 to Page, et al. shows a portable baby wipe warmer and container for heating and storing wipes. The container is made of soft fabric material that has at least two compartments with a common heat conduction wall between (col. 1, 1. 51–67). The container has two zippers 5 & 6 for opening (col. 2, 1. 26–28). The container may be used for other baby articles which are enhanced by warmth (col. 2, 1. 18–22). The heat for Page's warmer is provided by an optional heat disc of FIG. 3. The disc is preferably a microwavable gel pack, exothermic gel boil pack, most preferably a microwavable gel pack (col. 3, 1. 5–12). Examples of these gel packs are given (col. 3,1. 12–18) which include the exothermic dry heat organic oxidation pack HotHands™ by Heatmax, Inc. of Dalton, Ga. This product contains a mixture of natural ingredients that when exposed to air react together to produce heat. This is accomplished through an extremely fast oxygenation (or rusting) process. Ingredients include: iron powder, water, salt, activated charcoal and vermiculite. HeatMax, Inc. has perfected the process so that their warmers, depending on the individual product, produce heat anywhere from 100° F. to 180° F. for a duration of 1 to 20+hours. These warmers are used and disposed of in everyday garbage.
While Page's warmer is useful for portable applications, it has several disadvantages, including difficulty in removing the wipes due to the use of zippers 5 & 6 for opening. The use of zippers in conjunction with the soft flexible fabric makes it difficult to open with one hand. In addition, the use of disposable exothermic warmers, or microwavable gel warmers creates problems ensuring a reliable supply of warmer discs. When the microwavable gel warmer has cooled, it must be microwaved again. When the disposable exothermic warmer is used up, it must be replaced. Additionally, there is no suggestion for regulating the temperature of the wipes in the container. While the exothermic warmer may be designed to maintain a specific heat for the warmer itself, there is no suggestion for regulating the amount of heat transferred from this disc to the wipes in the container. Consequently, as Page et al.'s container is exposed to differing ambient heat temperatures and differing heat loss due to the amount and frequency of opening, there is no assurance that the wipes will remain the proper temperature, or within a range of proper temperatures, and may very well be maintained in a too hot or too cold condition. Further, with either of the suggested heat sources, once the disc is inserted in the warmer, it continues to warm and cannot be turned off. This unnecessarily wastes energy and uses up discs when the warmer is only used for short periods of time.
SUMMARY OF THE INVENTION
The present invention relates to a convenient, durable, and easily rechargeable warming container and dispenser for baby wipes and the like. The container serves to carry, store, protect, maintain in a clean state, maintain at a proper temperature or range of temperatures, and/or make conveniently available the contents thereof. It will be recognized that while the invention is described in its preferred embodiment with respect to a dispenser for baby wipes, the invention is equally useful for many other types of wipes, swabs, cloths, pads, towels, and the like, as well as other types of articles which may benefit from being carried, protected, kept in a clean state, warmed and/or made conveniently available. Such wipes and articles may be contained alone or in various combinations as desired by the user.
Applicant herein utilizes the term wipe to include not only baby wipes, but also the many types of wipes, swabs, cloths, pads, towels, and the like which are commonly removed from a container by hand in single or small quantities at a time, and used by hand or with an appliance for cleaning, moistening, treating and/or medicating various surfaces. One of ordinary skill in the art will recognize that the invention described herein by way of example may be utilized for other types of articles which may benefit from being protected, stored, kept in a clean state, warmed, and made conveniently available. Such wipes may be made of cloth, paper, plastic or other material as is known or may come to be known in the art. Examples of wipes, as defined by the inventor, include but are not limited to, dry, moistened and/or medicated swabs, mops, cloths, pads, towels, towelettes, and tissues. Of particular interest in respect to the present invention are moistened baby wipes made of soft cloths or paper towels and used to clean infants, and related baby articles. For certainty herein, in applications where such small quantities mentioned above are not known in the art with sufficient precision to enable understanding of the invention, small quantities shall be less than 13.
The preferred embodiment of the invention preferably includes a durable, rigid or semi-rigid container having dimensions such that holding and carrying with one hand are convenient and having an opening arrangement facilitating one hand operation and removal of items therefrom, insulation to prevent loss of heat, a heating element for heating the contents, an energy source supplying the heating element with energy, a temperature sensing element for sensing the temperature of the contents of the container directly or indirectly, and a controlling element for controlling the temperature of the contents in response to the temperature sensing element. The invention may include other features and configurations which will be known to those of ordinary skill in the art from the teachings herein taken in conjunction with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram illustrating the principal of the heating system of the invention.
FIG. 2 is a diagram for an embodiment of the heating system of the invention utilizing electricity as an energy source.
FIG. 3 is a diagram of an embodiment of the heating system of the invention utilizing exothermic fuel as an energy source.
FIG. 4 is a diagram illustrating the principal of the case of the invention.
FIG. 5 is a diagram of a detail of the diagram of FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1–3 demonstrate the heating and control of the contents of the container of the invention while FIGS. 4 and 5 demonstrate the container and arrangement of parts thereof in relation to the heating and control portions of the invention.
FIG. 1 shows an energy source 1 which stores energy in a suitable form known to those of ordinary skill, a heating element and control 2 which receives energy from energy source 1 via coupling 5 and converts that energy to heat which heats the container and wipes 3 , the temperature of which is sensed directly or indirectly by temperature sense element 4 via coupling 7 . The control of heating element 2 is responsive to the temperature sense element 4 via coupling 8 to control the amount of heat produced by 2 to be coupled to 3 .
Energy source 1 may be of any known type and may, for example, store energy in electrical or chemical form, for example, such as by battery or fuel container. Heating element and control 2 may be of any known type and form chosen for compatibility with the stored energy of 1 and configuration and expected contents of 3 . Examples of heating elements which may be used are restive electrical components, chemical oxidizers such as burners, and catalytic converters. The container 3 will be described in more detail and understood more specifically in respect to the preferred embodiment herein and is preferred to provide sufficient storage space for the needed number of wipes, as well as including insulation to prevent heat loss, and have a mechanical design which facilitates attachment and operation of elements 1 , 2 and 4 , as well as convenient usage and operation by the user. Temperature sensor 4 may be of any known type and is selected to facilitate operation with the container 3 , the particular contents expected to be stored in 3 , and the particular energy source 1 and heating element and control 2 . Examples of such temperature sense elements include thermostatic controls constructed with bimetallic strips which open and close electrical contacts or fluid or gas valves, thermocouples which produce varying electric potentials in response to varying temperatures, thermally sensitive electronic elements which change resistance or junction voltage in response to varying temperature, and optical sensors which sense the optical (i.e. infrared) radiation given off by warm elements.
It will be understood that combinations of temperature sensors may be utilized, and while sensing 4 and heating and control 2 are shown separately, such functions may be intermixed and combined as is conveniently known in the art. For example, an electronic component may be utilized for temperature control with a bimetal strip used as an over-temperature safety guarding against failure of the primary control. As another example, the heating element may be composed of a restive device having a positive temperature coefficient wherein the current flow through the element is self-limiting to maintain a fixed temperature. Such positive temperature coefficient devices are commonly used for self-resetting fuses. Such an embodiment is shown in FIG. 2 .
FIG. 3 illustrates another alternative embodiment wherein the electricity source ( 5 , 5 a ) is replaced with an exothermic fuel container 1 b , which flows through oxidizer and fuel flow component 2 b causing heat for wipes and container 36 . The general use of exothermic heating is well known.
FIGS. 4 and 5 illustrate embodiments of the case of the present invention. The case includes a front face 510 , a rear face 520 , and a top 530 . Fastener 512 , switch 514 , indicators 516 , hinges 522 , and power connector 524 are also shown. FIG. 5 also shows an alternative embodiment with fastener 513 on front 511 and a variation on rear face 521 . A variation to indicators 517 is also shown.
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A portable baby wipe warmer and container comprising a container for storing baby wipes, a heat source thermally coupled to the container, and a temperature regulating component coupled to the heat source for regulating the heat provided to the container by the heat source.
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BACKGROUND OF THE INVENTION
This application relates generally to air seeders used for planting agricultural crops and, more particularly, to the meter roller assemblies used in air seeders to meter the flow of seed and/or fertilizer into the flow or air and, more specifically, to segmented metering sections for use in such assemblies.
In modern large scale agricultural operations, seed and/or fertilizer are typically applied to the soil through a series of seed tubes which are associated with soil working tools across the width of a soil working machine. Typically a group of such tubes is fed seed or fertilizer by a distribution header. The distribution header is in turn fed from a tank which may be configured as a separate cart for towing in advance of or trailing the soil working implement.
A metering system is associated with the tank for distribution of product from the tank to the distribution headers of the seed tubes. The metering system normally includes a meter roller situated below the tank in a meter box assembly secured to the tank. Typically the meter box will have a series of outlets known as runs, each of which leads through intermediate tubing to one of the distribution headers. The total number of possible runs typically extends the length of the meter roller. Depending on the number of distribution headers on the soil working implement, the roller assembly will consist of fluted metering sections corresponding to runs which are operational and preferably a single blank roller spacer extending across the width of the runs which are not operational. Product is then delivered to distribution headers which are connected to the runs containing the fluted metering sections and no product is delivered from those runs which are, in effect, blanked off. Along with the metering sections and blank sections, the meter roller assembly may comprise various spacers, bearings, etc.
It is also typically the case that some distribution headers feed more runs than others, so that the amount of metered product to the headers will be required to be varied. Spacers, ring blanks, and the like have been used for this purpose.
Various problems have arisen in the use of known meter rollers. Typical such problems involve severe torque and tolerance problems, corrosion caused by leakage of product through gaps between segments; pulsing delivery of product to the headers; difficulties in delivering a large seed or large particle product to the headers at the proper rate; and difficulties in delivering very fine products to the headers at the desirable rate.
It is desirable to provide an improved meter roller assembly to address the problems enumerated above and others.
Various approaches have been used in the past to attempt to provide segmented meter rollers; that is, meter rollers in which metering sections are divided as between fluted or active segments, and blank, or inactive segments.
One such prior method varies the amount of product delivered by each fluted metering roller by fixing a varying number of thin rings about the center line of the roller to simply reduce the volume of product to be delivered by the roller. This was intended to compensate for the differing numbers of active seed or fertilizer delivery tubes emanating from the distribution header fed by that particular metering roller.
Another method used to reduce flow from a given run comprises reducing the width of the fluted metering section and inserting separate spacers on each side of the metering section. This method results in a very large number of parts in the segmented meter roll assembly with consequent severe tolerance and torque problems.
Of interest are Canadian Patents 1,289,013; and 1,149,235 and Canadian published application Serial No. 2,242,115.
SUMMARY OF THE INVENTION
It has now been discovered that substantially all of the problem areas to which reference was made in the background discussion above can be alleviated to a significant extent by the use of segmented metering sections which are formed as a single unit or unitary section per run, which may have any desired combination of blank and fluted surfaces. The unitary sections may be formed by molding a single piece or by molding and joining two or more pieces, preferably with one piece corresponding to each segment. In a preferred embodiment, the outer ends of a section formed from joined pieces are machined to tolerance.
Thus, the invention provides a meter roller assembly for metered product delivery between a meter box and a series of product runs leading to a series of product distributors or distribution headers, the assembly comprising: a shaft for mounting for rotation in the box; and a series of roller sections mounted on the shaft, the roller sections chosen from the group consisting of blank sections or metering sections; and wherein the series of roller sections includes at least one unitary segmented metering section, each said segmented metering section secured to the shaft for rotation therewith and comprising at least one fluted segment and at least one blank segment.
In the preferred configuration, the segmented metering sections have a one piece or unitary construction. In a further embodiment the invention provides a unitary metering section for use in a meter roller assembly, the unitary metering section comprising at least one fluted segment and at least one blank segment. In yet another embodiment of the invention, the blank segments of the segmented sections have a harder surface than do the fluted segments.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages of this invention will be apparent upon consideration of the following detailed disclosure of the invention, especially when taken in conjunction with the accompanying drawings wherein:
FIG. 1 illustrates an air cart of which the present invention may form a component;
FIG. 2 is a cross-section through a part of the cart of FIG. 1 illustrating the general layout in the meter box;
FIG. 3 is an exploded view of segmented metering sections and a meter roller assembly according to the invention;
FIG. 4 illustrates a front view of a meter roller in a meter box;
FIG. 5 is a perspective view of a segmented metering section illustrating offset flutes;
FIG. 6 is a perspective view of a segmented metering section illustrating discontinuous offset flutes or fingers; and
FIG. 7 is a perspective view of a further embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIGS. 1 and 2, an air cart 40 incorporating the principles of the instant invention is shown. The air cart 40 is of a known general configuration and comprises a tank 42, or optionally a number of tanks (not illustrated), which may be mounted on a frame 44, which is in turn carried on wheels 46. A metering assembly 48 is mounted on the bottom 50 of tank 42. A blower 52 forces air past the outlet area 54 of the metering assembly 48 to carry product 55 from the metering assembly 48 to appropriate tubing runs to distribution headers on a soil working implement (headers and implement not shown). A series of dividers 56 at the meter assembly outlet 54 define a series of runs which direct product into a corresponding series of delivery tubes 58. In addition to dividers 56, the meter assembly 48 includes a meter box 60 within which are disposed agitators 62 and a meter roller assembly 64.
With reference to the meter roller assembly illustrated in FIG. 3, a shaft 11, preferably of hexagonal configuration, is journalled for rotation in the metering box 60 of the air cart 40. A sprocket 1 is secured at one end of the shaft 11 to indicate shaft rotational speed. The shaft is preferably driven by a hydraulic motor, and certain implications of this drive mode will be defined below.
The meter roller assembly shown in FIG. 3 is intended for an air cart 40 having several runs, two of which include a segmented metering section 12. As will be understood by those skilled in the art, such assemblies may include additional runs, typically, for example, 8 runs. Any of those runs may contain a metering section or a blank section, depending on the number of distribution headers which are provided on the soil working implement in association with which the air cart 40 is used.
Depending on the configuration desired, each section may be blank, fully fluted across its width, or segmented as shown by metering sections 12. According to the principles of the instant invention, the roller assembly include at least one segmented section. A central blank section having an outer spacer 19 is illustrated to blank out unused runs. It is highly preferred that all unused runs be grouped centrally, so that a single extended blank section can be used across all unused runs. The central blank section comprises an outer spacer 19 and an inner spacer 20, the latter fixed by a pin 7 to the shaft 11 for centrally locating the spacer 20 on the shaft 11.
The bearing seats 14 abut against the inner spacer 20 and include a hexagonal bore, so that they rotate with the shaft 11. The bearing seats 14 abut a machined shoulder within the outer spacer 19. When the bearings 5 are seated on seats 14, the outer races of the bearings are in frictional engagement with the outer spacer 19, thus allowing the inner spacer 20 to rotate, while the outer spacer 19 is held against rotation by virtue of the cap screw 18 abutting against a part of the top of the meter box 60. The bearing shield 13 is then forced against the surface of the bearing seat 14 sealingly engaging the 0-ring 6 between the two. A bearing shield 13 is also in sealing engagement with the end of the central spacer assembly.
It should be noted that the central spacer assembly illustrated in FIG. 3 may be a special purpose arrangement which may serve functions unrelated to the metering per se as, for example, in pressure equalization.
The metering roller sections 12 abut against the bearing shields 13. Outer bearing seats 4 carry similar bearings 5 separated from the outer ends of the metering roller sections 12 by a second set of bearing shields 13. The outer bearing seats 4 are pinned by associated pins 7 to maintain the position of the sections between them. The outer bearings 5 journal the shaft 11. It is important to note that there would be no more bearings in the case of say, a 6 run assembly, in which case the intermediate sections or blank section would simply abut one another. In the absence of a central spacer assembly where all runs are in use, the shaft would carry only the two outer end bearings.
In this respect it is important to note that it is highly preferable that all of the sections be somewhat compressed together for sealing purposes. It is the outer seats 4 and their associated pins which maintain the compression across the roller assembly. The covers 3 are applied at the end of the metering section of the roll. A hub 2 is preferably fixed on the end of the shaft 11 and incorporates a speed sensor.
At the other end of the assembly there is preferably positioned an identification disk 23 to identify the metering roller type as, for example, between extra fine, fine, and coarse. A cam arrangement 24 and 25 is fixed to the end of the shaft 11 by a pin 26 and forms the driver for the agitator 62 (FIG. 2) to ensure smooth flow from the product tank into the meter box.
The segmented metering sections 12 preferably comprise a fluted segment 30 and two smooth blank segments 32. The combined width of the fluted segment and the two blank segments is essentially the same as the width of a single run.
While the positioning and the proportions of the segments may vary as desired, it is preferable that the metering sections comprise, as illustrated, a central fluted segment and two blank segments which are symmetric about the mid point of the roller.
Clearly, a run may have a preselected width, as in the case of existing machines, and the overall width of the metering section and of the fluted and blank segments of that roller can be varied to adapt an existing machine to the invention.
In a conventional assembly, wherein the metering roller is fluted across its entire width; that is, across the width of the run, and depending on the material to be delivered, the shaft will often be required to be operated at relatively low rpm, as, for example, typically down to about 2 rpm, in order to deliver correct amounts of product. At this lower rpm, there is a significant time during each rotation when no product is moved from the metering box into a run. This is because there is no flow when the end of a flute passes the run inlet. There is an interruption of flow as every flute passes. This has been found to result in a pulsing effect in the delivery of product to the distribution header and, consequently, in the uneven application of seed or fertilizer. By increasing the speed of rotation, the blank time during which a given flute is passing is reduced and the result is that a much more even flow of product to the distribution headers and hence into the soil can be achieved.
Clearly the increase in rotational speed, as measured by an increase in rpms, means that a larger quantity of product would be delivered to the distribution header by any given metering roller. The present arrangement avoids that problem by decreasing the capacity of the fluted segment of the metering roller. Thus, the shaft can be operated at higher rpm while delivering the same amount of product to the distribution header as would have been delivered under an older full width fluted metering section.
The arrangement offers the additional advantage that product can be readily handled which could not have been handled at low rpm rotational speed. For example, for large size low volume seed, such as corn, the metering rollers in the prior art could not be operated at a sufficiently low rpm to efficiently deliver proper amounts of product. At the higher rpm these types of product can readily be handled.
A further very significant advantage of the arrangement is that the hydraulic motors, which are the preferable drive means for the assembly, are very inefficient at low rotational speed. An increase of rpms from 2 to 4 or 6 rpm is highly significant in this regard. At those higher rpm values, the variable rate hydraulic drive will operate very efficiently. Furthermore, the equipment cost for the variable hydraulic motor to operate only at the higher rpms is significantly decreased.
Additional advantages can be obtained with variations in the construction of the segmented sections. In one preferred embodiment, the segmented sections are molded as a single unit. In another preferred embodiment, as illustrated in FIG. 7, the blank and fluted segments are again molded as a single unit, but with outer rings 91 installed as liners in that part of the mold defining the blank segments. The liners then become integral parts of the blank segments. In the preferred case the liners are harder than the rest of the material of the segmented section. This has the advantage that metered product is prevented from being pressed into the surface of the blank segments and potentially jamming between the blank segments and the box. The outer rings 91 can be adhered to the blank segments after molding, utilizing a suitable adhesive, to yield a one piece or unitary structure.
In a further preferred embodiment the blank and the fluted segments are molded separately, subsequently joined axially with a suitable adhesive to form the unitary section, and finally machined at the ends of the section to tolerance. The blank segments are molded from a harder material to thereby provide the advantage noted above.
In the preferred embodiments noted above, the preferred material is polyurethane. In that regard, typical hardness range for the harder part of the material is 75 to 80 shore D and for the fluted segment, 80 to 82 shore A.
Any suitable adhesive may be used for joining the parts where the segments are molded separately and then joined.
As a preferred alternative in the embodiment where liners are used in the mold, polycarbonate pipe bonds well to urethane during the molding process and so is preferred for that embodiment.
FIGS. 5 and 6 illustrate variations in fluted segment 30 of segmented section 12. In FIG. 5 fluted segment 30 comprises two integral rows of flutes 70 and 72 which can be seen to be out-of-phase relative to each other by one-half flute. This serves to reduce pulsing.
FIG. 6 illustrates discontinuous flutes 74 and 76, which are again out-of-phase relative to each other but which are also spaced axially from each other by reason of the discontinuity. Similar advantages are offered, particularly with larger diameter materials. In addition to reducing of pulsing, the proper placement of the discontinuous flutes serves to move metered product without the pinching or entrapment problems that have been encountered in prior art usage.
In the preferred configuration of this embodiment, the outer ends 78 of discontinuous flutes 74 and 76 abut against the inner sides 80 of blank segments 32. It has been found that pinching and jamming will almost inevitably result where large seed product is involved, if a gap is left between the flutes and the inner sides 80. In the most preferred embodiment, this metering section is a unitary structure with components molded together or held together by adhesive, or using a combination of molding and adhesive.
The central channel 82 between inner ends 84 and 86 of flutes 74 and 76 is preferably slightly wider than the largest dimension of the product to be metered. For example, for certain corn seed the width of the channel is preferably about 1/2". This will, in general, because of seed bunching over the flutes, allow seed to move through the metering segment without pinching, but will prevent seed from simply pouring unmetered through the segment.
In a preferred configuration of this embodiment, the extremities 88 of flutes 74 and 76 are recessed relative to surfaces 90 of blank segments 32.
Apart from the above operational advantages, there are significant improvements in life expectancy of the present assembly over prior art assemblies. Because there are significantly fewer components on the shaft, there is much less of a tolerance problem as between any two components. For example, in some prior art such assemblies, because there are a large number of components, the components must be manufactured with a shorter than ideal nominal size, in order to ensure that all components will be able to be fitted on the shaft. The result is potentially a somewhat sloppy and loose arrangement. This results in product working down through the gaps between components and resulting in corrosion problems, particularly in the bearings.
In the present case the components are substantially all urethane and are assembled on the shaft under overall compression, so that there are no gaps or much less chance of gaps developing. Hence corrosion problems are minimized.
In certain prior art such assemblies, where spacers or blanks are employed for various reasons, it is common to simply use a plastic blank with a circular bore which will fit over the shaft in a loose arrangement, such that the spacer does not rotate with the shaft. This frequently results in the bore in the blank becoming eccentric and this can contribute to the opening of gaps in the assembly, thus leading to the corrosion problem noted above. In the present case some of the blanks are integral with the metering rollers and others are separate blanks. For the separate blank section, the preferred construction comprises inner and outer shells. The outer shell is held against rotation but the inner shell rotates with the shaft, the two shells being separated by bearings.
Further, the use of multiple components which are in contact with, but not rotating with, the shaft results in severe torque problems.
In a typical air cart, there might be eight runs emanating from the meter box and thus up to eight metering sections. Typically a run is about 3 inches wide, so that the assembly would then be about 24 inches long. Typically a variety of metering sections are interchangeable on the shaft, the flutes of which are of varying degrees of fineness.
In the preferred case the tank is pressurized to essentially equalize pressure on both sides of the metering assembly. The pressurization may be at about 40 inches of water or 11/2 psi.
The product is pneumatically driven through the runs and ultimately to the soil, and such air seeders are well known in the art.
The metering roller sections in the present case may have fluted segments which are varied in width depending on the type of metered product and the volume required. For example, a run may be feeding an 8 port header or a 12 port header, thus requiring a different product volume.
It will be understood that changes in the details, materials, steps and arrangements of parts which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. The foregoing description illustrates the preferred embodiment of the invention; however, concepts, as based upon the description, may be employed in other embodiments without departing from the scope of the invention.
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A new and useful meter roller assembly is provided for an agricultural implement for metering material delivery between a meter box and a series of material runs leading to a series of material distributors, the assembly comprising a shaft for mounting for rotation in the box; a series of roller sections for mounting on the shaft, extending across the runs, the roller sections chosen from the group consisting of blank sections or metering sections; and wherein the series of roller sections includes at least one metering sections corresponding to one the run, for securing to the shaft for rotation therewith and comprising at least one fluted segment and at least one blank segment.
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TECHNICAL FIELD
The present invention relates to continuous ink jet printers and, more particularly, to a refill system and method for refilling fluid into a continuous ink jet fluid system.
BACKGROUND ART
Ink jet printing systems are known in which a print head defines one or more rows of orifices which receive an electrically conductive recording fluid from a pressurized fluid supply manifold and eject the fluid in rows of parallel streams. Printers using such print heads accomplish graphic reproduction by selectively charging and deflecting the drops in each of the streams and depositing at least some of the drops on a print receiving medium, while others of the drops strike a drop catcher device.
One traditional method of refilling fluid into a continuous ink jet fluid system was to use a simple, collapsible, refill container. This method relies on the system vacuum to squeeze ink out of the container. However, when the system vacuum has squeezed all of the ink that it can out of the container, the container still has a significant volume of fluid remaining in the neck, due to the inability to completely collapse the bottle at that location. This poses several problems. First, disposing of bottles still containing some volume of ink creates environmental safety issues. Another problem is that any amount of unused ink obviously results in some unrecovered cost of the refill fluid.
In an attempt to solve these problems associated with fluid remaining in the neck of a bottle, it would seem logical to put a tube in the bottle, extending from the cap to the bottom of the bottle. In this way, theoretically, ink will drain to the bottom of the bottle, so the application of the vacuum source there should be able to remove more ink. Unfortunately, a new problem was encountered with this method. As the ink is removed from the container, a vacuum is created at the top of the bottle which opposes the vacuum trying to remove the ink. Therefore, when the two vacuum levels are equal, removal of ink will cease and, again, a significant amount of ink is left in the refill container.
Thus far, removal of ink from the refill container assumed the restriction of relying on the fluid system for the vacuum source supplied during normal continuous ink jet operation. One possible fluid refill method relieves this restriction in an attempt to remove as much ink as possible from the refill bottle. In this method, the top of a non-collapsible refill container is vented to atmosphere, with the tube still extending to the bottom of the bottle. While this method eliminates the vacuum lock problem, it still does not remove all of the ink from the container because now the position of the tube relative to the last remains of ink in the container becomes important. And the optimum position of the tube relative to the last remains of ink is not achievable without the undesirable effect of increasing the cost of the container.
It is seen then that there is a need for a refill system and method which eliminates the environmental, as well as the cost inefficiency, concerns of emptying fluid refill containers.
SUMMARY OF THE INVENTION
This need is met by the system according to the present invention, wherein a collapsible container with a tube is vented, thereby significantly reducing the amount of ink left in the emptied container. This leaves such a negligible amount of ink in the container that environmental and cost inefficiency concerns are eliminated.
In accordance with one aspect of the present invention, a continuous ink jet imaging system comprises a means for providing a system vacuum for a constant fluidic system and a means for detecting the system vacuum and providing a signal in response thereto. The system further comprises a means for containing a refill fluid and a means for providing a bi-directional path. The bi-directional path is provided in one direction between the means for providing a system vacuum and the means for containing a refill fluid, and in the other direction between atmosphere and the means for containing a refill fluid. Finally, the system comprises a control means for removing air in the means for containing a refill fluid while maintaining the system vacuum within a predetermined range.
Accordingly, it is an object of the present invention to provide a refill system and method for emptying a refill container. Other objects and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating components of a continuous ink jet fluid system;
FIG. 2 is a timing diagram for the operation of the refill system and method of the present invention; and
FIG. 3 is a flow chart for accomplishing refill container air purge.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a system and a method for emptying a refill container for an ink jet fluid system, where a critical fluid vacuum source is used to draw from the refill system. It has been assumed in the prior art that inducing a significant volume of air into the normal operation of a fluid system is undesirable because the normal operation requires a minimum vacuum level to maintain proper printhead function. The present invention successfully deals with air in the refill container to reduce the amount of ink left in the refill container and to eliminate adverse effects in the event that air enters the fluid system through the refill apparatus.
Referring now to the drawings, in FIG. 1 a block diagram illustrates a refill system 10 associated with and comprised of components of a continuous ink jet fluid system. The refill system 10 includes a 3-way solenoid valve 12 and a float switch 14. When the float switch 14 determines that the system 10 does not require ink from the ink tank 16, the 3-way solenoid valve 12 provides a path for venting a refill container 18. This venting helps reduce the amount of ink (or other fluid) remaining in the refill container 18. When it is determined that the system 10 requires ink to be added, the 3-way solenoid valve 12 is energized and a vacuum originating from normal continuous ink jet fluid system operation. A vacuum switch 20 pulls ink from the bottom of the refill container 18 into the tank 16.
Continuing with FIG. 1, under these normal conditions, there are no further requirements placed on the fluid system. However, when the refill container 18 becomes emptied to the point where it nears the end of a tube 22, insertable in the container 18, there will suddenly be a surge of air towards the fluid system vacuum source, which includes the vacuum switch 20. Essentially, the refill container 18 is now at atmospheric pressure, i.e., near empty. Therefore, the fluid system will attempt to pull significantly more air from the refill system 10 than through the normal fluid system/printhead path.
Referring now to FIG. 2, and continuing with FIG. 1, the situation described above will create a drop in the fluid system vacuum, as illustrated in FIG. 2 at point A. At point A, it is beneficial to concentrate on compensating for the adverse effects in the event that air enters the fluid system through the refill container 18. In order to achieve this, the fluid system has been improved to include an air purge routine 24, illustrated in the flowchart of FIG. 3, through which the fluid system continually runs. The system begins at start block 26 and continues to decision block 28, where the system vacuum switch 20 is normally monitored to produce an error and halt continuous operation when there is a drop in the system vacuum below a setpoint. If no low vacuum condition exists, the program continues to block 29, where a refill solenoid 12 is energized and the refill system 10 draws ink, as required, by the float switch 14. When there is low vacuum in the fluid system, the air purge loop 24 continues to decision block 30. At decision block 30, the state of the refill solenoid 12 is determined. If the state of the solenoid 12 is on and the low vacuum condition exists, then the drop in vacuum is likely caused by air being pulled from the refill container 18. The fluid system boost vacuum pump, typically available in ink jet fluid systems to provide higher vacuum during start-ups, is energized at block 32 in an attempt to recover from vacuum loss. The boost vacuum is then kept energized at block 32 for a fixed time, as discussed below.
Continuing with FIG. 3, if no action were taken in response to the low vacuum condition determined at block 28, the vacuum would continue to drop, as air continues to be purged from the refill container 18, to the point where proper fluid system function would cease, as shown in FIG. 2 at point B. With the present invention, it can be determined when the fluid system vacuum would reach point B, and prevent that from occurring. The first attempt to recover the vacuum lost is at block 32, as described above, which corresponds to point C in FIG. 2. The advantage of using the boost vacuum at block 32 is that it provides two benefits. First, it halts the drop of vacuum and can begin recovery. Second, while it maintains or raises system vacuum, it also is pulling air from the refill container 18 and continuing to collapse the container 18. The time selected for the boost vacuum pump to be on is 1.5 seconds, which is based on a maximum time on and a minimum recover time, as discussed below.
Meanwhile, the vacuum level may still be below the switch 20 setpoint and continuing to indicate low vacuum condition. Therefore, another stage of recovery is necessary, as indicated at decision block 34. It is determined at decision block 34 whether the vacuum switch 20 is still indicating a low vacuum condition after a predetermined period of time, such as 750 milliseconds, based on information from point B in FIG. 2. The action of the second stage of recovery is to close the refill solenoid 12 as shown in FIG. 2 at point D, and the flowchart 24 of FIG. 3. This will cause more immediate recovery since the fluid system is now back to normal, and the boost vacuum at block 32 still on.
If the second stage of recovery is reached, the fill solenoid 12 is disabled for a predetermined period of time, such as five seconds, at block 36, to allow the possible overshoot from the boost vacuum to settle near normal system vacuum level. Point E in FIG. 2 illustrates the point where the boost vacuum time expires. The time for the fill valve 12 disable is simply chosen to be a sufficient time for the fluid system to return to near stable normal operation before allowing the loop 24 to repeat. Finally, after the fill valve 12 disable time expires, the system is approximately normal and the entire loop 24 is allowed to be repeated as often as necessary to collapse the refill container 18.
When the air purge loop 24 runs through its cycle, more air should be extracted from the container 18 during valve 12 open time than is allowed to enter the container 18 during valve 12 close time. This is accomplished by accurately selecting an orifice or restrictor 42, shown in FIG. 1. If the orifice 42 is too large, the loop 24 will create an artificial lung which will continuously `breathe`, preventing collapse of the refill container 18. The orifice 42, then, should be as large as allowable to prevent other problems, such as high air filtration requirements and clogging concerns. A typical orifice 42 size is 0.012 inches.
Continuing with FIG. 3, the maximum time allowed to endure the low vacuum condition is selected based on the time where the fluid system would fail if no action were taken or if the boost vacuum pump would fail. The time where low vacuum becomes a problem is approximately two seconds after the switch 20 has detected a low vacuum. Therefore, the maximum allowed time to endure the low vacuum condition is safely chosen to be approximately one second, as indicated at decision block 38. Therefore, if the loop 24 is failing and cannot recover vacuum, the fluid system will correctly halt continuous operation, as indicated at block 40, wherein continuous operation is halted in such a situation in time to prevent ink spill and ink jet printhead damage.
The time allowed to endure low vacuum and continue to purge air from the container 18 is based on the maximum allowed time to endure low vacuum, minus some margin of safety from the time the rapid vacuum recovery occurs, once the refill valve 12 was closed. Based on the one second maximum at decision block 38, the time allowed to keep the fill valve 12 on may safely be chosen to be 750 milliseconds, as indicated at decision block 34. Naturally, this time is desired to be as long as possible in order to purge as much air out of the refill container 18 as possible for each repetition of loop 24.
As explained above, the boost vacuum is turned on for approximately 1.5 seconds at block 32, which includes the one second maximum low vacuum endurance plus a recover time, since it is desired to actually recover to normal operating vacuum and not merely to the switch vacuum level. The boost vacuum on time cannot be too long, however, because it is undesirable to overshoot the normal vacuum level significantly. For example, when normal system vacuum level is sixty inches of water, as shown in FIG. 2, maximum vacuum should be considered to be approximately 90 inches of water, to prevent print quality degradation problems.
Industrial Applicability and Advantages
The present invention is useful in the field of ink jet printing, and has the advantage of maximizing removal of fluid from a refill container. Previous methods for emptying refill containers leave anywhere from 50 ml to 350 ml of fluid in a 1500 ml container, whereas the system and method of the present invention can reduce that amount to less than 10 ml. This is such a negligible amount that it provides the advantages of alleviating environmental concerns associated with disposing partially empty refill containers, and increasing cost efficiencies.
Having described the invention in detail and by reference to the preferred embodiment thereof, it will be apparent that other modifications and variations are possible without departing from the scope of the invention defined in the appended claims.
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A system and method for emptying a refill container used in a continuous ink jet fluid system reduces the amount of ink left in the refill container and eliminates adverse effects in the event that air enters the fluid system through the refill apparatus. The system for emptying the container includes a system vacuum and a refill container. A bi-directional path is provided between the system vacuum and the refill container. The air is then removed from the refill container while maintaining the system vacuum within a predetermined range.
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FIELD OF THE INVENTION
The present Invention relates to the crystalline forms of a drug compound. To be specific, it relates to the new crystal forms of a benzene sulfonamide thiazole compound, dabrafenib, methods of preparation and use thereof.
BACKGROUND OF THE INVENTION
Polymorphism is the ability of a solid material to exist in more than one form or crystal structure. Polymorphism may result from different molecular packing and/or molecular conformations of the molecules of a given compound in the crystal lattice. Polymorphic forms of a given compound have different physical properties, such as solubility, stability, thermal property, morphology of crystals, and mechanical property, etc. One or combination of multiple characterization methods may be used to differentiate the different crystal forms of the same compound, such as X-ray powder diffraction, differential scanning calorimetry, infrared spectroscopy, raman spectroscopy, and solid-state NMR spectroscopy, etc.
New crystalline forms (including anhydrous forms, hydrates and solvates) of the active pharmaceutical ingredients may offer better properties, such as solubility and bioavailability, stability, processability, purification ability. Some new crystalline form may serve as an intermediate crystal form to facilitate solid state transformation to a desired form. Desired new polymorphs can help formulation scientists broaden the choice of crystal forms to optimize the dosage forms.
Dabrafenib is a benzene sulfonamide thiazole compound and is a selective BRAF inhibitor. Results of the Phase I/II clinical trials show Dabrafenib has therapeutical activities and an acceptable safety profile in patients with BRAFV600E-mutan melanoma. The chemical name of Dabrafenib is N-[3-[5-(2-aminopyrimidin-4-yl)-2-(tert-butyl)thiazo-4-lyl]-2-fluoro phenyl]-2,6-difluorobenzenesulfonamide; molecular formula: C 23 H 20 F 3 N 5 O 2 S 2 ; formula weight: 519.6; and chemical structural formula as follows:
Patent documents WO2009/137391A2 and U.S. Pat. No. 7,994,185B2 (incorporated into the present application by reference) disclosed identification, preparing process and uses of Dabrafenib. To be specific, example 58a˜c disclosed a number of crystal forms of Dabrafenib and their preparation methods. Wherein, example 58a disclosed a crystal form (hereinafter referred to as the Known Crystal Form 1) and its preparation method. Example 58b and 58c disclosed another crystal form (hereinafter referred to as the Known Crystal Form 2) and its preparation method. Moreover, such patent documents also disclosed that Dabrafenib has the inhibitory effection on one or more Raf-family kinases. The above patent documents mentioned that the Known Crystal Form 1 is crystalline and provided its 1 H-NMR data, XRPD pattern and DSC thermogram; the Known Crystal Form 2 was characterized by Raman, XRPD and DSC/TGA analyses to show it is different from the Known Crystal Form 1, but detailed data was not given. The above patent documents did not mention the stability and the conversion relationship of these two crystal forms.
In addition, patent documents WO2012/148588A2 (incorporated into the present application by reference) disclosed a number of crystal forms of Dabrafenib and their preparation methods. Wherein, example 1 disclosed a crystal form (hereinafter referred to as the Known Crystal Form 3) and its preparation method. Furthermore, this patent document provided further characteristic data for the Known Crystal Form 1 and the Known Crystal Form 2 which were previously mentioned in WO2009/137391A2; This patent document provided Raman, XRPD and DSC/TGA analysis data of the Known Crystal Form 1, the Known Crystal Form 2 and the Known Crystal Form 3, but it did not mention the stability and the conversion relationship of these three crystal forms.
Patent document US2012/0196886A1 disclosed a pharmaceutical composition containing Dabrafenib methanesulfonate and use thereof.
In the present research, it was discovered that the Known Crystal Form 1 has the following defects: as an anhydrate, it has about 1.9% of weight change between 20˜80% RH, indicating some hygroscopicity; and it readily converts to other form(s) in water or other water containing system(s), thus unable to maintain its original form.
In the present research, it was discovered that the Known Crystal Form 2 has the following defects: it is unstable; it would convert to other form(s) when exposed to water or other water containing system(s), thus unable to maintain the original form; and after stirring in dichloromethane followed by filtering and drying, it can convert to the Known Crystal Form 1.
In the present research, it was discovered that the Known Crystal Form 3 has the following defects: It is very unstable; it can convert to the Known Crystal Form 1 at room temperature; and it may convert to other form(s) in water or other water containing system(s), thus unable to maintain the original form.
Therefore, there is a need to discover new crystal forms of Dabrafenib with good purity, improved thermodynamical stability at room temperature or in water, and/or little mass change under high humidity conditions, etc., to meet the strict demands for crystal properties in industrial production of pharmaceutical formulations.
SUMMARY OF THE INVENTION
In view of the defects in the prior art, the purpose of the present invention is mainly to provide new crystal forms of Dabrafenib with improved thermodynamical stability at room temperature or in aqueous system, and to provide preparation methods and uses thereof.
Dabrafenib
According to the purpose of the present invention, Crystal Form VI of Dabrafenib (hereinafter referred to as Crystal Form VI) is provided. Crystal Form VI is an hydrate, wherein per mol of Dabrafenib contains about 1 mol of water.
Measured using Cu—Kα radiation, Crystal Form VI is characterized by a X-ray powder diffraction pattern having the specific peaks at the diffraction angle 2θ of 10.4±0.2°, 17.6±0.2°, 21.6±0.2° and 25.1±0.2°.
In one preferred embodiment of the present invention, Crystal Form VI is characterized by a X-ray powder diffraction pattern having the specific peaks at the diffraction angle 2θ of 10.4±0.2°, 11.2±0.2°, 13.1±0.2°, 13.3±0.2°, 16.7±0.2°, 17.6±0.2°, 18.3±0.2°, 21.2±0.2°, 21.6±0.2°, 25.1±0.2°, 25.8±0.2°, 27.6±0.2° and 31.8±0.2°.
In the further preferred embodiment of the present invention, Crystal Form VI is characterized by a X-ray powder diffraction pattern having the specific peaks at the diffraction angle 2θ of 8.1±0.2°, 10.4±0.2° 11.2±0.2°, 13.1±0.2°, 13.3±0.2°, 14.4±0.2°, 16.2±0.2°, 16.7±0.2°, 17.6±0.2°, 18.3±0.2°, 21.2±0.2°, 21.6±0.2°, 25.1±0.2°, 25.8±0.2°, 26.3±0.2°, 26.8±0.2°, 27.6±0.2°, 31.1±0.2°, 31.8±0.2° and 32.9±0.2°.
In the even further preferred embodiment of the present invention, Crystal Form VI is characterized by a X-ray powder diffraction pattern having the following specific peaks at the diffraction angle 2θ and their relative intensities:
Diffraction angle 2θ
Relative intensity %
8.1 ± 0.2°
11.0
10.4 ± 0.2°
40.5
11.2 ± 0.2°
17.1
13.1 ± 0.2°
13.2
13.3 ± 0.2°
25.4
14.4 ± 0.2°
10.2
16.2 ± 0.2°
12.8
16.7 ± 0.2°
27.6
17.6 ± 0.2°
44.7
18.3 ± 0.2°
13.3
21.2 ± 0.2°
18.2
21.6 ± 0.2°
100.0
25.1 ± 0.2°
34.0
25.8 ± 0.2°
16.6
26.3 ± 0.2°
10.6
26.8 ± 0.2°
10.0
27.6 ± 0.2°
13.3
31.1 ± 0.2°
12.3
31.8 ± 0.2°
23.2
32.9 ± 0.2°
10.3.
Non-restrictively, in one specific embodiment of the present invention, the X-ray powder diffraction pattern of Crystal Form VI is shown in FIG. 1 .
Crystal Form VI may be prepared by any one of the following preparation methods:
(1) Putting a known crystal form or an amorphous form of Dabrafenib into a solvent system to form a suspension, stirring to recrystallize, separating and drying the precipitated crystals to get Crystal Form VI of Dabrafenib, wherein the solvent system is selected from water or a mixed solvents of water and an organic solvent, and the organic solvent is selected from C 1 ˜C 4 alcohols, C 4 ˜C 5 ester, C 2 ˜C 5 ethers, C 3 ˜C 4 ketones, tetrahydrofuran, nitromethane, acetonitrile, C 5 ˜C 8 alkanes and their mixtures;
Preferably, the known crystal form of Dabrafenib is the Known Crystal Form 2 of Dabrafenib;
Preferably, the organic solvent is selected from methanol, ethanol, propanol, butanol, ethyl acetate, isopropyl acetate, ethyl ether, methyl tert-butyl ether, acetone, butanone, tetrahydrofuran, nitromethane, acetonitrile, methyl cyclohexane, n-heptane, n-hexane or cyclohexane;
Preferably, the volume content of water in the mixed solvents of water and organic solvents is at least 0.01%, and more preferably, at least 0.1%;
Preferably, the amount of the known crystal form or the amorphous form of Dabrafenib is 1.1˜20 times of its solubility in the solvent system at the operation temperature, and more preferably, 1.5˜10 times;
Preferably, the operation temperature is room temperature to 60° C., and more preferably, room temperature;
Preferably, the duration of recrystallization is 3˜14 days, and more preferably, 3˜7 days.
(2) At room temperature, forming a solution of a known crystal form or an amorphous form of Dabrafenib by completely dissolving them in a mixed solvent of water and an organic solvent, placing the solution in a sealed atmosphere full of the diffusive solvent to precipitate crystals, separating and drying the precipitated crystal to get Crystal Form VI of Dabrafenib, wherein the organic solvent is selected from nitromethane or isopropyl alcohol and the diffusive solvent is the volatile ether;
Preferably, the known crystal form of Dabrafenib is the Known Crystal Form 2 of Dabrafenib;
Preferably, the volume content of water in the mixed solvent of water and organic solvent is at least 0.01%˜10%, and more preferably, at least 0.1%˜10%;
Preferably, the diffusive solvent is mineral ether or isopropyl ether;
Preferably, the solution concentration of the known crystal form or the amorphous form of Dabrafenib in the mixed solvent of water and organic solvent is 0.1˜5 mg/mL, and more preferably, 0.1˜3 mg/mL;
Preferably, the duration of crystallizing is 1˜3 weeks.
(3) Adding water or a water-saturated C 5 ˜C 8 alkane solution into a solution of a known crystal form or an amorphous form of Dabrafenib in an organic solvent, stirring to crystallize for 3˜14 days, separating and drying the precipitated crystal to get Crystal Form VI of Dabrafenib, wherein the organic solvent is selected from C 1 ˜C 4 alcohols, C 4 ˜C 5 esters, C 2 ˜C 5 ethers, C 3 ˜C 4 ketones, tetrahydrofuran, nitromethane, acetonitrile, or their mixtures;
Preferably, the known crystal form of Dabrafenib is the Known Crystal Form 2 of Dabrafenib;
Preferably, the organic solvent is selected from methanol, ethanol, propanol, butanol, ethyl acetate, isopropyl acetate, ethyl ether, methyl tert-butyl ether, acetone, butanone, tetrahydrofuran, nitromethane or acetonitrile;
Preferably, C 5 ˜C 8 alkane is selected from cyclohexane, methyl cyclohexane, n-hexane, n-heptane or their mixtures; and more preferably, C 5 ˜C 8 alkane is selected from methyl cyclohexane or n-heptane;
Preferably, the volume ratio of water or water-saturated C 5 ˜C 8 alkane solution to the organic solvent is 0.1:1˜100:1, and more preferably, 0.5:1˜50:1;
Preferably, the amount of the known crystal form or the amorphous form of Dabrafenib in the solution is 0.1-1 times of its solubility in the organic solvent at the operation temperature, and more preferably, 0.5˜1 times;
Preferably, the operation temperature is room temperature to 60° C., and more preferably, room temperature;
Preferably, the duration of crystallizing is 3˜7 days.
(4) Preparing a solution of the known crystal form or an amorphous form of Dabrafenib in a mixed solvent of water and an organic solvent at high temperature, cooling and stirring the solution to crystallize, separating and drying the precipitated crystals to get Crystal Form VI of Dabrafenib, wherein the organic solvent is selected from C 1 ˜C 4 alcohols, C 4 ˜C 5 esters, C 2 ˜C 5 ethers, C 3 ˜C 4 ketones, tetrahydrofuran, nitromethane, acetonitrile or their mixtures;
Preferably, the known crystal form of Dabrafenib is the Known Crystal Form 2 of Dabrafenib;
Preferably, the organic solvent is selected from methanol, ethanol, propanol, butanol, ethyl acetate, isopropyl acetate, ethyl ether, methyl tert-butyl ether, acetone, butanone, tetrahydrofuran, nitromethane or acetonitrile;
Preferably, the volume content of water in the mixed solvent of water and an organic solvent is at least 0.01%˜50%, and more preferably, 0.1%˜50%; generally, if water is slightly soluble or poorly soluble in the selected organic solvent, then the volume content of water in the mixed solvents will be 0.01%˜ of the maximum solubility of water in such solvent; and more preferably, 0.1%˜ of the maximum solubility of water in such solvent;
Preferably, the amount of the known crystal form or the amorphous form of Dabrafenib in the solution is 0.1-1 times of its solubility in the organic solvent at high temperature, and more preferably, 0.5˜1 times;
Preferably, the high temperature is 40° C. to the boiling point of the mixed solvents, and more preferably 50˜80° C.; and the temperature after cooling is 0° C. to room temperature, and preferably, room temperature;
Preferably, the duration of crystallizing is 3˜14 days, and more preferably, 3˜7 days.
In the above preparation methods (1)˜(4) of Crystal Form VI of Dabrafenib, the drying temperature is room temperature to 60° C., and preferably, 40° C.; the drying time is 1˜48 h, and preferably 1˜24 h.
In the above preparation methods (1)˜(4) of Crystal Form VI of Dabrafenib:
The mentioned organic solvents are miscible with water and the proportion of miscible solvents is based on the mutual solubility of solvents;
C1˜C4 alcohols include methanol, ethanol, n-propanol, isopropanol, n-butanol and sec-butanol;
C4˜C5 esters include ethyl acetate and isopropyl acetate;
C2˜C5 ethers include ethyl ether and methyl tert-butyl ether;
C3˜C4 ketones include acetone and butanone;
C5˜C8 alkane include cyclohexane, methyl cyclohexane, n-hexane and n-heptane.
The preparation method of water-saturated organic solvent solution comprises: taking equal volume of the organic solvent and water, stirring for 2˜5 h at room temperature and then collecting the organic layer.
Crystal Form VI has the following beneficial properties:
(1) When Crystal Form VI was stored for 3 months in a desiccator at room temperature, or in a drying oven at 40° C., or at room temperature and 97% RH, or at room temperature and 75% RH or at room temperature and 44% RH, its crystal form did not change.
(2) The mass change of Crystal Form VI is only about 0.5% between 20˜80% RH and its hygroscopicity is lower than that of the Known Crystal Form 1 (whose mass change is 1.9% between 20˜80% RH).
(3) Crystal Form VI is the most stable crystal form in the existence of water. According to the research of the inventors, it is found that the Known Crystal Form 1, the Known Crystal Form 2 and all the other crystal forms disclosed in the present invention are unstable when stirred in water or aqueous ethanol solution at room temperature or high temperature (40° C.), and form conversion happens, Crystal Form VI keeps its form unchanged under the same conditions.
(4) Crystal Form VI is the most stable crystal form in the wet granulation process or in the suspension. In the wet granulation process or in the suspension, the Known Crystal Form 1, the Known Crystal Form 2 and all the other crystal forms disclosed in the present invention are unstable and their crystal forms converts; however, Crystal Form VI keeps its form unchanged in the wet granulation process or in the suspension.
The above properties of Crystal Form VI show that compared with the Known Crystal Form 1 and the Known Crystal Form 2 of Dabrafenib, Crystal Form VI of Dabrafenib of the present invention has good form stability and low hygroscopicity, therefore it can better deal with problems such as poor content uniformity, decreased purity, which were caused by time, humidity and other factors during manufacture, storage and transportation, and it can effectively mitigate the risk of reduced treatment effect and safety risk arising from the form changes of active substances, content variations and/or increasing in impurity content; moreover, Crystal Form VI of the present invention is the most stable crystal form in aqueous systems, and is well suitable for the wet granulation process or to be made into the suspensions; and it has excellent processability, good production reproducibility and is beneficial to the storage and transportation in the late period. (As the Known Crystal Form 3 is extremely unstable, it is not used for comparison in the present invention.)
According to the purpose of the present invention, Crystal Form VII of Dabrafenib (hereinafter referred to as “Crystal Form VII”) is also provided.
Measured using Cu—Kα radiation, Crystal Form VII is characterized by a X-ray powder diffraction pattern having the specific peaks at the diffraction angle 2θ of 7.9±0.2°, 14.5±0.2°, 19.4±0.2° and 24.3±0.2°.
In one preferred embodiment of the present invention, Crystal Form VII is characterized by a X-ray powder diffraction pattern having the specific peaks at the diffraction angle 2θ of 7.9±0.2°, 11.6±0.2°, 14.5±0.2°, 17.7±0.2°, 19.4±0.2°, 20.6±0.2°, 24.3±0.2°, 27.8±0.2°, 29.2±0.2°, 30.1±0.2° and 32.6±0.2°.
In the further preferred embodiment of the present invention, Crystal Form VII is characterized by a X-ray powder diffraction pattern having the specific peaks at the diffraction angle 2θ of 7.9±0.2°, 11.6±0.2°, 13.7±0.2°, 14.5±0.2°, 16.3±0.2°, 17.7±0.2°, 19.4±0.2°, 20.6±0.2°, 24.3±0.2°, 25.3±0.2°, 25.5±0.2°, 27.8±0.2°, 29.2±0.2°, 30.1±0.2° and 32.6±0.2°.
In the even further preferred embodiment of the present invention, Crystal Form VII is characterized by a X-ray powder diffraction pattern having the following specific peaks at the diffraction angle 2θ and their relative intensities:
Diffraction angle 2θ
Relative intensity %
7.9 ± 0.2°
34.2
11.6 ± 0.2°
16.2
13.7 ± 0.2°
6.7
14.5 ± 0.2°
38.1
16.3 ± 0.2°
6.7
17.7 ± 0.2°
15.1
19.4 ± 0.2°
27.6
20.6 ± 0.2°
12.9
24.3 ± 0.2°
100.0
25.3 ± 0.2°
6.6
25.5 ± 0.2°
5.9
27.8 ± 0.2°
14.8
29.2 ± 0.2°
11.4
30.1 ± 0.2°
9.2
32.6 ± 0.2°
7.5
Non-restrictively, in one specific embodiment of the present invention, Crystal Form VII of Dabrafenib is characterized by a X-ray powder diffraction pattern as shown in FIG. 8 .
Crystal Form VII may be prepared by any one of the following methods:
(1) At room temperature, adding water or a C 5 ˜C 8 alkane into an organic solvent solution made from a known crystal form or an amorphous form of Dabrafenib, stirring to crystallize for 1˜60 mins, separating and drying the precipitated crystal to get Crystal Form VII of Dabrafenib, wherein the organic solvent is selected from ethyl ether, 1,4-dioxane or C 2 ˜C 3 alcohols;
Preferably, the known crystal form of Dabrafenib is the Known Crystal Form 2 of Dabrafenib;
Preferably, the organic solvent is selected from ethanol, isopropanol, ethyl ether or 1,4-dioxane;
Preferably, C 5 ˜C 8 alkane is selected from cyclohexane, methyl cyclohexane, n-hexane, n-heptane or their mixtures; and more preferably, C 5 ˜C 8 alkane is selected from methyl cyclohexane or n-heptane;
Preferably, the volume ratio of water or C 5 ˜C 8 alkane to the organic solvent is 0.1:1˜100:1, more preferably, 0.5:1˜50:1, and the most preferably, 0.5:1˜5:1;
Preferably, the amount of the known crystal form or the amorphous form of Dabrafenib in the solution is 0.1-1 times of its solubility in the organic solvent at room temperature, and more preferably, 0.5˜1 times;
Preferably, the duration of crystallizing is 1˜30 mins.
(2) At room temperature, placing the isopropyl acetate solution of a known crystal form or an amorphous form of Dabrafenib in a sealed atmosphere full of the diffusive solvent to crystallize, separating and drying the precipitated crystals to get Crystal Form VII of Dabrafenib, wherein the diffusive solvent is the volatile ether solvent;
Preferably, the known crystal form of Dabrafenib is the Known Crystal Form 2 of Dabrafenib;
Preferably, the diffusive solvent is mineral ether or isopropyl ether;
Preferably, the concentration of the isopropyl acetate solution is 0.1˜5 mg/mL, and more preferably, 0.1˜3 mg/mL;
Preferably, the duration of crystallization is 1˜3 weeks.
(3) At room temperature, putting an amorphous form of Dabrafenib into a C 3 ˜C 4 alcohol to form a suspension, stirring to crystallize, separating and drying the precipitated crystals to get Crystal Form VII of Dabrafenib;
Preferably, the amount of the amorphous form of Dabrafenib is 1.1˜20 times of its solubility in a C 3 ˜C 4 alcohol at room temperature, and more preferably, 1.5˜10 times;
Preferably, C 3 ˜C 4 alcohol is selected from isopropanol, n-propanol, n-butanol or sec-butanol;
Preferably, the duration of crystallization is 0.1˜10 hours, and more preferably, 0.1˜2 hours.
(4) Raising the temperature of Crystal Form VI of Dabrafenib until its crystal water is completely removed, then cooling naturally to room temperature to get Crystal Form VII of Dabrafenib; preferably, the temperature is raised to 125° C. at the speed of 10° C./min.
(5) Evaporating the ethyl acetate solution of a known crystal form or an amorphous form of Dabrafenib to crystallize, separating and drying the precipitated crystals to get Crystal Form VII of Dabrafenib;
Preferably, the known crystal form of Dabrafenib is the Known Crystal Form 2 of Dabrafenib;
Preferably, the amount of the known crystal form or the amorphous form of Dabrafenib in the ethyl acetate solution is 0.1˜1 times of its solubility in ethyl acetate at room temperature, and more preferably, 1.5˜1 times.
Preferably, the duration of crystallizing is 1˜7 days, and more preferably 3˜7 days.
Crystal Form VII has the following beneficial properties:
(1) The mass change of Crystal Form VII is only about 0.1% between 20˜80% RH and its hygroscopicity is lower than that of the Known Crystal Form 1 (whose mass change is 1.9% between 20˜80% RH);
(2) When Crystal Form VII is stored for 3 months in a desiccator at room temperature, at room temperature and 97% RH, at room temperature and 75% RH, at room temperature and 44% RH or in a drying oven at 40° C., its crystal form does not change;
(3) Competitive slurring of Crystal Form VII and the Known Crystal Form 1 in purified water indicates that Crystal Form VII is more stable than the Known Crystal Form 1;
(4) Crystal Form VII is of rod-shaped particles, which have larger particle size than those of the Known Crystal Form 1 and the Known Crystal Form 2; and the flowability of such particles is good.
The above properties of Crystal Form VII show that, compared with the Known Crystal Form 1 and the Known Crystal Form 2 of Dabrafenib, Crystal Form VII of Dabrafenib in the present invention has good form stability and low hygroscopicity, so it can better deal with the problems such as poor content uniformity, decreased purity, caused by time, humidity and other factors during manufacture, storage and transportation, it can effectively mitigate the risk of reduced treatment effect and the safety risk arising from the form changes of the active substance, content variations and/or increasing in impurity. Moreover, compared with the Known Crystal Form 1 and the Known Crystal Form 2 of Dabrafenib, Crystal Form VII of the present invention has good particle morphology and good flow properties which are beneficial for accurate quantification and process, and it has good production reproducibility and excellent suitability for the formulation process. (As the Known Crystal Form 3 is extremely unstable, it is not used for comparison in the present invention.)
By providing the new Crystal Form VI or Crystal Form VII of Dabrafenib in the present invention, the problems of crystal forms in the prior art have been solved. Compared with the known crystal forms, the new crystal form has at least one or more beneficial properties, such as higher crystallinity, solubility, dissolution rate, good morphology, less tendency to convert to other forms and/or to dehydrate, good thermal stability and mechanical properties, low hygroscopicity, better flowability and compressibility, improved bulk density and storage stability, low content of residual solvent, etc.
In addition, according to the purpose of the present invention, Crystal Form III of Dabrafenib (hereinafter referred to as “Crystal Form III”) is also provided.
Measured using Cu—Kα radiation, Crystal Form III is characterized by a X-ray powder diffraction pattern having the specific peaks at the diffraction angle 2θ of 10.3±0.2°, 12.9±0.2°, 17.5±0.2°, 21.7±0.2° and 25.1±0.2θ.
Further, Crystal Form III is characterized by a X-ray powder diffraction pattern also having the specific peaks at the diffraction angle 2θ of 7.8±0.2°, 11.0±0.2°, 15.9±0.2°, 16.9±0.2°, 18.1±0.2°, 18.6±0.2°, 20.9±0.2°, 21.3±0.2°, 25.7±0.2°, 26.0±0.2°, 27.2˜0.2°, 27.6±0.2°, 30.9±0.2°, 31.8±0.2° and 33.9±0.2°.
Non-restrictively, measured using Cu—Kα radiation, Crystal Form III is characterized by a X-ray powder diffraction pattern substantially as shown in FIG. 15 .
Crystal Form III may be prepared by the following method: Suspending a known crystal form or an amorphous form of Dabrafenib in sec-butanol to form a suspension, stirring to crystallize, and then separating the precipitated crystals without drying to get Crystal Form III of Dabrafenib;
Preferably, the known crystal form of Dabrafenib is the Known Crystal Form 2 of Dabrafenib;
Preferably, the amount of the known crystal form or the amorphous form of Dabrafenib is 2˜100 times of its solubility in sec-butanol at the operation temperature, and more preferably, 2˜10 times;
Preferably, the operation temperature is room temperature to 60° C., and more preferably, room temperature;
Preferably, the duration of crystallization is 3˜14 days, and more preferably 3˜7 days.
In addition, according to the purpose of the present invention, Crystal Form IV of Dabrafenib (hereinafter referred to as “Crystal Form IV”) is also provided.
Measured using Cu—Kα radiation, Crystal Form IV is characterized by a X-ray powder diffraction pattern having the specific peaks at the diffraction angle 2θ of 5.9±0.2°, 6.6±0.2°, 12.0±0.2°, 18.1±0.2° and 24.3±0.2°.
Further, Crystal Form IV is characterized by a X-ray powder diffraction pattern also having the specific peaks at the diffraction angle 2θ of 7.9±0.2°, 8.9±0.2°, 11.7±0.2°, 14.5±0.2°, 16.2±0.2°, 16.5±0.2°, 17.8±0.2°, 19.4±0.2°, 20.3±0.2°, 20.6±0.2°, 21.2±0.2°, 22.3±0.2°, 25.4±0.2°, 25.6±0.2°, 26.9±0.2°, 27.8±0.2°, 28.2±0.2°, 28.4±0.2° and 29.2±0.2°.
Non-restrictively, measured using Cu—Kα radiation, Crystal Form IV is characterized by a X-ray powder diffraction pattern substantially as shown in FIG. 16 .
Crystal Form IV may be prepared by the following method: Volatilizing the methyl tert-butyl ether solution of a known crystal form or an amorphous form of Dabrafenib to crystallize, separating the precipitated crystal without drying to get Crystal Form IV of Dabrafenib;
Preferably, the known crystal form of Dabrafenib is the Known Crystal Form 2 of Dabrafenib;
Preferably, the amount of the known crystal form or the amorphous form of Dabrafenib in the methyl tert-butyl ether solution is 0.1˜1 times of its solubility in methyl tert-butyl ether at room temperature, and more preferably, 0.5˜1 times;
Preferably, the duration of crystallization is 1˜7 days, and more preferably 3˜7 days.
In addition, according to the purpose of the present invention, Crystal Form V of Dabrafenib (hereinafter referred to as “Crystal Form V”) is also provided.
Measured using Cu—Kα radiation, Crystal Form V is characterized by a X-ray powder diffraction pattern having the specific peaks at the diffraction angle 2θ of 9.3±0.2°, 13.4±0.2°, 16.5±0.2°, 19.8±0.2° and 21.3±0.2°.
Furthermore, Crystal Form V is characterized by a X-ray powder diffraction pattern also having the specific peaks at the diffraction angle 2θ of 8.2±0.2°, 11.8±0.2°, 12.6±0.2°, 14.5±0.2°, 16.0±0.2°, 20.7±0.2°, 20.9±0.2°, 21.7±0.2°, 22.4±0.2°, 22.7±0.2°, 23.5±0.2°, 24.5±0.2°, 24.9±0.2°, 25.2±0.2°, 25.5±0.2°, 25.8±0.2°, 26.6±0.2°, 26.9±0.2°, 27.2±0.2°, 29.2±0.2°, 30.4±0.2° and 32.9±0.2°.
Non-restrictively, measured using Cu—Kα radiation, Crystal Form V is characterized by a X-ray powder diffraction pattern substantially as shown in FIG. 17 .
Crystal Form V may be prepared by the following method: Suspending a known crystal form or an amorphous form of Dabrafenib in dichloromethane to form a suspension, stirring to crystallize, and then separating the precipitated crystals without drying to get Crystal Form V of Dabrafenib;
Preferably, the known crystal form of Dabrafenib is the Known Crystal Form 2 of Dabrafenib;
Preferably, the amount of the known crystal form or the amorphous form of Dabrafenib is 2˜100 times of its solubility in dichloromethane at the operation temperature, and more preferably, 2˜10 time;
Preferably, the operation temperature is room temperature to 60° C., and more preferably, room temperature;
Preferably, the duration of crystallization is 3˜14 days, and more preferably 3˜7 days.
In addition, according to the purpose of the present invention, Crystal Form VIII of Dabrafenib (hereinafter referred to as “Crystal Form VIII”) is also provided.
Measured using Cu—Kα radiation, Crystal Form VIII is characterized by a X-ray powder diffraction pattern having the specific peaks at the diffraction angle 2θ of 9.6±0.2°, 14.2±0.2°, 19.5±0.2°, 20.4±0.2° and 20.9±0.2°.
Furthermore, Crystal Form VIII is characterized by a X-ray powder diffraction pattern also having the specific peaks at the diffraction angle 2θ of 3.5±0.2°, 12.2±0.2°, 13.7±0.2°, 13.9±0.2°, 14.7±0.2°, 15.0˜0.2°, 15.5±0.2°, 16.2±0.2°, 16.5±0.2°, 17.0±0.2°, 19.0±0.2°, 21.7±0.2°, 22.0±0.2°, 22.3±0.2°, 23.6±0.2°, 24.2±0.2°, 24.4±0.2°, 24.6±0.2°, 29.0±0.2° and 30.2±0.2°.
Non-restrictively, measured using Cu—Kα radiation, Crystal Form VIII is characterized by a X-ray powder diffraction pattern substantially as shown in FIG. 18 .
In addition, according to the purpose of the present invention, Crystal Form VIIIa of Dabrafenib (hereinafter referred to as “Crystal Form VIIIa”) is also provided.
Measured using Cu—Kα radiation, Crystal Form VIIIa is characterized by a X-ray powder diffraction pattern having the specific peaks at the diffraction angle 2θ of 3.5±0.2°, 9.8±0.2°, 12.2±0.2° and 16.4±0.2°.
Furthermore, Crystal Form VIIIa is characterized by a X-ray powder diffraction pattern also having the specific peaks at the diffraction angle 2θ of 7.2±0.2°, 8.3±0.2°, 9.2±0.2°, 11.2±0.2°, 13.2±0.2°, 13.9±0.2°, 14.7±0.2°, 18.4˜0.2°, 19.1±0.2°, 19.8±0.2°, 21.5±0.2°, 22.1±0.2°, 24.2±0.20°, 24.7±0.2°, 26.0±0.2° and 29.7±0.2°.
Non-restrictively, measured using Cu—Kα radiation, Crystal Form VIIIa is characterized by a X-ray powder diffraction pattern substantially as shown in FIG. 21 .
Crystal Form VIII and Crystal Form VIIIa may be prepared by the following method: At room temperature, placing the ethyl acetate solution of a known crystal form or an amorphous form of Dabrafenib in a sealed atmosphere full of isopropyl ether to crystallize, separating the precipitated crystals without drying to get Crystal Form VIIIa of Dabrafenib; keeping the separated crystals still for 2 h at room temperature to get Crystal Form VIII;
Preferably, the known crystal form of Dabrafenib is the Known Crystal Form 2 of Dabrafenib;
Preferably, the concentration of the ethyl acetate solution is 0.1˜5 mg/mL, and more preferably, 0.1˜3 mg/mL;
Preferably, the duration of crystallization is 1˜7 weeks.
In addition, according to the purpose of the present invention, Crystal Form Ie of Dabrafenib (hereinafter referred to as “Crystal Form Ie”) is also provided.
Measured using Cu—Kα radiation, Crystal Form Ie is characterized by a X-ray powder diffraction pattern having the specific peaks at the diffraction angle 2θ of 7.9±0.20°, 10.5±0.2°, 15.2±0.2°, 20.5±0.2° and 20.8±0.2°.
Furthermore, Crystal Form Ie is characterized by a X-ray powder diffraction pattern also having the specific peaks at the diffraction angle 2θ of 3.9±0.2°, 9.5±0.2°, 10.0±0.2°, 11.4±0.2°, 12.5±0.2°, 13.3±0.2°, 14.3±0.2°, 16.1±0.2°, 16.6±0.2°, 17.4±0.2°, 17.9±0.2°, 18.3±0.2°, 19.7±0.2°, 20.2±0.2°, 22.2±0.2°, 22.7±0.2°, 23.8±0.2°, 24.4±0.2°, 25.2±0.2°, 25.9±0.2°, 26.2±0.2°, 28.3±0.2° and 29.5±0.2°.
Non-restrictively, measured using Cu—Kα radiation, Crystal Form Ie is characterized by a X-ray powder diffraction pattern substantially as shown in FIG. 19 .
Crystal Form Ie may be prepared by any one of the following methods:
1) Suspending an amorphous form of Dabrafenib in toluene to form a suspension, stirring to crystallize, and then separating the precipitated crystals without drying to get Crystal Form Ie;
Preferably, the amount of the amorphous form of Dabrafenib is 2˜100 times of its solubility in toluene at the operation temperature, and more preferably, 2˜10 times;
Preferably, the operation temperature is room temperature to 60° C., and more preferably, room temperature;
Preferably, the duration of crystallization is 0.1˜2 hours.
2) Preparing the toluene solution containing a known crystal form or an amorphous form of Dabrafenib at high temperature, cooling the solution rapidly and stirring to crystallize, and then separating the precipitated crystal without drying to get Crystal Form Ie;
Preferably, the known crystal form of Dabrafenib is the Known Crystal Form 2 of Dabrafenib;
Preferably, the amount of the known crystal form or the amorphous form of Dabrafenib is 0.1˜1 times of its solubility in toluene at high temperature, and more preferably, 0.5˜1 times;
Preferably, the duration of crystallization is 0.1˜2 hours;
Preferably, the high temperature is 40° C. to the boiling point of toluene, and more preferably 50˜80° C.; and the temperature after cooling is 0° C. to room temperature, and preferably, room temperature.
In addition, according to the purpose of the present invention, Crystal Form VIIb of Dabrafenib (hereinafter referred to as “Crystal Form VIIb”) is also provided.
Measured using Cu—Kα radiation, Crystal Form VIIb is characterized by a X-ray powder diffraction pattern having the specific peaks at the diffraction angle 2θ of 9.8±0.2°, 11.4±0.2°, 12.2±0.2°, 15.9±0.2° and 21.4±0.2°.
Furthermore, Crystal Form VIIb is characterized by a X-ray powder diffraction pattern also having the specific peaks at the diffraction angle 2θ of 6.7±0.2°, 7.8±0.2°, 10.3±0.2°, 12.9±0.2°, 14.5±0.2°, 14.8±0.2°, 17.2±0.2°, 17.5±0.2°, 18.8±0.2°, 19.2±0.2°, 20.3±0.2°, 21.0±0.2°, 22.1±0.2°, 24.2±0.2° and 30.4±0.2°.
Non-restrictively, measured using Cu—Kα radiation, Crystal Form VIIb is characterized by a X-ray powder diffraction pattern substantially as shown in FIG. 20 .
Crystal Form VIIb may be prepared by the following method: Adding methyl cyclohexane into the butanone solution of a known crystal form or an amorphous form of Dabrafenib, stirring to crystallize, and then separating the precipitated crystals without drying to get Crystal Form VIIb;
Preferably, the known crystal form of Dabrafenib is the Known Crystal Form 2 of Dabrafenib;
Preferably, the amount of the known crystal form or the amorphous form of Dabrafenib in the solution is 0.1-1 times of its solubility in butanone at the operation temperature, and more preferably, 0.5˜1 times;
Preferably, the volume ratio of methyl cyclohexane to butanone is 0.1:1˜10:1, and more preferably, 0.5:1˜5:1;
Preferably, the operation temperature is room temperature to 60° C., and more preferably, room temperature;
Preferably, the duration of crystallizing is 3˜14 days, and more preferably 3˜7 days.
By providing the new Crystal Form III, Crystal Form IV, Crystal Form V, Crystal Form VIII, Crystal Form Ie, Crystal Form VIIb or Crystal Form VIIIa of Dabrafenib in the present invention, the problems of crystal forms in the prior art have been solved. Each new crystal form has at least one of the following beneficial properties: better thermal stability, good morphology, low hygroscopicity, better flowability, better apparent density and better storage stability.
In the preparation methods of Crystal Form VI, Crystal Form VII, Crystal Form III, Crystal Form IV, Crystal Form V, Crystal Form VIII, Crystal Form Ie, Crystal Form VIIb and Crystal Form VIIIa in the present invention:
The mentioned “the Known Crystal Form of Dabrafenib” includes but not limited to the Known Crystal Form 1, the Known Crystal Form 2, the Known Crystal Form 3 of Dabrafenib or their mixtures.
The mentioned “Room Temperature” refers to 15˜25° C.
The mentioned “Stirring” is accomplished with the routine methods in this field, such as magnetic stirring or mechanical stirring; the stirring speed is 50˜1,800 rpm, and preferably, 300˜900 rpm.
The mentioned “Separating” is accomplished with the routine methods in this field, such as centrifugation or filtration. The operation of “centrifugation” is as follows: place the sample to be separated in the centrifugal tube and centrifugate it at 6,000 rpm until all the solids settle down on the bottom of the centrifugal tube. “Filtration” generally refers to the suction filtration at the pressure less than the atmospheric pressure; and the preferable pressure is less than 0.09 MPa.
Unless otherwise specified, the mentioned “Drying” may be conducted at room temperature or higher temperature. The drying temperature is room temperature to about 60° C., or to 40° C., or to 50° C. The drying time may be 2˜48 hours, or overnight. “Drying” may be conducted in a fume hood, a blast drying oven or a vacuum drying oven.
The mentioned “Sealed Atmosphere” is operated as follows: place a small uncovered 20 mL-vial filled with the prepared solution into a 100 mL sealed glass bottle which was prefilled with 10˜30 mL diffusive solvent, after the diffusive solvent diffused for 1˜3 weeks into the vial, separate the precipitated solids.
In the present invention, “Crystal” or “Crystal Form” refers to the crystal or the crystal form being identified by the X-ray diffraction pattern shown herein. The scientists in this field are able to understand that physical and chemical properties discussed herein can be characterized, wherein the experimental errors depend on the conditions of instruments, the sample preparations and the purity of samples. In particular, the scientists in this field generally know that the X-ray diffraction pattern usually may change with the change of the experimental conditions. It is necessary to point out that, the relative intensity of the X-ray diffraction pattern is likely to change with the change of the experimental conditions; therefore, the sequence of peak intensity cannot be regarded as the only or the determining factor. Moreover, generally, the experimental errors of the peak angles are 5% or less, so such errors shall be considered and generally the allowed errors are ±0.2° 2θ. In addition, due to the effect of the experimental factors including sample height, peak angles may have an overall shifting; generally, certain shifting is allowed. Hence, the scientists in this field may understand that, it is unnecessary that the X-ray diffraction pattern of a crystal form in the present invention should be exactly the same with X-ray diffraction patterns of the example shown herein. Any crystal forms whose X-ray diffraction pattern have the same or similar characteristic peaks should be within the scope of the present invention. The scientists in this field can compare the patterns shown in the present invention with that of an unknown crystal form in order to identify whether these two groups of patterns reflect the same or different crystal forms.
“Crystal Form” and “Polymorphic Form” as well as other related terms in the present invention refer to the solid compounds whose crystal structure is being in a special crystal form state. The difference in the physical and chemical properties of the polymorphic forms may be embodied in storage stability, compressibility, density, dissolution rate, etc. In extreme cases, the difference in solubility or dissolution rate may result in inefficient drugs, even developing toxicitys.
Unless otherwise specified, the “Anhydrate” mentioned in the present invention refers to the crystal form with its water content no more than 1.5% (weight ratio) or 1.0% (weight ratio) measured by TGA.
In some embodiments, the new crystal forms in the present invention, including Crystal Forms VI, VII, III, IV, V, VIII, Ie, VIIb and VIIIa, are pure, substantially not contaminated with any other crystal forms. In particular, Crystal Forms VI and VII are substantially not contaminated with any other crystal forms. In the present invention, when used to refer to the new crystal form, “substantially not” means that the crystal form contains less than 20% (weight) of the other crystal forms; further, less than 10% (weight); furthermore, less than 5% (weight); and the furthest, less than 1% (weight).
Generally, Crystal Forms VI, VII, III, IV, V, VIII, Ie, VIIb and VIIIa substantially do not contain either the Known Crystal Form 1, or the Known Crystal Form 2 or the Known Crystal Form 3; in particular, these crystal forms have no characteristic peaks of the Known Crystal Form 1 at 9.5±0.2°, 10.1±0.2°, 12.7±0.2°, 16.1±0.20 and 19.0±0.20, and have no characteristic peaks of the Known Crystal Form 2 at 7.9±0.2°, 13.6±0.2°, 14.6±0.2°, 15.8±0.2°, 20.3±0.2° and 21.9±0.2°, and have no characteristic peaks of the Known Crystal Form 3 at 12.2±0.2°, 12.8˜0.2°, 15.9±0.2°, 21.3±0.20 and 24.9±0.2°.
The polymorphic forms of drugs may be obtained by the methods including but not limited to the following: melting and recrystallization, melting and cooling, solvent recrystallization, desolvation, rapid volatilization, rapid cooling, slow cooling, vapor diffusion and sublimation. The polymorphic form may be tested, discovered and classified via X-ray powder diffraction (XRPD), differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), optical microscopy, hygroscopicity, etc.
The crystallization methods for the crystal forms of the present invention include evaporation at room temperature, slurry, cooling and recrystallization, diffusion and anti-solvent recrystallization.
Evaporation at room temperature means, for example, putting the clear solution of the sample into an uncovered 5 mL-vial and evaporate at room temperature, with or without nitrogen purge.
Slurry means, for example, stirring the over-saturated solution (with the presence of insoluble solids) of the sample in a solvent system to crystallize, generally for 2 hours˜2 weeks.
Cooling and recrystallization means, for example, under certain high temperature conditions, dissolving the sample in suitable solvent(s), putting the solution into a 5 mL-vial, placing the vial in a temperature-variable shaker, then cooling it in turn at certain cooling rate and stirring overnight. The experimental temperature may be 75˜0° C. and preferably 50˜15° C. At each specific temperature, the sample solution is kept warm for 2 hours˜2 days.
Diffusion means, for example, dissolving the sample in a good solvent and then placing the solution in a sealed atmosphere full of the volatile solvent to recrystallize.
Anti-solvent recrystallization means, for example, dissolving the sample in a good solvent, adding an appropriate amount of anti-solvent, and then stirring to recrystallize.
In addition, the present invention provides a pharmaceutical composition, which comprises a therapeutically and/or preventively effective amount of one or more selected from, including Crystal Form VI, Crystal Form VII, Crystal Form III, Crystal Form IV, Crystal Form V, Crystal Form VIII, Crystal Form Ie, Crystal Form VIIb or Crystal Form VIIIa of Dabrafenib of the present invention, and at least one pharmaceutically acceptable excipient. Moreover, the pharmaceutical composition may also comprise pharmaceutical acceptable other crystal forms or the amorphous form of Dabrafenib or its salts, and such crystal forms include but not limited to the Known Crystal Form 1, the Known Crystal Form 2 and the Known Crystal Form 3. Optionally, the pharmaceutical composition may also comprise one or more of other pharmaceutical active ingredients, such as any treatment drugs having the activity to treat sensitive tumors.
The above pharmaceutical composition may be prepared in certain forms and be administered by suitable routes, such as oral, parenteral (including subcutaneous, intramuscular, intravenous or intradermal), rectal, transdermal, nasal, vaginal, etc. The suitable pharmaceutical dosage forms for oral route include tablets, capsules, granules, pulvisie, pills, powders, pastilles, solutions, syrups, suspensions, etc, which, according to the actual demand, may be suitable for rapid release, delayed release or adjustable release of pharmaceutical active ingredients. The suitable pharmaceutical dosage forms for parenteral routes include aqueous or non-aqueous sterile injectable solutions, emulsions or suspensions. The suitable pharmaceutical dosage forms for rectal routes include suppository or enema. The suitable pharmaceutical dosage forms for transdermal routes include ointments, creams and patches. The suitable pharmaceutical dosage forms for nasal routes include aerosols, sprays and nasal drops. The suitable pharmaceutical dosage forms for vaginal routes include suppository, plug agents, gels, pastes or sprays. Preferably, as the crystal forms of the present invention have unexpected low hygroscopicity and good stability in water or aqueous ethanol solution, they are particularly suitable for the preparation of tablets, suspensions, capsules, disintegrating tablets, immediate release tablets, slow release tablets and controlled release tablets; and more preferably, tablets, suspensions and capsules.
The pharmaceutically acceptable excipients in the above pharmaceutical composition, in case of the oral solid form, include but not limited to: diluents, such as starch, pregelatinized starch, lactose, powdered cellulose, microcrystalline cellulose, bicalcium phosphate, tricalcium phosphate, mannitol, sorbitol, and sugar; binders, such as Arabia gum, guar gum, gelatin, polyvinylpyrrolidone, hydroxypropyl cellulose, hydroxypropyl methylcellulose, and polyethylene glycol; disintegrating agents, such as starch, sodium starch glycolate, pregelatinized starch, cross-linked polyvinylpyrrolidone, cross-linked sodium carboxymethylcellulose, and colloidal silicon dioxide; lubricants, such as stearic acid, magnesium stearate, zinc stearate, sodium benzoate, and sodium acetate; flow aids, such as colloidal silicon dioxide; complex-forming agents, such as cyclodextrins and resins of various levels; release rate controlling agents, such as hydroxypropyl cellulose, carboxymethyl cellulose, hydroxypropyl methyl cellulose, ethyl cellulose, methyl cellulose, methyl methacrylate, and wax. The other useable pharmaceutical acceptable excipients include but not limited to film-forming agent, plasticizer, coloring agent, flavoring agent, viscosity regulator, preservative and antioxidant, etc. Optionally, tablets are coated with the coating layer; for example, providing shellac isolating coating, sugar coating or polymer coating. The coating layer may contain polymers such as hydroxypropyl methyl cellulose, polyvinyl alcohol, ethyl cellulose, methyl acrylic polymer, hydroxypropyl cellulose or starch, and may also contain antiadherents, such as silica, talcum powder; opacifying agents, such as titanium dioxide; colorants, such as iron oxide. In case of the oral liquid form, the suitable excipients include water, oils, alcohol, glycol, flavoring agents, preservatives, stabilizers and colorants. The aqueous or non-aqueous sterile suspensions may contain suspending agents and thickeners. The suitable excipients for the aqueous suspension include synthetic gum or natural gum, such as Arabia gum, Cocklebur gum, alginate, glucan, sodium carboxymethyl cellulose, methyl cellulose, polyvinyl pyrrolidone or gelatin. In case of parenteral route dosage forms, the excipients in aqueous or non-aqueous sterile injection solutions generally are sterile water, normal saline or dextrose in water, and may contain buffering agent, antioxidant, antibacterial agent, and the solutes which enable the pharmaceutical composition isotonic with blood, etc. Each excipient must be acceptable, be compatible with the other ingredients in the formula and harmless to patients.
The pharmaceutical composition may be prepared by the methods in the art known to the scientists in this field. When preparing the pharmaceutical composition, mix Crystal Form VI, Crystal Form VII, Crystal Form III, Crystal Form IV, Crystal Form V, Crystal Form VIII, Crystal Form Ie, Crystal Form VIIb or Crystal Form VIIIa of Dabrafenib of the present invention with one or more pharmaceutically acceptable excipients, and optionally, mix with one or more of other active pharmaceutical ingredients. For example, tablets, capsules and granules may be prepared with such technologies as mixing, granulation, tableting, capsule filling, etc; powders may be prepared by mixing the pulverized active pharmaceutical ingredients with suitable size and excipients; solutions and syrups may be prepared by dissolving active pharmaceutical ingredients into the appropriately flavored water or aqueous solution; suspensions may be prepared by dispersing active pharmaceutical ingredients in the pharmaceutically acceptable carriers.
What should be specially mentioned is the wet granulation process for solid preparations. With the wet granulation of tablets as the example, the preparation process is as follows: mix the dry solids such as the active ingredient, the bulking agent, the binder, etc. and then wet them with a wetting agent such as water or alcohol; coagulate or granulate the wetted solids; continue the wet granulating until the required particle size of granules were uniformly obtained; after that, dry the granules. Then, mix the dried granules with a disintegrating agent, lubricant(s), antiadherent(s), etc.; tablet the mixture in a tableting machine; and optionally, coat the tablets with suitable coating powders.
What should be specially mentioned is the oral suspension. One advantage of this administration form is that patients need not to swallow solids, especially for elderly people, children or patients with injuries in the mouth or the throat, who may have difficulties in swallowing solids. The suspension is a two-phase system formed by dispersing solid grains into a liquid. For example, Crystal Form VI, Crystal Form VII, Crystal Form III, Crystal Form IV, Crystal Form V, Crystal Form VIII, Crystal Form Ie, Crystal Form VIIb or Crystal Form VIIIa of Dabrafenib of the present invention can keep its original solid form in water or an aqueous carrier of the suspension. The other ingredients in the oral suspension may include buffering agents, surface active agents, viscosity regulators, preservatives, antioxidants, colorants, flavoring agents and taste masking agents.
In addition, the present invention provides uses of Crystal Form VI, Crystal Form VII, Crystal Form III, Crystal Form IV, Crystal Form V, Crystal Form VIII, Crystal Form Ie, Crystal Form VIIb or Crystal Form VIIIa of Dabrafenib of the present invention in making drugs for inhibiting one or more Raf-family kinases.
In addition, the present invention provides a method of treating and/or preventing diseases associated with one or more Raf-family kinases, which comprising the administration of a therapeutically and/or preventively effective amount of Crystal Form VI, Crystal Form VII, Crystal Form III, Crystal Form IV, Crystal Form V, Crystal Form VIII, Crystal Form Ie, Crystal Form VIIb or Crystal Form VIIIa of Dabrafenib or the pharmaceutical composition containing Crystal Form VI, Crystal Form VII, Crystal Form III, Crystal Form IV, Crystal Form V, Crystal Form VIII, Crystal Form Ie, Crystal Form VIIb or Crystal Form VIIIa of Dabrafenib to the patients in need thereof. The patients include but not limited to mammals, such as humans.
The diseases associated with one or more Raf-family kinases include but not limited to sensitive tumors. The specific categories of sensitive tumors can refer to patent documents WO2009/137391 or U.S. Pat. No. 7,994,185. The “Sensitive Tumors” refers to the tumors which are sensitive to the treatment by kinase inhibitors, especially the tumors which are sensitive to the treatment by Raf inhibitor. The tumors associated with inappropriate activity of one or more Raf-family kinases, and particularly the tumors which exhibit the mutation of the Raf-family kinases, the overexpression of the Raf-family kinases, the mutation of the upstream activators of the Raf-family kinases, or the overexpression of the upstream activators of the Raf-family kinases, and are therefore sensitive to the treatment by Raf inhibitors are known in the prior art, including primary and metastatic tumors and cancers. The specific examples of sensitive tumors include but not limited to: Barret's adenocarcinoma; biliary tract carcinoma; breast cancer; cervical carcinoma; cholangiocarcinoma; central nervous system tumors including primary CNS tumors such as glioblastoma, astrocytoma and ependymal cell tumor, and secondary CNS tumors (i.e. metastatic tumor of central nervous system originates outside the central nervous system); colorectal cancer, including large intestinal colorectal cancer; gastric carcinoma; head and neck cancer including head and neck squamous cell carcinoma; hematological cancer including leukemia and lymphoma such as acute lymphocytic leukemia, acute myeloid leukemia, myelodysplastic syndrome, chronic myeloid leukemia, Hodgkin's lymphoma, non Hodgkin's lymphoma, megakaryocytic leukemia, multiple myeloma and erythroleukemia; hepatocellular carcinoma; lung cancer including small cell lung cancer and non-small cell lung cancer; ovarian cancer; endometrial carcinoma; pancreatic cancer; pituitary adenoma; prostate cancer; renal carcinoma; sarcoma; skin cancer including melanoma; and thyroid carcinoma.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is the X-ray powder diffraction pattern of Crystal Form VI of the present invention.
FIG. 2 is the PLM plot of Crystal Form VI of the present invention.
FIG. 3 is the DSC thermogram of Crystal Form VI of the present invention.
FIG. 4 is the TGA thermogram of Crystal Form VI of the present invention.
FIG. 5 is the dynamic vapor sorption isothermal of Crystal Form VI of the present invention.
FIG. 6 is another X-ray powder diffraction pattern of Crystal Form VI of the present invention.
FIG. 7 is another X-ray powder diffraction pattern of Crystal Form VI of the present invention.
FIG. 8 is the X-ray powder diffraction pattern of Crystal Form VII of the present invention.
FIG. 9 is the PLM plot of Crystal Form VII of the present invention.
FIG. 10 is the DSC thermogram of Crystal Form VII of the present invention.
FIG. 11 is the TGA thermogram of Crystal Form VII of the present invention.
FIG. 12 is the dynamic vapor sorption isotherm of Crystal Form VII of the present invention.
FIG. 13 is another X-ray powder diffraction pattern of Crystal Form VII of the present invention.
FIG. 14 is another X-ray powder diffraction pattern of Crystal Form VII of the present invention.
FIG. 15 is the X-ray powder diffraction pattern of Crystal Form III of the present invention.
FIG. 16 is the X-ray powder diffraction pattern of Crystal Form IV of the present invention.
FIG. 17 is the X-ray powder diffraction pattern of Crystal Form V of the present invention.
FIG. 18 is the X-ray powder diffraction pattern of Crystal Form VIII of the present invention.
FIG. 19 is the X-ray powder diffraction pattern of Crystal Form Ie of the present invention.
FIG. 20 is the X-ray powder diffraction pattern of Crystal Form VIIb of the present invention.
FIG. 21 is the X-ray powder diffraction pattern of Crystal Form VIIIa of the present invention.
FIG. 22 is the X-ray powder diffraction pattern of the Known Crystal Form 2 prepared by the method described in example 58b of patent document WO2009/137391A2 or U.S. Pat. No. 7,994,185B2.
FIG. 23 is the PLM plot of the Known Crystal Form 2 prepared by the method described in example 58b of patent document WO2009/137391A2 or U.S. Pat. No. 7,994,185B2.
FIG. 24 is the dynamic vapor sorption isothermal of the Known Crystal Form 2 prepared by the method described in example 58b of patent document WO2009/137391A2 or U.S. Pat. No. 7,994,185B2.
FIG. 25 is the X-ray powder diffraction pattern of the Known Crystal Form 1 prepared by the method described in example 58a of patent document WO2009/137391A2 or U.S. Pat. No. 7,994,185B2.
FIG. 26 is the PLM plot of the Known Crystal Form 1 prepared by the method described in example 58a of patent document WO2009/137391A2 or U.S. Pat. No. 7,994,185B2.
FIG. 27 is the dynamic vapor sorption isotherm of the Known Crystal Form 1 prepared by the method described in example 58a of patent document WO2009/137391A2 or U.S. Pat. No. 7,994,185B2.
FIG. 28 is the X-ray powder diffraction comparison pattern of Crystal Form VI at various stages in Experimental Example 2 of the present invention (in the figure, the samples from top to bottom are: Crystal Form VI; the sample obtained by physically blending Crystal Form VI and the excipients according to the formula quantity of the preparation; the sample obtained by the wet granulation process with Crystal Form VI as API; and the sample obtained by physically blending the excipients according to the formula quantity of the preparation).
FIG. 29 is the X-ray powder diffraction comparison pattern of the Known Crystal Form 1 at various stages in Experimental Example 2 (in the figure, the samples from top to bottom are: Crystal Form VI, the Known Crystal Form 1; the sample obtained by the wet granulation process with the Known Crystal Form 1 as API; the sample obtained by physically blending the Known Crystal Form 1 and the excipients according to the formula quantity of the preparation; and the sample obtained by physically blending the excipients according to the formula quantity of the preparation).
FIG. 30 is the X-ray powder diffraction comparison pattern of the Known Crystal Form 2 at various stages in Experimental Example 2 (in the figure, the samples from top to bottom are followed by: Crystal Form VI; the Known Crystal Form 2; the sample obtained by the wet granulation process with the Known Crystal Form 2 as API; the sample obtained by physically blending the Known Crystal Form 2 and the excipients according to the formula quantity of the preparation; and the sample obtained by physically blending the excipients according to the formula quantity of the preparation).
DETAILED DESCRIPTION OF EMBODIMENTS
The present invention is defined with further reference to the following examples, which describe the preparation and usage of the crystal forms of the present invention in details. It is obvious to the scientists in this field that various changes in materials and methods may be embodied without deviating from the scope of the present invention. Instruments and methods used for data collection
The instrument for X-ray powder diffraction (XPRD) is Bruker D8 Advance diffractometer, which uses the Cu Kα X-ray with 1.54 angstroms in wavelength, under the operation conditions of 40 kV and 40 mA, 0˜20 goniometer, Mo monochromator and Lynxeye detector. Prior to use, the instrument is calibrated with the standard substance (generally corindon) attached. The acquisition software is Diffrac Plus XRD Commander. The sample is examined at room temperature, and placed on sample holder. The detailed testing conditions are as follows: range: 3˜40°2θ; step size: 0.02°2θ; speed: 0.2 s/step.
Polarized Light Microscope (PLM) plots are collected from XP-500E polarized light microscope (by Shanghai Changfang Optical Instrument Co., Ltd). Place a small amount of powder sample on a slide glass, drip some mineral oil to disperse the powder sample, place the cover slip, then place the sample on the loading table of XP-500E polarized light microscope, choose the appropriate magnitude to observe the morphology of the sample and take pictures thereof.
The particle size distribution (PSD) plot is obtained using Microtrac S3500 laser diffraction particle size analyzer. The method parameters are as follows: flow velocity of the dispersant is 50%; the dispersant is water (added with 2% tween-80); the sample refractivity is 1.58; the laser source wavelength is 780 nm; and the integral mode is volume.
The Differential Scanning Calorimeter (DSC) data are collected by TA Instruments Q200 MDSC; the instrument control software is Thermal Advantage and the analysis software is Universal Analysis. Generally, take 1˜10 mg of the sample and place it in an uncovered (unless otherwise specified) aluminum pan and under the protection of 50 mL/min dry N 2 , heat the sample from room temperature to 250° C. at the heating rate of 10° C./min; and heat absorption by and heat release from the sample during the course are recorded by TA software simultaneously. In the present application, the melting point is reported based on DSC onset temperature.
The thermogravimetric analysis (TGA) data are collected by TA Instruments Q500 TGA; the instrument control software is Thermal Advantage and the analysis software is Universal Analysis. Generally, take 5˜15 mg sample and place it in a platinum pan, adopt the segmental high-resolution testing mode, and under the protection of 50 mL/min dry N 2 , heat the sample from room temperature to 300° C. at the heating rate of 10° C./min, the weight changes of the sample during the course are recorded by TA software simultaneously.
The nuclear magnetic resonance hydrogen spectrum ( 1 HNMR) data are collected by Bruker Avance II DMX 400M HZ NMR spectrometer. Weigh 1˜5 mg of the sample, dissolve it with 0.5 mL DMSO-d6 to get a 2 mg/mL-10 mg/mL solution.
The dynamic vapor sorption analysis (DVS) data are collected by TA Instruments Q5000 TGA; the instrument control software is Thermal Advantage and the analysis software is Universal Analysis. Generally, take 1˜10 mg of the sample and place it in a platinum pan, and the weight changes of the sample are recorded during the course of the relative humidity changing from 0% to 80% and then to 0%. According to the specifics of the samples, different adsorption and desorption steps may be used.
Preparation Example 1
The preparation of the Known Crystal Form 1: Refer to the preparation method described in example 58a of patent document WO2009/137391A2 or U.S. Pat. No. 7,994,185B2, with the details as follows:
Add N-{3-[5-(2-chloro-4-pyrimidinyl)-2-(1,1-dimethylethyl)-1,3-thiazol-4-yl]-2-fluorophenyl}-2,6-difluorobenzenesulfonamide (196 mg, 0.364 mmol) and 7M methanol solution of ammonia (8 ml, 56 mmol) into a 25 mL autoclave, heat to 90° C. and react for 24 h; when the TLC shows the raw material is completely reacted, cool the above reaction system to room temperature, filter to get N-{3-[5-(2-amino-4-pyrimidinyl)-2-(1,1-dimethylethyl)-1,3-thiazol-4-yl]-2-fluorophenyl}-2,6-difluorobenzenesulfonamide (i.e. Dabrafenib). 1 H-NMR (400 MHz, DMSO-d6) δppm 10.83 (s, 1H), 7.93 (d, J=5.2 Hz, 1H), 7.55-7.70 (m, 1H), 7.35-7.43 (m, 1H), 7.31 (t, J=6.3 Hz, 1H), 7.14-7.27 (m, 3H), 6.70 (s, 2H), 5.79 (d, J=5.13 Hz, 1H), 1.35 (s, 9H).
The XPRD pattern is as shown in FIG. 25 and is substantially the same as that of the Known Crystal Form 1 of Dabrafenib prepared in example 58a of patent document U.S. Pat. No. 7,994,185B2.
The PLM plot is as shown in FIG. 26 . It shows small block-shaped crystals.
PSD shows: D10, D50 and D90 are 40 μm, 104 μm and 151 μm, respectively.
The dynamic vapor sorption isothermal is as shown in FIG. 27 . It shows: the weight change is 1.9% between 20% RH˜80% RH.
Preparation Example 2
The Known Crystal Form 2 may be prepared by the following method: Refer to the preparation method described in example 58b of patent document WO2009/137391A2 or U.S. Pat. No. 7,994,185B2, with the details as follows: At room temperature, add 19.6 mg of the Known Crystal Form 1 prepared by the method described in example 58a of patent document WO2009/137391A2 or U.S. Pat. No. 7,994,185B2 and 500 μL of ethyl acetate in a 2 mL-vial, circulate the slurry for 48 h at 0˜40° C., then cool to room temperature, filter to get the solids.
The XPRD pattern is shown in FIG. 22 and is substantially the same as that of the Known Crystal Form 2 of Dabrafenib disclosed by patent document WO2012/148588A2.
The PLM plot is shown in FIG. 23 . It shows small block-shaped crystals.
PSD shows: D10, D50 and D90 are 16 μm, 36 μm and 74 μm, respectively.
The dynamic vapor sorption isotherm is shown in FIG. 24 . It shows: the weight change is 0.03% between 20% RH˜80% RH.
Preparation Example 3
Preparation of the amorphous form: Take 10 mg of the Known Crystal Form 2 of Dabrafenib and place it in a 5 mL-vial, add 4 mL of anhydrous ethanol, take the ultrasonic treatment until the solution becomes clear; then remove the solvent completely by the rotary evaporation at 40° C. to get an oil.
Unless otherwise specified, all the following examples are operated at room temperature.
In the examples, the ultrasonic operation facilitates the dissolution of the sample. Place the container filled with the suspension of the sample in the ultrasonic cleaner and treat it for 1˜30 min at the working power of 20 Khz˜40 Khz. Generally, keep the ultrasonic treatment for 5 min at the ultrasonic power of 40 Khz.
In the examples, the operation of the rotary evaporation is as follows: At the temperature between room temperature and the boiling point of the solvent (preferably 30˜50° C.), and under the pressure below the atmospheric pressure (preferably below 0.08 MPa), the operation is carried out at the rotation speed of 10˜180 rpm (preferably 50˜100 rpm).
Example 1
Take 5.0 mg the Known Crystal Form 2 of Dabrafenib and place it into a 250 mL round-bottom flask, add 200 mL of water, use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 20 times of its solubility in water at room temperature), stir it for 7 days at room temperature, centrifugate, and then dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 3.4 mg and the yield is 68%.
The XPRD pattern is as shown in FIG. 1 .
The PLM plot is as shown in FIG. 2 . It shows fine crystals.
PSD shows: D10, D50 and D90 are 7 pun, 18 μm and 40 μm, respectively.
The DSC thermogram is as shown in FIG. 3 . It shows: Crystal Form VI has a wide and large endothermic peak (the solvent peak) at 64˜128° C. and the melting point of the dehydrated sample is 206° C.
The TGA thermogram is as shown in FIG. 4 . It shows the weight loss of Crystal Form VI prior to 112° C. is about 3.8% and the decomposition temperature is 271° C. Based on the weight loss of TGA, it is confirmed that Crystal Form VI is monohydrate.
The dynamic vapor sorption isotherm is as shown in FIG. 5 . It shows the weight change is 0.5% between 20% RH˜80% RH.
The above test results show that Crystal Form VI is very stable at high temperature and not hygroscopic.
Example 2
Take 8.4 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL vial, add 0.3 mL aqueous methanol solution (wherein the water volume content is 0.01%), use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 1.5 times of its solubility in the mentioned aqueous methanol solution at room temperature), stir it for 3 days at room temperature, centrifugate, and then dry it in a vacuum oven for 24 h at room temperature to get Crystal Form VI of the present invention. The product is 6.7 mg and the yield is 80%. The XPRD pattern is as shown in FIG. 6 and is substantially same as FIG. 1 .
Example 3
Take 7.9 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 0.5 mL of aqueous ethanol solution (wherein the water volume content is 80%), use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 3 times of its solubility in the mentioned aqueous ethanol solution at room temperature), stir it for 3 days at 40° C., centrifugate, and then dry it in vacuum for 24 h at room temperature to get Crystal Form VI of the present invention. The product is 6.1 mg and the yield is 77%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 4
Take 6.7 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 1.0 mL of aqueous isopropanol solution (wherein the water volume content is 99.99%), use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 10 times of its solubility in the mentioned aqueous isopropanol solution at room temperature), stir it for 7 days at room temperature, centrifugate, and then dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 4.9 mg and the yield is 73%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 5
Take 4.1 mg of the Known Crystal Form 1 of Dabrafenib and place it into a 5 mL-vial, add 0.35 mL of water-saturated n-butanol solution, use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 20 times of its solubility in the water-saturated n-butanol solution at 60° C.), stir it for 7 days at 60° C., centrifugate, and then dry it in a vacuum oven for 48 h at 60° C. to get Crystal Form VI of the present invention. The product is 2.9 mg and the yield is 71%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 6
Take 6.9 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 4.0 mL of water-saturated nitromethane solution, use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 1.5 times of its solubility in the water-saturated nitromethane solution at 60° C.), stir it for 7 days at 60° C., centrifugate, and then dry it in vacuum for 48 h at 60° C. to get Crystal Form VI of the present invention. The product is 4.0 mg and the yield is 58%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 7
Take 4.1 mg of the amorphous form of Dabrafenib and place it into a 5 mL-vial, add 0.1 mL of aqueous acetone solution (wherein the water volume content is 0.1%), use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 1.5 times of its solubility in the mentioned aqueous acetone solution at room temperature), stir it for 14 days at room temperature, centrifugate, and then dry it in a vacuum oven for 2 h at room temperature to get Crystal Form VI of the present invention. The product is 3.8 mg and the yield is 93%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 8
Take 9.4 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 0.3 mL of water-saturated butanone solution, use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 1.5 times of its solubility in the water-saturated butanone solution at room temperature), stir it for 7 days at room temperature, centrifugate, and then dry it in a vacuum oven for 2 h at room temperature to get Crystal Form VI of the present invention. The product is 6.8 mg and the yield is 72%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 9
Take 15.3 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 0.3 mL of water-saturated ethyl ether solution, use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 10 times of its solubility in the water-saturated ethyl ether solution at room temperature), stir it for 14 days at room temperature, centrifugate, and then dry it in a vacuum oven for 2 h at room temperature to get Crystal Form VI of the present invention. The product is 12.7 mg and the yield is 83%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 10
Take 18.9 mg of the amorphous form of Dabrafenib and place it into a 5 mL-vial, add 0.5 mL of water-saturated ethyl acetate solution, use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 2 times of its solubility in the water-saturated ethyl acetate solution at room temperature), stir it for 7 days at 40° C., centrifugate, and then dry it in a vacuum oven for 24 h at room temperature to get Crystal Form VI of the present invention. The product is 17.7 mg and the yield is 94%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 11
Take 1.3 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 0.5 mL of water-saturated methyl tert-butyl ether solution, use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 20 times of its solubility in the water-saturated methyl tert-butyl ether solution at room temperature), stir it for 14 days at room temperature, centrifugate, and then dry it in vacuum for 2 h at room temperature to get Crystal Form VI of the present invention. The product is 0.8 mg and the yield is 62%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 12
Take 10.3 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 0.4 mL of water-saturated isopropyl acetate solution, use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 1.5 times of its solubility in the water-saturated isopropyl acetate solution at room temperature), stir it for 3 days at room temperature, centrifugate, and then dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 6.8 mg and the yield is 66%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 13
Take 10.3 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 0.1 mL of aqueous tetrahydrofuran solution (wherein the water volume content is 0.1%), use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 1.5 times of its solubility in the mentioned aqueous tetrahydrofuran solution at room temperature), stir it for 3 days at room temperature, centrifugate, and then dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 6.8 mg and the yield is 66%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 14
Take 10.3 mg of the Known Crystal Form 1 of Dabrafenib and place it into a 5 mL-vial, add 0.8 mL of aqueous acetonitrile solution (wherein the water volume content is 20%), use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 5 times of its solubility in the mentioned aqueous acetonitrile solution at room temperature), stir it for 3 days at room temperature, centrifugate, and then dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 6.8 mg and the yield is 66%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 15
Take 1.0 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 4.0 mL water-saturated n-hexane solution, use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 20 times of its solubility in the water-saturated n-hexane solution at room temperature), stir it for 14 days at 40° C., centrifugate, and then dry it in a vacuum oven for 24 h at room temperature to get Crystal Form VI of the present invention. The product is 0.6 mg and the yield is 60%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 16
Take 1.2 mg of the Known Crystal Form 1 of Dabrafenib and place it into a 5 mL vial, add 5.0 mL of water-saturated n-heptane solution, use the ultrasonic treatment to get a suspension (wherein the quantity of Dabrafenib is 20 times of its solubility in the water-saturated n-heptane solution at room temperature), stir it for 7 days at room temperature, centrifugate, and then dry it in a vacuum oven for 24 h at room temperature to get Crystal Form VI of the present invention. The product is 0.5 mg and the yield is 42%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 17
Take 4.8 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 20 mL-vial, add 1.6 mL aqueous isopropanol solution (wherein the water volume content is 0.1%), use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 μm organic filter membrane, place the uncovered vial filled with the filtrate in a sealed 100 mL-space filled with 15 mL of mineral ether—for 3 weeks, centrifugate until after mineral ether diffused into the isopropanol solution and a great amount of solids emerge, dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 4.0 mg and the yield is 83%. The XPRD pattern is as shown in FIG. 7 and substantially the same as FIG. 1 .
Example 18
Take 0.4 mg of the amorphous form of Dabrafenib and place it into a 20 mL-vial, add 4.0 mL of aqueous isopropanol solution (wherein the water volume content is 10%), use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 μm organic filter membrane, place the uncovered vial filled with the filtrate in a sealed 100 mL space filled with 15 mL of isopropyl ether—for 1 week, centrifugate until after isopropyl ether diffused into the isopropanol solution and a great amount of solids emerge, dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 0.1 mg and the yield is 25%. Its XPRD pattern is substantially same as FIG. 1 .
Example 19
Take 2.5 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 20 mL-vial, add 0.5 mL of aqueous nitromethane solution (wherein the water volume content is 1%), use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 μm organic filter membrane, place the uncovered vial filled with the filtrate in a sealed 100 mL-space filled with 15 mL of isopropyl ether—for 3 weeks, centrifugate until after isopropyl ether diffused into the nitromethane solution and a great amount of solids emerge, dry it in a vacuum oven for 48 h at 40° C. to get Crystal Form VI of the present invention. The product is 1.9 mg and the yield is 76%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 20
Take 0.5 mg of the Known Crystal Form 1 of Dabrafenib and place it into a 20 mL-vial, add 5 mL of aqueous nitromethane solution (wherein the water volume content is 0.01%), use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 μm organic filter membrane, place the uncovered vial filled with the filtrate in a sealed 100 mL space filled with 15 mL of mineral ether—for 3 weeks, centrifugate until after mineral ether diffused into the nitromethane solution and a great amount of solids emerge, dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 0.2 mg and the yield is 40%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 21
At room temperature, take 9.5 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 20 mL-vial, add 1.5 mL of methanol, use the ultrasonic treatment for 5 mins to dissolve the sample completely (wherein the quantity of Dabrafenib is 0.5 times of its solubility in methanol at room temperature), in which add 0.15 mL of water dropwise to get white solid immediately, stir it for 7 days at room temperature, centrifugate, and dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 9.0 mg and the yield is 95%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 22
At room temperature, take 0.6 mg of the Known Crystal Form 1 of Dabrafenib and place it into a 20 mL-vial, add 5 mL of n-butanol, use the ultrasonic treatment for 5 min, then filter it with 0.45 μm organic filter membrane to get the filtrate (wherein the quantity of Dabrafenib is 1 time of its solubility in n-butanol at room temperature), in which dropwise add 2.5 mL of n-hexane phase of the water-saturated n-hexane solution to get white solid immediately, stir it for 10 days at room temperature, centrifugate, and dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 0.4 mg and the yield is 67%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 23
At room temperature, take 19.0 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 100 mL-round-bottomed flask, add 1 mL of ethyl acetate, use the ultrasonic treatment for 5 min to dissolve the sample completely (wherein the quantity of Dabrafenib is 1 time of its solubility in ethyl acetate at room temperature), in which dropwise add 50 mL of n-heptane phase of the water-saturated n-heptane solution to get white solid immediately, stir it for 10 days at room temperature, centrifugate, and dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 15.1 mg and the yield is 79%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 24
At room temperature, take 3.2 mg of the amorphous form of Dabrafenib and place it into a 300 mL-round-bottomed flask, add 2.5 mL of isopropyl acetate, use the ultrasonic treatment for 5 min to dissolve the sample completely (wherein the quantity of Dabrafenib is 0.1 times of its solubility in isopropyl acetate at room temperature), in which add 250 mL of cyclohexane phase of the water-saturated cyclohexane solution dropwise to get white solid immediately, stir it for 10 days at 40° C., centrifugate, and dry it in vacuum for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 0.8 mg and the yield is 25%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 25
At room temperature, take 4.2 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 1 mL of ethyl ether, use the ultrasonic treatment for 5 min to dissolve the sample completely (wherein the quantity of Dabrafenib is 1 time of its solubility in ethyl ether at room temperature), in which add 0.5 mL of methyl cyclohexane phase of the water-saturated methyl cyclohexane solution dropwise to get white solid immediately, stir it for 7 days at room temperature, centrifugate, and dry it in vacuum for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 3.3 mg and the yield is 78%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 26
At room temperature, take 5.2 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 1 mL of methyl tert-butyl ether, use the ultrasonic treatment for 5 min to dissolve the sample completely (wherein the quantity of Dabrafenib is 1 time of its solubility in methyl tert-butyl ether at room temperature), in which add 0.5 mL of methyl cyclohexane phase of the water-saturated methyl cyclohexane solution dropwise to get white solid immediately, stir it for 7 days at room temperature, centrifugate, and dry it in vacuum for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 5.0 mg and the yield is 96%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 27
At room temperature, take 23.2 mg of the Known Crystal Form 1 of Dabrafenib and place it into a 5 mL-vial, add 1 mL of acetone, use the ultrasonic treatment for 5 mins to dissolve the sample completely (wherein the quantity of Dabrafenib is 1 time of its solubility in acetone at room temperature), in which add 0.1 mL of water dropwise to get white solid immediately, stir it for 3 days at room temperature, centrifugate, and dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 19.3 mg and the yield is 83%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 28
At room temperature, take 15.3 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 20 mL-vial, add 1 mL of butanone, use the ultrasonic treatment for 5 mins to dissolve the sample completely (wherein the quantity of Dabrafenib is 1 time of its solubility in butanone at room temperature), in which add 10 mL of cyclohexane phase of the water-saturated cyclohexane solution dropwise to get white solid immediately, stir it for 8 days at 40° C., centrifugate, and dry it in a vacuum oven for 48 h at 40° C. to get Crystal Form VI of the present invention. The product is 7.3 mg and the yield is 46%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 29
At room temperature, take 20.1 mg of the amorphous form of Dabrafenib and place it into a 50 mL-vial, add 0.3 mL of tetrahydrofuran, use the ultrasonic treatment for 5 min to dissolve the sample completely (wherein the quantity of Dabrafenib is 1 time of its solubility in tetrahydrofuran at room temperature), in which add 30 mL of water dropwise to get white solid immediately, stir it for 1 week at room temperature, centrifugate, and dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 15.2 mg and the yield is 76%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 30
At 60° C., take 3.5 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 1 mL of nitromethane, use the ultrasonic treatment for 5 mins to dissolve the sample completely (wherein the quantity of Dabrafenib is 1 time of its solubility in nitromethane at room temperature), in which add 0.5 mL of methyl cyclohexane phase of the water-saturated methyl cyclohexane solution dropwisely to get white solid immediately, stir it for 14 days at 60° C., centrifugate, and dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 2.1 mg and the yield is 60%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 31
At room temperature, take 6.5 mg of the Known Crystal Form 1 of Dabrafenib and place it into a 5 mL-vial, add 1 mL of acetonitrile, use the ultrasonic treatment for 5 mins to dissolve the sample completely (wherein the quantity of Dabrafenib is 1 time of its solubility in acetonitrile at room temperature), in which add 0.5 mL of water dropwise to get white solid immediately, stir it for 3 days at room temperature, centrifugate, and dry it in vacuum for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 6.2 mg and the yield is 95%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 32
Take 18.2 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 0.8 mL of aqueous methanol solution (wherein the water volume content is 0.01%), heat to 50° C. in a water bath, stir until the sample is completely dissolved (wherein the quantity of Dabrafenib is 1 time of its solubility in the mentioned aqueous methanol solution at 50° C.), turn off the water bath to naturally cool to room temperature, then continue stirring for 3 days to get white solid, centrifugate, and dry it in vacuum for 24 h at room temperature to get Crystal Form VI of the present invention. The product is 11.6 mg and the yield is 64%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 33
Take 4.8 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 3 mL water-saturated n-butanol solution and heat to 80° C. in a water bath, stir until the sample is completely dissolved (wherein the quantity of Dabrafenib is 1 time of its solubility in water-saturated n-butanol solution at 80° C.), close the water bath to naturally cool to room temperature, then continue stirring for 7 days to get white solid, centrifugate, and dry it in vacuum for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 1.6 mg and the yield is 33%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 34
Take 10.1 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 0.1 mL of water-saturated ethyl acetate solution, heat to 60° C. in a water bath, stir until the sample is completely dissolved (wherein the quantity of Dabrafenib is 0.5 times of its solubility in water-saturated ethyl acetate solution at 60° C.), turn off the water bath to naturally cool to room temperature, then continue stirring for 7 days to get white solid, centrifugate, and dry it in vacuum for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 6.7 mg and the yield is 66%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 35
Take 8.6 mg of the Known Crystal Form 1 of Dabrafenib and place it into a 5 mL-vial, add 0.4 mL of water-saturated isopropyl acetate solution, heat to 40° C. in a water bath, stir until the sample is completely dissolved (wherein the quantity of Dabrafenib is 0.1 times of its solubility in water-saturated isopropyl acetate solution at 40° C.), stir for 14 days at 0° C. to get white solid, centrifugate, and dry it in vacuum for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 5.8 mg and the yield is 67%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 36
Take 8.1 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 1 mL of water-saturated ethyl ether solution and heat to 50° C. in a water bath, stir until the sample is completely dissolved (wherein the quantity of Dabrafenib is 1 time of its solubility in water-saturated ethyl ether solution at 50° C.), turn off the water bath to naturally cool to room temperature, then continue stirring for 14 days to get white solid, centrifugate, and dry it in vacuum for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 3.0 mg and the yield is 37%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 37
Take 21.4 mg of the amorphous form of Dabrafenib and place it into a 5 mL-vial, add 5 mL of water-saturated methyl tert-butyl ether solution, heat to 50° C. in a water bath (wherein the quantity of Dabrafenib is 1 time of its solubility in water-saturated methyl tert-butyl ether solution at 50° C.), stir until the sample is completely dissolved, turn off the water bath to naturally cool to room temperature, then continue stirring for 14 days to get white solid, centrifugate, and dry it in vacuum for 24 h at room temperature to get Crystal Form VI of the present invention. The product is 10.3 mg and the yield is 48%. Its XPRD pattern is substantially the same as in FIG. 1 .
Example 38
Take 11.4 mg of the Known Crystal Form 1 of Dabrafenib and place it into a 5 mL-vial, add 0.2 mL of aqueous acetone solution (wherein the water volume content is 0.1%) and heat to 50° C. in a water bath, stir until the sample is completely dissolved (wherein the quantity of Dabrafenib is 1 time of its solubility in the mentioned aqueous acetone solution at 50° C.), turn off the water bath to naturally cool to room temperature, then continue stirring for 3 days to get white solid, centrifugate, and dry it in vacuum for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 3.0 mg and the yield is 30%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 39
Take 11.2 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 0.7 mL of water-saturated butanone solution and heat to 40° C. in a water bath, stir until the sample is completely dissolved (wherein the quantity of Dabrafenib is 0.1 times of its solubility in water-saturated acetone solution at 40° C.), stir for 14 days at 0° C. to get white solid, centrifugate, and dry it in vacuum for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 2.0 mg and the yield is 18%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 40
Take 7.3 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 0.1 mL of aqueous tetrahydrofuran solution (wherein the water volume content is 50%) and heat to 50° C. in a water bath, stir until the sample is completely dissolved (wherein the quantity of Dabrafenib is 0.1 times of its solubility in the mentioned aqueous tetrahydrofuran solution at 50° C.), turn off the water bath to naturally cool to room temperature, then continue stirring for 3 days to get white solid, centrifugate, and dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 1.2 mg and the yield is 16%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 41
Take 8.1 mg of the Known Crystal Form 1 of Dabrafenib and place it into a 5 mL-vial, add 1 mL of water-saturated nitromethane solution and heat to 40° C. in a water bath, stir until the sample is completely dissolved (wherein the quantity of Dabrafenib is 0.5 times of its solubility in water-saturated nitromethane solution at 80° C.), turn off the water bath to naturally cool to room temperature, then continue stirring for 7 days to get white solid, centrifugate, and dry it in vacuum for 24 h at 40° C. to get Crystal Form VI of the present invention. The product is 5.0 mg and the yield is 62%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 42
Take 12.3 mg of the amorphous form of Dabrafenib and place it into a 5 mL-vial, add 0.8 mL of aqueous acetonitrile solution (wherein the water volume content is 50%) and heat to 80° C. in a water bath, stir until the sample is completely dissolved (wherein the quantity of Dabrafenib is 0.5 times of its solubility in the mentioned aqueous acetonitrile solution at 80° C.), turn off the water bath to naturally cool to room temperature, then continue stirring for 1 week to get white solid, centrifugate, and dry it in vacuum for 16 h at 40° C. to get Crystal Form VI of the present invention. The product is 4.2 mg and the yield is 34%. Its XPRD pattern is substantially the same as FIG. 1 .
Example 43
At room temperature, take 5.0 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 20 mL-vial, add 1.7 mL of isopropyl acetate, use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 μm membrane, place the uncovered vial filled with the filtrate in a sealed 100 mL space filled with 15 mL of isopropyl ether—for 3 weeks, centrifugate until after isopropyl ether diffused into the isopropyl acetate solution and a great amount of solids emerge, dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VII of the present invention. The product is 4.0 mg and the yield is 80%.
The XPRD pattern is as shown in FIG. 8 .
The PLM plot is as shown in FIG. 9 . It shows rod-shaped crystals.
PSD shows: D10, D50 and D90 are 91 μm, 207 μm and 378 μm, respectively. And the particle size is larger than that of the Known Crystal Form 1 and the Known Crystal Form 2.
The DSC thermogram is as shown in FIG. 10 . It shows: Crystal Form VII has a small endothermic peak at 192˜211° C. and the melting point thereafter is 226° C.
The TGA thermogram is as shown in FIG. 11 . It shows: Crystal Form VII has almost no weight loss prior to 175° C., about 0.6% weight loss between 175° C.˜212° C. and the decomposition temperature is 270° C.
The dynamic vapor sorption isotherm is as shown in FIG. 12 . It shows: the weight change is 0.1% between 20% RH˜80% RH.
The above test results show that Crystal Form VII has good morphology, is very stable at high temperature, and has low hygroscopicity.
Example 44
At room temperature, take 5.0 mg of the Known Crystal Form 1 of Dabrafenib and place it into a 20 mL-vial, add 1.0 mL of isopropyl acetate, use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 μm organic filter membrane, place the vial filled with the filtrate in a sealed 100 mL-space filled with 15 mL of mineral ether—for 1 week, centrifugate until after mineral ether diffused into the isopropyl acetate solution and a great amount of solids emerge, and dry it in vacuum for 24 h at 40° C. to get Crystal Form VII of the present invention. The product is 2.7 mg and the yield is 54%. Its XPRD pattern is substantially the same as FIG. 8 .
Example 45
Take 3.2 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 0.2 mL of ethyl acetate, use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 min organic filter membrane, place the vial filled with the filtrate (wherein the quantity of Dabrafenib is 0.5 times of its solubility in ethyl acetate at room temperature) at room temperature to volatilize and crystallize for 7 days, centrifugate the solid obtained, dry it in vacuum for 24 h at 40° C. to get Crystal Form VII of the present invention. The product is 2.0 mg and the yield is 62%. The XPRD pattern is as shown in FIG. 13 and is substantially the same as FIG. 8 .
Example 46
Take 4.3 mg of Crystal Form VI of Dabrafenib, heat it up to 125° C. at 10° C./min to remove the crystalline water, then cool naturally to room temperature, and dry the obtained crystals in a vacuum oven for 24 h at 40° C. to get Crystal Form VII of the present invention. The product is 4.0 mg and the yield is 93%. The XPRD pattern is as shown in FIG. 14 and is substantially the same as FIG. 8 .
Example 47
Take 10.1 mg of the oily form (the amorphous form) of Dabrafenib and place it into a 5 mL-vial, add 0.2 mL of isopropanol to form a suspension (wherein the quantity of the amorphous form is 10 times of its solubility in isopropanol at room temperature), stir to crystallize for 2 h, immediately centrifugate after the white solids emerge, dry it in vacuum for 24 h at 40° C. to get Crystal Form VII of the present invention. The product is 9.0 mg and the yield is 89%. Its XPRD pattern is substantially the same as FIG. 8 .
Example 48
Take 1.0 mg of the oily form (the amorphous form) of Dabrafenib and place it into a 5 mL-vial, add 5.0 mL of n-butanol to form a suspension (wherein the quantity of the amorphous form is 2 times of its solubility in butanol at room temperature), stir to crystallize for 0.2 h, immediately centrifugate after the white solids emerge, dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VII of the present invention. The product is 0.7 mg and the yield is 70%. Its XPRD pattern is substantially the same as FIG. 8 .
Example 49
Take 7.9 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 1.0 mL of ethanol, use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 μm organic filter membrane, add the filtrate (wherein the quantity of Dabrafenib is 0.5 times of its solubility in ethanol at room temperature) to a 30 ml-vial filled with 25 mL of n-heptane, stir it at room temperature for Imin until the white solid precipitated, immediately centrifugate it, dry it in vacuum for 24 h at 40° C. to get Crystal Form VII of the present invention. The product is 6.5 mg and the yield is 82%. Its XPRD pattern is substantially the same as FIG. 8 .
Example 50
Take 8.4 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 2 mL of ethyl ether, use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 μm organic filter membrane, add the filtrate (wherein the quantity of Dabrafenib is 1 times of its solubility in ethyl ether at room temperature) to a 20 ml-vial filled with 10 mL of methyl cyclohexane, stir it at room temperature for 30 min until the white solid precipitated, immediately centrifugate it, dry it in vacuum for 24 h at 40° C. to get Crystal Form VII of the present invention. The product is 6.5 mg and the yield is 77%. Its XPRD pattern is substantially the same as FIG. 8 .
Example 51
Take 7.9 mg of the amorphous form of Dabrafenib and place it into a 5 mL-vial, add 2 mL of 1,4-dioxane, use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 μm organic filter membrane, add the filtrate (wherein the quantity of Dabrafenib is 0.1 times of its solubility in 1,4-dioxane at room temperature) to a 25 ml-vial filled with 20 mL of water, stir it at room temperature for 60 min until the white solid precipitated, immediately centrifugate it, dry it in a vacuum oven for 24 h at 40° C. to get Crystal Form VII of the present invention. The product is 2.4 mg and the yield is 30%. Its XPRD pattern is substantially the same as FIG. 8 .
Example 52
Take 4.9 mg of the Known Crystal Form 1 of Dabrafenib and place it into a 5 mL vial, add 0.5 mL of isopropanol, use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 μm organic filter membrane, add the filtrate (wherein the quantity of Dabrafenib is 1 time of its solubility in isopropanol at room temperature) to a 20 ml-vial filled with 5 mL of cyclohexane, stir it at room temperature for 30 min until the white solid precipitated, immediately centrifugate it, dry it in vacuum for 24 h at 40° C. to get Crystal Form VII of the present invention. The product is 1.8 mg and the yield is 37%. Its XPRD pattern is substantially the same as FIG. 8 .
Example 53
Take 7.8 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 1 mL of sec-butanol, take the ultrasonic treatment to get a suspension, stir it at room temperature for 7 days, centrifugate, without drying, get Crystal Form III of the present invention. The product is 7.0 mg and the yield is 90%. Its XPRD pattern is as shown in FIG. 15 .
Example 54
Take 20.0 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 1 mL methyl tert-butyl ether, use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 μm organic filter membrane, place the vial filled with the filtrate to evaporate at room temperature for 1 week, centrifugate the precipitated crystal, without drying, get Crystal Form IV of the present invention. The product is 17.0 mg and the yield is 85%. Its XPRD pattern is as shown in FIG. 16 .
Example 55
Take 10.6 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 1 mL dichloromethane, use the ultrasonic treatment to get a suspension, stir it at room temperature for 7 days, centrifugate, without drying, get Crystal Form V of the present invention. The product is 7 mg and the yield is 66%. Its XPRD pattern is as shown in FIG. 17 .
Example 56
Take 15.0 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 20 mL-vial, add 4 mL of ethyl acetate, use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 μm organic filter membrane, place the vial filled with the filtrate in a sealed 100 mL space filled with 15 mL of isopropyl ether—for 3 weeks, centrifugate until after isopropyl ether diffused into the ethyl acetate solution and a great amount of solids emerge, then keep it for 2 h at room temperature to get Crystal Form VIII of the present invention. The product is 10.0 mg and the yield is 67%. Its XPRD pattern is as shown in FIG. 18 .
Example 57
Take 10.0 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 3 mL of toluene, raise the temperature to 60° C. until the solution becomes clear, filter it without cooling, then directly place the container filled with the filtrate into an environment at 0° C., immediately the solids precipitate, stir it for 0.2 h and then centrifugate, without drying, get Crystal Form Ie of the present invention. The product is 5.4 mg and the yield is 54%. Its XPRD pattern is as shown in FIG. 19 .
Example 58
Take 10.9 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 2 mL of ethanol, use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 μm organic filter membrane, rapidly rotary evaporate to dry to get an oil (an amorphous form). At room temperature, add 1 mL of toluene to form a suspension, stir it for 2 h, immediately the solid is precipitated, centrifugate, without drying, get Crystal Form Ie of the present invention. The product is 5.8 mg and the yield is 53%. Its XPRD pattern is as shown in FIG. 19 .
Example 59
Take 10.4 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 5 mL-vial, add 1 mL of butanone, use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 μm organic filter membrane, add 1 mL of methyl cyclohexane to the filtrate, immediately the solid is precipitated, centrifugate, directly take the wet sample (still containing some solvent) to get Crystal Form VIIb of the present invention. The product is 10.3 mg and the yield is 99%. Its XPRD pattern is as shown in FIG. 20 .
Example 60
Take 15.0 mg of the Known Crystal Form 2 of Dabrafenib and place it into a 20 mL-vial, add 2 mL of ethyl acetate, use the ultrasonic treatment until the solution becomes clear, then filter it with 0.45 μm organic filter membrane, place the vial filled with the filtrate in a sealed 100 mL space filled with 15 mL of isopropyl ether—at 30° C. for 7 days, centrifugate until after isopropyl ether diffused into the ethyl acetate solution and a great amount of solids emerge, directly take the wet sample (still containing some solvent) without drying to get Crystal Form VIIIa of the present invention. The product is 15.0 mg and the yield is 100%. Its XPRD pattern is as shown in FIG. 21 .
Experimental Example 1
Take Crystal Form VI of the present invention prepared by Example 1, Crystal Form VII of the present invention prepared by Example 43, the Known Crystal Form 1 prepared by Preparation Example 1 and the Known Crystal Form 2 prepared by Preparation Example 2, and compare them in stability, hygroscopicity and morphology. As the Known Crystal Form 3 is extremely unstable and converts to the Known Crystal Form 1 when placed at room temperature, it is not used for comparison.
The stability is compared by the storage stability and the competition test.
The storage stability test is: storing the sample under constant conditions (i.e. constant humidity or constant temperature) for a certain time, and then comparing the XRPDs before and after storing.
The competition test is: take equal amount of the samples, and respectively place them in isopropanol or in a mixture of water (pure water) and ethanol (wherein the volume percentage of ethanol is 0%, 20%, 50%, 80% and 100%, respectively) to form a suspension, stir it overnight at room temperature, then compare their XRPDs.
The hygroscopicity is obtained by DVS testing of the weight changes between 20%-80% RH.
The morphology comparison is obtained by PLM testing of particle shape and PSD testing of particle size.
The results are shown in the following Table 1.
TABLE 1
Property Comparison Results of Different Crystal Forms
Crystal form
Crystal Form VI
Crystal Form VII
the Known
the Known
of the present
of the present
Properties
Crystal Form 2
Crystal Form 1
invention
invention
Hygroscopicity
0.03% (FIG. 24)
1.9% (FIG. 27)
0.49% (FIG. 5)
0.09% (FIG. 12)
(weight changes
between 20%-80% RH)
Morphology
small block
small block
Fine particles
Rod shape
particles (FIG.
particles (FIG.
(FIG. 2), D10,
(FIG. 9), D10,
23), D10, D50
26), D10, D50
D50 and D90 are
D50 and D90 are
and D90 are 16 μm
and D90 are 50 μm
7 μm, 18 μm and
91 μm, 207 μm
36 μm and
104 μm and
40 μm,
and 378 μm,
74 μm,
151 μm,
respectively.
respectively.
respectively.
respectively.
Stability
Storage
Stable after storing for 3 months in the desiccator at room temperature, at
stability
room temperature-97% RH, at room temperature-75% RH, at room
temperature-44% RH or in the oven of 40° C.
Competition
In pure water, comparison of stability: Crystal Form VI of the present
test
invention >The Known Crystal Form 1 >Crystal Form VII of the present
invention >The Known Crystal Form 2.
In aqueous ethanol solution (wherein the volume percentage of ethanol is
20%, 50% and 80% respectively), comparison of stability: Crystal Form VI
of the present invention >the other three crystal forms.
In isopropanol or ethanol, comparison of stability: The Known Crystal
Form 1 >The other three crystal forms.
According to the results observed in the experiments, Crystal Form VI of the present invention is the most stable crystal form in the aqueous system. The Known Crystal Form 1, the Known Crystal Form 2 and Crystal Form VII of the present invention, if stirred in water or aqueous ethanol solution at room temperature or high temperature, all convert to Crystal Form VI of the present invention. In contrast, Crystal Form VI of the present invention keeps unchanged under the same conditions; Crystal Form VI of the present invention has low hygroscopicity; and Crystal Form VI of the present invention has good storage stability, it is stable when stored for a long time in the desiccator at room temperature, at room temperature-97% RH, at room temperature-75% RH, at room temperature-44% RH or in the oven of 40° C.
During the experiments, it is also found that Crystal Form VII of the present invention is of rod-shaped particles in large size and has good flowability; Crystal Form VII of the present invention has low hygroscopicity; and Crystal Form VII of the present invention has good storage stability, it is stable when stored for a long time in the desiccator at room temperature, at room temperature-97% RH, at room temperature-75% RH, at room temperature-44% RH or in the oven of 40° C.
Experimental Example 2
The Known Crystal Form 1, the Known Crystal Form 2 and Crystal Form VI of the present invention are examined for their stability during the formulation preparation of the wet granulation process.
The preparation process of the tablet is a parallel experiment. The formulation of tablets is as shown in Table 2 below.
TABLE 2
Tablet formulation
Content
Ingredient
(mg/tablet)
Pharmaceutical active ingredient (API)
100
Lactose (monohydrate)
280
Microcrystalline cellulose
112
Polyethylene glycol 6000
8
The steps to prepare the tablet are as follows:
(1) Blend API (selected from the Known Crystal Form 1, the Known Crystal Form 2 or Crystal Form VI of the present invention), lactose (monohydrate) and microcrystalline cellulose uniformly.
(2) Make the above mixture into soft materials by using an appropriate amount of 50% aqueous ethanol solution, screen to produce the wet granules and then dry the wet granules.
(3) Granulate the dried sample, blend with polyethylene glycol 6000 uniformly and then compress into tablets.
Respectively, take XRPD tests on the following samples obtained in the formulation preparing process of the Known Crystal Form 1, the Known Crystal Form 2 and Crystal Form VI of the present invention: (Sample 1) the sample obtained by physically blending API, lactose, microcrystalline cellulose with polyethylene glycol 6000 according to the preparation formula; (Sample 2) the sample obtained by granulating with API, lactose, microcrystalline cellulose and polyethylene glycol 6000 according to the “wet granulation” process (excluding the sample obtained after the Step (3)); (Sample 3) excluding API, the sample obtained by physically blending lactose, microcrystalline cellulose with polyethylene glycol 6000 according to the preparation formula. The XRPD patterns of Samples 1-3 are shown in FIGS. 28-30 .
According to FIG. 29 and FIG. 30 , it is shown that in respect of the Known Crystal Form 1 or the Known Crystal Form 2 as API, the comparison of XRPD patterns of its Sample 1 and its Sample 3 shows that the crystal form of API keeps unchanged after API is physically blended with the excipients; however, the comparison of XRPD patterns of its Sample 2 and its Sample 1 shows that API in Sample 2 has partially or totally converted to Crystal Form VI of the present invention, which indicates that the Known Crystal Form 1 and the Known Crystal Form 2 are unstable in the wet granulation process and convert to the more stable Crystal Form VI of the present invention.
According to FIG. 28 , it is shown that in respect of Crystal Form VI of the present invention as API, the comparison of XRPD patterns of its Sample 1 and its Sample 3 shows that the crystal form of API keeps unchanged after API is physically blended with the excipients; the consistency of XRPD patterns of its Sample 1 and its Sample 2 shows that Crystal Form VI of the present invention is stable in the wet granulation process.
It is also discovered that Crystal Form VI of the present invention is stable after tableting.
Therefore, Crystal Form VI of the present invention is more stable than the Known Crystal Form 1 and the Known Crystal Form 2 in the wet granulation process of tableting, and it is also stable after tableting. It has good preparation processing adaptability and thus it is the advantageous crystal form.
It is also discovered that the tablet containing Crystal Form VI prepared by the wet granulation process is still stable even if it is stored for 6 months at 40° C./75% RH.
Example 61
The preparation of the capsules containing the crystal forms of the present invention.
The formulation of capsules is shown in Table 3.
TABLE 3
Capsule Formulation
Ingredient
Content (mg/piece)
API (selected from the Known Crystal Form 1, the
71
Known Crystal Form 2, Crystal Form VI of the
present invention)
Microcrystalline cellulose (Avicel)
60
Sodium carboxymethyl starch (SSG)
13
The steps to prepare the capsules are as follows:
1) Appropriately/according to the actual demand, separate the 0 # hard capsules into a top and a bottom half, and mark/identify each half.
2) Place the bottom half into a capsule filling machine and make sure the filling funnel being on the top.
3) Blend API (selected from the Known Crystal Form 1, the Known Crystal Form 2 and Crystal Form VI of the present invention), microcrystalline cellulose (avicel) and sodium carboxymethyl starch (SSG) uniformly.
4) Make the above mixture into soft materials by using an appropriate amount of 50% aqueous ethanol solution, then screen to produce the wet granules.
5) Dry the wet granules, grind and disperse uniformly and then transfer them into the capsules.
6) Place the top half on the capsule, close the capsule until finally close tightly; then tap the capsules in order to blend/disperse the ingredients.
7) If the powder is near the top of the capsules at the beginning, slightly knock the capsule to settle down the powders.
8) Place such capsules in a small bottle marked appropriately (which should be large enough to move easily).
The XRPD test shows that, when the capsules use the Known Crystal Form 1 and the Known Crystal Form 2 as API and are prepared by the wet granulation process with water as the wetting agent, the crystal form in such capsules is unstable and has converted to Crystal Form VI of the present invention; when the capsules use Crystal Form VI of the present invention as API and are prepared by the wet granulation process with water as the wetting agent, the crystal form in such capsule is stable and still stable even if it is stored for 6 months at 40° C./75% RH.
Example 62
The preparation of the oral suspension containing the crystal forms of the present invention.
API (selected from Crystal Form VI of Dabrafenib of the present invention): 2 g;
Cocklebur gum: 8 g;
Sodium dihydrogen citrate: 2 g;
Methylparaben: 1.4 g;
Syrupus simplex: 150 mL;
Orange flavor: 1 mL;
Water: to 1,000 mL.
The steps to prepare the oral suspension are as follows:
Blend API (selected from Crystal Form VI of Dabrafenib of the present invention), cocklebur gum, sodium dihydrogen citrate, methylparaben, syrupus simplex and orange flavor, add water to 1,000 mL and stir the mixture uniformly. After that, divide the solution into 100 bottles with 20 mg API in each bottle.
The XRPD test shows that, the crystal form in the oral suspension in which the Known Crystal Form 1 and the Known Crystal Form 2 as API is unstable and has converted to Crystal Form VI of the present invention; Crystal Form VI of the present invention being as API in the oral suspension is stable and still stable even if it is stored for 6 months at 40° C./75% RH.
The scientists in this field may understand that, with the instructions of the present specification, some modifications or changes may be made on this Invention. These shall be made within the scope of this invention defined by the claims.
|
The invention relates to Crystal Hydrate Form VI of Dabrafenib and preparation method thereof, wherein Crystal Hydrate Form VI of Dabrafenib has the advantage of being more stable at room temperature or in aqueous systems, and has low hygroscopicity, and thus is more suitable for a wet granulation process or being prepared into a suspension; and the present invention also relates to a pharmaceutical composition and formulations comprising Crystal Hydrate Form VI of Dabrafenib, and their use in the treatment of Raf family kinase-related diseases.
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RELATED PATENT APPLICATIONS
[0001] This patent application is related to U.S. patent application Ser. No. ______, CL5104, entitled “Di-isoimide composition;” U.S. patent application Ser. No. ______, CL5289, entitled “Laminate comprising curable epoxy film layer comprising a di-isoimide and process for preparing same;” U.S. patent application Ser. No. ______, CL5290, entitled “Printed wiring board encapsulated by adhesive laminate comprising a di-isoimide, and process for preparing same;” and, U.S. patent application Ser. No. ______, CL5428, entitled “Process for Preparing a Di-Isoimide Composition.”
FIELD OF THE INVENTION
[0002] The present invention deals with a novel curable epoxy composition comprising an aromatic di-isoimide chemical compound that has utility as a catalyst and as a curing agent.
BACKGROUND OF THE INVENTION
[0003] Epoxy compositions are widely used in many applications including, among others, the electronics industry. In some applications they are blended with rubber to provide enhanced flexibility, toughness, and adhesive strength. One such application is as a flexible cover layer for flexible printed wiring boards.
[0004] While epoxies offer many desirable properties, they are known to be undesirably flammable, often requiring the addition of a flame retardant to a curable epoxy formulation in order to meet fire resistance standards. In addition, it is desirable to have a curable epoxy composition with as long a shelf life as possible. One approach to achieving long shelf-life is to prepare a so-called latent curing catalyst or cross-linking agent (curing agent). A latent catalyst or curing agent could be inactive at room temperature but thermally activated at a temperature well above room temperature. For practical reasons, it is desirable for uncured compositions to remain stable at temperatures up to 40 or 50° C. Thus a latent catalyst or curing agent activated at a temperature above 50° C. but below a temperature that will degrade the epoxy or electronic circuit elements is highly desirable in the art. A catalyst or curing agent that further obviates the need for a flame retardant additive would be so much the better for the properties of the resultant composition.
SUMMARY OF THE INVENTION
[0005] The composition of the present invention provides a curing catalyst and cross-linking agent suitable for use in a curable epoxy composition, a curable epoxy composition prepared therewith, a cured composition prepared therefrom, a film or sheet coated with the curable composition, and an encapsulated printed wiring board comprising the cured composition.
[0006] In one aspect, the present invention provides a di-isoimide composition represented by Structure I
[0000]
[0000] wherein R 1 is H, halogen, hydrocarbyl, hydrocarbyloxy, hydrocarbylthio, amido, sulfonamido, cyclic amino, acyl, morpholino, piperidino, or NR′R″ where R′ and R″ are independently H, alkyl or aromatic, substituted or unsubstituted.
[0007] In another aspect, the invention provides a first process for preparing a di-isoimide composition represented by the Structure I, the process comprising mixing, at a temperature in the range of −10 to 160° C., in a first solvent pyromellitic dianhydride (PMDA) with a substituted or unsubstituted di-amino triazine represented by the Structure II
[0000]
[0000] wherein R 1 is H, halogen, hydrocarbyl, hydrocarbyloxy, hydrocarbylthio, amido, sulfonamido, cyclic amino, acyl, morpholino, piperidino, or NR′R″ where R′ and R″ are independently H, alkyl or aromatic, substituted or unsubstituted.
[0008] In a further aspect, the present invention provides a curable composition comprising a solvent having mixed therewithin an epoxy and a di-isoimide composition represented by Structure I
[0000]
[0000] wherein R 1 is H, halogen, hydrocarbyl, hydrocarbyloxy, hydrocarbylthio, amido, sulfonamido, cyclic amino, acyl, morpholino, piperidino, or NR′R″ where R′ and R″ are independently H, alkyl or aromatic, substituted or unsubstituted.
[0009] In a further aspect, the present invention provides a second process comprising heating the curable composition hereof to a temperature in the range of 100 to 250° C. for a period of time in the range of 30 seconds to 5 hours, thereby forming the corresponding cured composition.
[0010] In another aspect, the present invention is directed to a laminated article comprising a substrate and a coating deposited thereupon wherein said substrate is a polymeric sheet or film and said coating comprises a curable composition comprising a second solvent having mixed therewithin an epoxy and a di-isoimide composition represented by Structure I.
[0011] In a further aspect, the present invention is directed to a printed wiring board comprising in order a first layer of a first dielectric substrate, a second layer of one or more discrete electrically conductive pathways disposed upon said first dielectric substrate, a third layer of an adhesively bonding layer in adhesive contact with said discrete electrically conductive pathways, and a fourth layer of a second, flexible, dielectric substrate, said adhesively bonding layer comprising a curable composition comprising a second solvent having mixed therewithin an epoxy and a di-isoimide composition represented by Structure I.
[0012] In another aspect, the present invention provides a process for preparing an encapsulated printed wiring board, the process comprising adhesively contacting the coated surface of a laminated article having a surface with a coating disposed thereupon to at least a portion of the discrete conductive pathways disposed upon a dielectric substrate thereby forming a multilayer article; and, applying pressure to the printed wiring board so formed at a temperature in the range of 100 to 250° C. for a period of time in the range of 30 seconds to 5 hours, thereby forming an encapsulated printed wiring board; wherein said printed wiring board comprises in order a first layer of a first dielectric substrate, a second layer of one or more discrete electrically conductive pathways disposed upon said first dielectric substrate, a third layer of an adhesively bonding layer in adhesive contact with said discrete electrically conducting pathways, and a fourth layer of a second, flexible, dielectric substrate, said adhesively bonding layer comprising a curable composition comprising a second solvent having mixed therewithin an epoxy and a di-isoimide composition represented by Structure I.
BRIEF DESCRIPTION OF THE DRAWING
[0013] FIG. 1 is a schematic representation of the process hereof for creating the printed wiring board hereof, as described in Example 12.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The term “epoxy” refers to a polymeric, generally an oligomeric, chemical comprising epoxide groups. A cross-linking agent suitable for use in the processes disclosed herein is a multifunctional molecule reactive with epoxide groups. The cross-linked reaction product thereof is the reaction product formed when the cross-linking agent reacts with the epoxide or other group in the epoxy molecule. The term “epoxy” is conventionally used to refer to the uncured resin that contains epoxide groups. With such usage, once cured, the epoxy resin is no longer actually an epoxy. However, reference to epoxy herein in the context of the cured material shall be understood to refer to the cured material. The term “cured epoxy” shall be understood to mean the reaction product of an epoxy as defined herein and a curing agent as defined herein.
[0015] The term “cured” refers to an epoxy composition that has undergone substantial cross-linking, the word “substantial” indicating an amount of cross-linking of 75% to 100% of the available cure sites in the epoxy. Preferably more than 90% of the available cure sites are cross-linked in a “fully cured” epoxy composition. The term “uncured” refers to an epoxy composition when it has undergone little cross-linking. The terms “cured” and “uncured” shall be understood to be functional terms. An uncured epoxy composition is characterized by solubility in organic solvents and the ability to undergo plastic flow under ambient conditions. A cured epoxy composition suitable for the practice of the invention is characterized by insolubility in organic solvents and the absence of plastic flow under ambient conditions. It is well-known in the art that some of the available cure sites in an uncured epoxy composition could be cross-linked and some of the available cure sites in a cured epoxy composition could remain uncross-linked. In neither case, however, are the distinguishing properties of the respective compositions significantly affected.
[0016] The art also distinguishes a partially cured epoxy composition known as a “B-stage” material. The B-stage material may contain up to 10% by weight of solvent, and exhibits properties intermediate between the substantially cured and the uncured state.
[0017] For the purposes of the present invention the term “curable composition” shall refer to a composition that comprises all the elements necessary for producing a “cured” composition, but that has not yet undergone the “curing process” and is therefore not yet cured. The curable composition is readily deformable and processible, the cured composition is not. The terms “curable” and “cured” are similar in meaning, respectively, to the terms “crosslinkable” and “crosslinked.”
[0018] While the invention is not limited thereto, it is believed that the cure reaction of an epoxy with the di-isoimide hereof is mostly a reaction of an amine group of the di-isoimide to open the oxirane ring (or epoxy group, as it is often referred to) resulting in a nitrogen carbon bond, and an alkyl hydroxyl group. So in the above instance, the di-isoimide serves as a cross-linking agent. When, for example, a phenolic novolac is also present, the oxirane ring opening reaction is effected primarily by the reaction of the phenol hydroxyl group of the novolac with the oxirane ring, thereby creating an oxygen-carbon bond and an alkyl hydroxyl group. When a more active cross-linking agent, such as the phenol is not present, the di-isoimide serves as both cross-linking agent and a catalyst.
[0019] The terms “film” and “sheet” refer to planar shaped articles having a large length and width relative to thickness. Films and sheets differ only in thickness. Sheets are typically defined in the art as characterized by a thickness of 250 micrometers or greater, while films are defined in the art as characterized by a thickness less than 250 micrometers. As used herein, the term “film” encompasses coatings disposed upon a surface.
[0020] The term “discrete conductive pathway” as used herein refers to an electrically conductive pathway disposed upon a dielectric substrate in the form of a film or sheet which leads from one point to another on the plane thereof, or through the plane from one side to the other.
[0021] There are several terms that are repeated throughout this invention that are described in detail only upon the first mention thereof. However, in order to avoid prolixity the descriptions of the term are not repeated when the term reappears further on in the text. It shall be understood for the purposes of the present invention that when a term is repeated in the text hereof, the description and meaning of that term is unchanged from and the same as that provided for the term upon its first mention. For example the term “di-isoimide composition represented by Structure I” shall be understood each time it appears to encompass all the possible embodiments recited with respect to Structure I upon its first appearance in the text. For another example, the term “second solvent” shall be understood to refer to the same set of solvents described for the “second solvent” at the first appearance of the term in the text.
[0022] For the purposes of this invention, the term “room temperature” is employed to refer to ambient laboratory conditions. As a term of art, “room temperature” is normally taken to mean about 23° C., encompassing temperatures ranging from about 20° C. to about 30° C.
[0023] The term “printed wiring board” (PWB) shall refer to a dielectric substrate layer having disposed thereupon a plurality of discrete conductive pathways. The substrate is a sheet or film. In one embodiment of the invention the dielectric substrate is a polyimide film. In a further embodiment, the polyimide film has a thickness of 5-75 micrometers. In one embodiment the discrete conductive pathways are copper.
[0024] PWBs suitable for the practice of the present invention can be prepared by well-known and wide-spread practices in the art. Briefly, a suitable PWB can be prepared by a process comprising laminating a copper foil to a dielectric film or sheet using a combination of an adhesive layer, often an epoxy, and the application of heat and pressure. To obtain high resolution circuit lines (≦125 micrometers in width) photoresists are applied to the copper surface. A photoresist is a light-sensitive organic material that when subject to imagewise exposure an engraved pattern results when the photoresist is developed and the surface etched. In a suitable PWB, the image is in the form of a plurality of discreet conductive pathways upon the surface of the dielectric film or sheet.
[0025] A photoresist can either be applied as a liquid and dried, or laminated in the form, for example, of polymeric film deposited on a polyester release film. When liquid coating is employed, care must be employed to ensure a uniform thickness. When exposed to light, typically ultraviolet radiation, a photoresist undergoes photopolymerization, thereby altering the solubility thereof in a “developer” chemical. Negative photoresists typically consist of a mixture of acrylate monomers, a polymeric binder, and a photoinitiator. Upon imagewise UV exposure through a patterning photomask, the exposed portion of the photoresist polymerizes and becomes insoluble to the developer. Unexposed areas remain soluble and are washed away, leaving the areas of copper representing the conductive pathways protected by the polymerized photoresist during a subsequent etching step that removes the unprotected conductive pathways. After etching, the polymerized photoresist is removed by any convenient technique including dissolution in an appropriate solvent, or surface ablation. Positive photoresists function in the opposite way with UV-exposed areas becoming soluble in the developing solvent. Both positive and negative photoresists are in widespread commercial use. One well-known positive photoresist is the so-called DNQ/novolac photoresist composition.
[0026] Any PWB prepared according to the methods of the art is suitable for use in the present invention.
[0027] In one aspect, the present invention provides a di-isoimide composition represented by Structure I
[0000]
[0000] wherein R 1 is H, halogen, hydrocarbyl, hydrocarbyloxy, hydrocarbylthio, amido, sulfonamido, cyclic amino, acyl, morpholino, piperidino, or NR′R″ where R′ and R″ are independently H, alkyl or aromatic, substituted or unsubstituted. In one embodiment, R 1 is NH 2 .
[0028] In another aspect, the present invention provides a first process that can be used to prepare the composition represented by the Structure I, the first process comprising mixing in a first solvent, at a temperature in the range of −10 to +160° C., PMDA with a di-amino triazine represented by the Structure II
[0000]
[0000] wherein R 1 is H, halogen, hydrocarbyl, hydrocarbyloxy, hydrocarbylthio, amido, sulfonamido, cyclic amino, acyl, morpholino, piperidino, or NR′R″ where R′ and R″ are independently H, alkyl or aromatic, substituted or unsubstituted.
[0029] In one embodiment, R 1 is NH 2 .
[0030] Suitable first solvents include but are not limited to polar/aprotic solvents characterized by a dipole moment in the range of 1.5 to 3.5 D. While the reaction between the aminoazine and PMDA takes place in solution, full miscibility of the reactants in the solvent is not necessary. Even limited solubility will permit the reaction to proceed, with additional reactants dissolving as they are consumed in the reaction. Suitable solvents include but are not limited to acetone, methyl ethyl ketone (MEK), methyl isobutyl ketone, ethyl propionate, ethyl-3-ethoxy propionate, cyclohexanone, and mixtures thereof. Mixtures thereof with small amounts (for example, less than 30% by weight) of non-polar solvents such as benzene are also suitable. In one embodiment, the solvent is cyclohexanone.
[0031] When the dipole moment is below 1.5 D, solubility of melamine, already low, becomes so low that the reaction can take weeks to go to completion. When the dipole moment of the solvent exceeds 3.5 D the rate of the reaction converting the di-isoimide to di-imide can proceed at an inconveniently rapid rate, causing excessive loss of the desired di-isoimide.
[0032] According to the first process of the invention, PMDA and a suitable diamino triazine, substituted or unsubstituted, as described supra, are combined in the presence of a suitable first solvent, and allowed to react. The reaction temperature can be in the range of −10 to +160° C. The yield of di-imide increases with increasing temperature, at the expense of the di-isoimide. While this invention is directed to the preparation of and the advantageous use of the di-isoimide, the presence of some di-imide mixed in with the di-isoimide does not necessarily have any particularly negative impact. In some instances, it could be advantageous to use a higher reaction temperature which results in lower selectivity but higher reaction rate.
[0033] In general, higher reaction temperature corresponds to faster reaction. Selectivity depends on temperature and the specific choices of dianhydride, triazine, and solvent. For example PMDA and melamine in cyclohexanone produce pure isoimide at 25° C., almost pure isoimide at 50° C., and produce about 80% isoimide at reflux (˜155° C.). PMDA and melamine react faster in N,N-dimethyl formamide (DMF) than in cyclohexanone at the same temperature but the reaction continues on to form imide from a di-isoimide intermediate if the reaction is not stopped in time.
[0034] In one embodiment, the reaction temperature is in the range of room temperature to 100° C. In a further embodiment, the reaction temperature is in the range of room temperature to 50° C.
[0035] The first process hereof does not require a water scavenger (such as trifluoroacetic acid) in order to provide the desired di-isoimide as represented by Structure I. It is highly preferred in the first process hereof to omit any water scavenger, in order to avoid having subsequently to remove the water scavenger after reaction is complete.
[0036] It is observed in the practice of the invention that the di-isoimide hereof is more soluble than the analogous imide in relatively mild, low boiling point solvents such as cyclohexanone and MEK. Much stronger high boiling point solvents, such as dimethyl acetamide (DMAC) or n-methyl pyrrolidone (NMP), are required to dissolve the imide. This feature of the di-isoimide hereof is of considerable importance in the formulation of epoxies with practical commercial applicability. It is difficult to remove high boiling point solvents without also initiating the epoxy cure. For adhesive applications, particularly highly critical applications such as the fabrication of encapsulated PWBs as described herein, it is essential to have the solvent removed completely since the adhesive is sealed between the two surfaces it is binding together, and there is no place to which solvent can escape without causing bubbles and voids in the finished product. Bubbles and voids adversely affect the uniformity of the dielectric constant.
[0037] Maintaining a high degree of mixing during reaction is important for achieving full conversion of the reactants into the di-isoimide product. For example, melamine is of very limited solubility in the suitable solvents. PMDA is also only poorly soluble. In order to achieve high conversion within a commercially viable time frame, it is necessary to maintain good intermixing of the reactants with each other and with the solvent. While the invention is not thereby limited, it is believed that the solution equilibrium for the reactants causes small amounts of reactants to dissolve, and that the thus dissolved reactants react to form a precipitate of the di-isoimide, thereby causing additional reactants to dissolve. This process is believed to continue until the reactants are exhausted, and conversion is quantitative as indicated by the disappearance of the reactant peaks in the infra-red (IR) spectrograph of the solvent dispersion.
[0038] Suitable mixing can be achieved using mechanical stirring such as magnetic stirring. A satisfactory state of mixing is one wherein the dispersion of reactants (and product) in the solvent has a uniform appearance with no regions of stagnant solids. It is preferred to stir to maintain a uniform appearance throughout the duration of the reaction.
[0039] It is found in the practice of the invention, as herein exemplified infra in Examples 7 and 8, performing the first process hereof in the presence of a rubber compound containing carboxylic acid groups in solution causes the reaction to achieve a higher rate of conversion than the same reaction when run without the rubber.
[0040] In a further aspect, the present invention provides a curable composition comprising a second solvent having mixed therewithin an epoxy and a di-isoimide composition represented by Structure I. In one embodiment, the second solvent is the same as the first solvent.
[0041] Solvents suitable for use as the second solvent include but are not limited to acetone, MEK, cyclohexanone, pentanone, dioxolane, tetrahydrofuran, glycol ethers, propylene glycol methyl ether acetate (PMA), N-methyl pyrrolidone, N,N-dimethylacetamide, DMF, dimethyl sulfoxide, N,N-diethylacetamide, N,N-diethylformamide, N,N-dimethylmethoxyacetamide. Preferred solvents are MEK, cyclohexanone, PMA, and DMF. Mixtures of solvents are also suitable.
[0042] Referring to Structure I, in one embodiment, R 1 is NH 2 .
[0043] Suitable epoxies for the curable composition hereof are epoxies comprising an average of at least two epoxide groups per polymer chain. Suitable epoxies include but are not limited to polyfunctional epoxy glycidyl ethers of polyphenol compounds, polyfunctional epoxy glycidyl ethers of novolak resins, alicyclic epoxy resins, aliphatic epoxy resins, heterocyclic epoxy resins, glycidyl ester epoxy resins, glycidylamine epoxy resins, and glycidylated halogenated phenol epoxy resins. Preferred epoxies include epoxy novolacs, biphenol epoxy, bisphenol-A epoxy and naphthalene epoxy. Preferred epoxies are oligomers having 1-5 repeat units. Most preferably the epoxy is bisphenol-A or novolac epoxy, especially bisphenol A diglycidyl ether.
[0044] Epoxies can be derivatized in any manner described in the art. In particular they can be halogenated, especially by bromine to achieve flame retardancy, or by fluorine.
[0045] In one embodiment of the curable composition hereof R 1 is NH 2 ; the solvent is MEK, cyclohexanone, propylene glycol methyl ether acetate, DMF, or a mixture thereof; and, the epoxy is of the bisphenol-A type.
[0046] The di-isoimide represented by Structure I can serve both as a curing catalyst and/or as a curing agent in the curable composition hereof. The isoimide moiety reduces the flammability of the cured epoxy (vs. phenolic novolac, which does not have a comparable flame retardant effect) and thus reduces the need for flame retadants. In one embodiment, the curable composition further comprises a curing agent. Any curing agent known in the art can be used in the compositions and processes disclosed herein. Suitable curing agents include organic acid anhydrides and phenols. Monoanhydride curing agents are preferred for ease of handling.
[0047] In an alternative embodiment, the curable composition hereof does not include a separate curing agent. It is found in the practice of this embodiment of the invention that the nucleophilic character of the amine group is much reduced by the presence of the triazine ring and the isoimide linkage. It is further found that once one of the amine groups on the ring undergoes reaction, the second amine group becomes still less reactive. Therefore in formulating the curable composition in this embodiment, it is found that satisfactory results are achieved by treating each mole of the di-isoimide of Structure I as representing two equivalents from the standpoint of cross-linking the epoxy. A formulation on that basis that contains a 20% excess in equivalents of epoxy has been found to be satisfactory.
[0048] The curable composition hereof can include any and all of the numerous additives commonly incorporated into epoxy formulations in the art. This can include flame retardants, rubber or other tougheners, inorganic particles, plasticizers, surfactants and rheology modifiers.
[0049] In one embodiment, the curable composition hereof comprises a low molecular weight liquid epoxy that serves as a dispersion medium for the di-isoimide composition represented by Structure I. Low molecular weight epoxies, such as EPON™ Resin 828, are characterized by equivalent weight of 185-192 g/eq. However, such low molecular weight epoxies are less preferred than the pastier, more viscous, higher molecular weight high performance epoxies that are well-known in the art. Higher molecular weight epoxies, such as EPON™ Resin 1001 F, are characterized by equivalent weight of 525-550 g/eq. While the reaction mixture formed from the higher molecular weight epoxies can be heated in order to lower viscosity, it is undesirable to apply heat for that purpose, especially in the presence of a catalyst, because of the risk of causing premature curing. In a highly preferred embodiment a high molecular weight epoxy is dissolved in a second solvent hereof—or, less preferably dispersed therein—into which a solution or dispersion of the di-isoimide composition of Structure I is then dispersed to form the curable composition hereof.
[0050] Suitable curing agents are phenol and aromatic anhydrides. The epoxy and the curing agent are mixed in quantities based on their equivalent weights. In the case of phenolic curing agents, 0.3-0.9 equivalent of phenol is preferred for each equivalent of epoxy has been found to be suitable. With anhydride curing agents, 0.4-0.6 equivalent of anhydride is preferred for one equivalent of epoxy.
[0051] Suitable phenol curing agents include biphenol, bisphenol A, bisphenol F, tetrabromobisphenol A, dihydroxydiphenyl sulfone, novolacs and other phenolic oligomers obtained by the reaction of above mentioned phenols with formaldehyde. Suitable anhydride curing agents are nadic methyl anhydride, methyl tetrahydrophthalic anhydride and aromatic anhydrides.
[0052] Aromatic anhydrides curing agents include but are not limited to aromatic tetracarboxylic acid dianhydrides such as pyromellitic dianhydride, biphenyltetracarboxylic acid dianhydride, benzophenonetetracarboxylic acid dianhydride, oxydiphthalic acid dianhydride, 4,4′-(hexafluoroisopropylidene)diphthalic acid dianhydride, naphthalene tetracarboxylic acid dianhydride, thiophene tetracarboxylic acid dianhydride, 3,4,9,10-perylene tetracarboxylic acid dianhydride, pyrazine tetracarboxylic acid dianhydride, and 3,4,7,8-anthraquinone tetracarboxylic acid dianhydride. Other suitable anhydride curing agents are oligomers or polymers obtained by the copolymerization of maleic anhydride with ethylene, isobutylene, vinyl methyl ether and styrene. Maleic anhydride grafted polybutadiene can also be used as a curing agent.
[0053] Suitable tougheners are low molecular weight elastomers or thermolastic polymers and contain functional groups for reaction with epoxy resin. Examples are polybutadienes, polyacrylics, phenoxy resin, polyphenylene ethers, polyphenylene sulfide and polyphenylene sulfone, carboxyl terminated butadiene nitril elastomers (CTBN), epoxy adducts of CTBN, amine terminated butadiene nitril elastomers (ATBN), carboxyl functionalized elastomers, polyol elastomers and amine terminated polyol elastomers. Epoxy adducts of CTBN, CTBN and carboxyl functionalized elastomer are preferred.
[0054] In one embodiment, the di-isoimide can be pre-dispersed in the solvent in which it was prepared. In an alternative embodiment, the di-isoimide may be added as particles to the epoxy solution and dispersed therein using mechanical agitation.
[0055] In a further aspect, the present invention provides a second process, a process for preparing a cured composition from the curable composition hereof by heating the curable composition to a temperature in the range of 100 to 250° C. for a period of time in the range of 30 seconds to 5 hours. For adhesive applications the solvent needs to be removed completely before curing, as described in the Examples, infra.
[0056] The viscosity of the uncured composition can be adjusted by either adding solvent to decrease the viscosity, or by evaporating solvent to increase viscosity. The uncured composition can be poured into a mold, followed by curing, to form a shaped article of any desired shape. One such process known in the art is reaction injection molding. In particular, the composition can be used in forming films or sheets, or coatings. The viscosity of the solution is adjusted as appropriate to the requirements of the particular process. Films, sheets, or coatings are prepared by any process known in the art. Suitable processes include but are not limited to solution casting, spray-coating, spin-coating, or painting. A preferred process is solution casting using a Meyer rod for draw down of the casting solution deposited onto a substrate. The substrate can be treated to improve the wetting and release characteristics of the coating. Solution cast films are generally 10 to 75 micrometers in thickness. The solution casting of a solution/dispersion hereof onto a substrate film or sheet to form a laminated article is further described in the specific embodiments hereof, infra.
[0057] In another aspect, the present invention is directed to a laminated article comprising a substrate and a coating adheringly deposited thereupon wherein said substrate is a polymeric sheet or film and said coating comprises a curable composition comprising a second solvent having mixed therewithin an epoxy and a di-isoimide composition represented by Structure I. In one embodiment, the substrate is a polyimide film. In a further embodiment said second dielectric substrate is a fully aromatic polyimide film or sheet. In a further embodiment the polyimide film has a thickness of 10-50 micrometers. In one embodiment, R 1 is NH 2 . In one embodiment, the coating has a thickness of 10 to 75 micrometers.
[0058] In one embodiment, the substrate is coated on both sides thereof. In a further embodiment, the coatings on both sides are chemically identical.
[0059] In a further aspect, the present invention is directed to a printed wiring board comprising in order a first layer of a first dielectric substrate, a second layer of one or more discrete electrically conductive pathways disposed upon said first dielectric substrate, a third layer of a bonding layer in adhesive contact with said discrete electrically conducting pathways, and adheringly disposed upon a fourth layer comprising a second dielectric substrate, said bonding layer comprising a curable composition comprising a second solvent having mixed therewithin an epoxy and a di-isoimide composition represented by Structure I.
[0060] In one embodiment of the printed wiring board hereof, the first layer is a polyimide film having a thickness of 10-50 micrometers.
[0061] In one embodiment of the printed wiring board hereof, the electrically conductive pathways are copper.
[0062] In a further embodiment of the printed wiring board hereof, the copper electrically conductive pathways are characterized by a thickness of 10-50 micrometers and lines and spacing from 10-150 micrometers.
[0063] In one embodiment of the printed wiring board hereof, in said adhesively bonding layer said second solvent is MEK, cyclohexanone, PMA, DMF, or a mixture thereof.
[0064] In one embodiment of the printed wiring board hereof, in said adhesively bonding layer in said di-isoimide composition represented by Structure I, R 1 is NH 2 .
[0065] In one embodiment of the printed wiring board hereof, the second dielectric substrate is a polyimide film or sheet. In a further embodiment said second dielectric substrate is a fully aromatic polyimide film or sheet. In a still further embodiment, said second dielectric substrate is a film or sheet comprising a polyimide that is the condensation product of PMDA and 4,4′-ODA. In a still further embodiment, said second dielectric substrate is a fully aromatic polyimide film having a thickness of 10-50 micrometers.
[0066] The printed wiring board hereof is conveniently formed by contacting the coating side of the laminated article hereof to the conductive pathways disposed upon the first dielectric substrate. The printed wiring board hereof has several embodiments that differ from one another in the degree of consolidation. In one embodiment the printed wiring board hereof is formed simply by disposing upon a horizontal surface a first dielectric substrate having one or more discrete conductive pathways disposed upon at least one surface thereof, where said conductive pathways are facing upward; followed by placing a coated side of the laminated article hereof in contact with the conductive pathways, thereby preparing a so-called “green” or uncured printed wiring board.
[0067] In a further embodiment, the green printed wiring board is subject to pressure thereby causing some consolidation. In a further embodiment the green printed wiring board is subject to both pressure and temperature. The temperature exposure may be sufficient to induce only a small amount of cross-linking or curing. This represents a so-called “B-stage” curing—an intermediate level of consolidation that causes the printed wiring board to have some structural integrity while retaining formability and processibility. The B-stage can be followed by complete curing. Alternatively, complete curing can be effected in a single heating and pressurization step from the green state.
[0068] In one embodiment of the printed wiring board hereof, the first dielectric substrate bears conductive pathways on both sides, permitting the formation of the multi-layer construction described supra on both sides of the first dielectric substrate.
[0069] In another embodiment of the printed wiring board hereof, the second dielectric substrate is coated on both sides with a composition comprising a solution/dispersion of epoxy, a second solvent, and the di-isoimide composition represented by Structure I.
[0070] In still a further embodiment, the first dielectric substrate bears conductive pathways on both sides, and the second dielectric substrate bears a coating on both sides, that coating comprising a solution/dispersion of epoxy, a second solvent, and the di-isoimide composition represented by Structure I. This embodiment permits printed wiring boards hereof to be constructed with an indefinite number of repetitions of the basic structure of the multilayer article.
[0071] In a further embodiment, at least a portion of the conductive pathways disposed upon one side of the first dielectric substrate are in electrically conductive contact with at least a portion of the conductive pathways disposed upon the other side of the first dielectric substrate through so-called “vias” that serve to connect the two sides of the dielectric substrate.
[0072] In another aspect, the present invention provides a third process, a process for preparing an encapsulated printed wiring board, the process comprising adhesively contacting the coated surface of a laminated article having a surface with a coating disposed thereupon to at least a portion of the discrete conductive pathways disposed upon a dielectric substrate thereby forming a multilayer article; wherein said coating comprises a curable composition comprising a second solvent having mixed therewithin an epoxy and a di-isoimide composition represented by Structure I; and, applying pressure to the printed wiring board so formed at a temperature in the range of 100 to 250° C. for a period of time in the range of 30 seconds to 5 hours, thereby forming an encapsulated printed wiring board.
[0073] In one embodiment, the third process hereof further comprises extracting said second solvent before applying pressure to the printed wiring board. Solvent extraction can be effected conveniently by heating in an air circulating oven set at 110° C. for a period of time ranging from 2-20 minutes.
[0074] In one embodiment of the third process hereof, R 1 is NH 2 .
[0075] In one embodiment of the third process hereof, the first and second dielectric substrates are both polyimide films.
[0076] In a further embodiment of the third process hereof, the polyimide films are fully aromatic polyimides.
[0077] In a still further embodiment of the third process hereof, the polyimide films are the condensation product of PMDA and ODA.
[0078] The invention is further described in the following specific embodiments though not limited thereby.
EXAMPLES
Determining Reaction Completion Point
[0079] In the following examples, infrared spectroscopy (IR) was employed to determine the end-point of the reaction. Small aliquots of the reacting medium were withdrawn by dropper-full, dried in a vacuum oven with N 2 purge at about 60° C. for about 60 minutes. Following conventional methodology for preparing solids for IR spectroscopic analysis, the resulting powder was then compounded with KBr followed by the application of pressure to the resulting compound, thereby forming a test pellet. IR absorption peaks at 1836 cm −1 and 1769 cm −1 were monitored to follow the increase in the concentration of the di-isoimide product. Similarly, IR absorption peaks at 1856 cm −1 and 1805 cm −1 characteristic of PMDA and 1788 cm −1 characteristic of melamine were monitored to follow the consumption of reactants. When the PMDA and melamine peaks became undetectable, the reaction was considered to be complete.
[0080] Peaks at 1788 cm −1 and 1732 cm −1 characteristic of imide were also monitored to follow the synthesis of any imide by-product of the present process.
[0081] The time to reaction completion was observed to vary considerably with the reaction temperature and the particular choice of solvent.
Reaction Medium
[0082] Both melamine and PMDA are only slightly solubile in the solvents employed herein so it was necessary to maintain good mixing during reaction to ensure a high degree of conversion. Without constant vigorous mixing, the solids settled and the reaction slowed down or stopped. The amount of energy that was needed for mixing was determined by observation. When the dispersion was of uniform appearance and no stagnant solid phase was observed, mixing was deemed to be of sufficient energy. The di-isoimide product formed into platelet particles with dimensions in the hundreds of nanometers range. These platelet particles also remained suspended with mixing. By the time reaction was completed, no detectable amounts of PMDA or melamine were present in the reaction mixture—all the suspended particles were di-isoimide, or, in some instances, di-isoimide with some imide mixed in.
Printed Wiring Board
[0083] A Pyralux® AC182000R copper clad laminate sheet (Dupont Company) was etched according to a common commercial etching process to form a series of parallel copper conductive strips 35 micrometers high, 100 micrometers wide, and spaced 100 micrometers apart. This was used in Examples 9-12, and is referred to therein as “a PWB test sheet.” Information on methods for preparing printed wiring boards can found in Chris A. Mack, Fundamental Principles of Optical Lithography: The Science of Microfabrication, John Wiley & Sons, (London: 2007). Hardback ISBN: 0470018933; Paperback ISBN: 0470727306.
Reagents
[0084] Except where otherwise noted, all reagents were obtained from Sigma Aldrich Chemical Company.
Example 1
[0085] 6.31 grams of melamine, 5.45 grams of PMDA and 25 grams of MEK were mixed using a magnetic stirrer in a round bottom flask. The mixture was refluxed under nitrogen for two days until conversion was complete. MEK was added as needed during refluxing to keep the volume of the reaction mixture approximately constant. The thus prepared product mixture was cooled to room temperature while maintaining stirring. As confirmed by IR spectroscopy, the product mixture contained only MEK and di-isoimide. No imide was detectable. The dispersion so prepared was suitable for immediate use in formulating a curable epoxy composition.
Example 2
[0086] 6.31 grams of melamine, 5.45 grams of PMDA and 35 grams of ethyl 3-ethoxypropionate were mixed in a round bottom flask. The mixture was refluxed under nitrogen for two days until conversion was complete. The mixture was cooled to room temperature. A small sample from the mixture was washed with MEK. As confirmed by IR spectroscopy, the product mixture contained MEK, di-isoimide, and a small amount of imide indicated by a small IR peak at 1734 cm −1 . The dispersion so prepared was suitable for immediate use in formulating a curable epoxy composition.
Example 3
[0087] 69 . 69 grams of melamine (0.534 moles), 60.26 grams of PMDA (0.267 moles) and 360 grams cyclohexanone are added into a reaction vessel, and stirred at room temperature for 6 days until conversion was complete. A sample from the reaction mixture was dried in vacuum oven. IR spectra of the final solid product showed the disappearance of the PMDA peaks at 1856 & 1805 cm −1 and melamine peak at 1558 cm −1 and the appearance of the isoimide peaks at 1836 & 1769 cm −1 .
Example 4
[0088] 6.31 grams of melamine, 5.45 grams of PMDA and 25 grams of MIBK (methyl isobutyl ketone) were mixed in a round bottom flask. The mixture was refluxed under nitrogen for 90 minutes. The mixture was cooled to room temperature. A sample was dried. IR spectra of the dried sample showed the formation of isoimide (peaks at 1836 & 1769 cm −1 ). Reaction was complete to the di-isoimide and no imide was detected.
Example 5
[0089] 5.81 grams of melamine, 5.00 grams of PMDA, 10 grams of DMF and 10 grams of ethyl acetate were mixed overnight in a flask at room temperature. Reaction was complete to the di-isoimide and no imide was detected. A small sample was dried. IR spectra of the dried sample showed the formation of isoimide (peaks at 1836 & 1769 cm −1 ).
Example 6
[0090] 5.81 grams of melamine, 5.00 grams of PMDA, 10 grams of MIBK, and 10 grams of toluene were mixed overnight in a flask at room temperature. A small sample was dried. IR spectra of the dried sample showed the formation of isoimide (peaks at 1836 & 1769 cm −1 ). Reaction was complete to the di-isoimide and no imide was detected.
Example 7
[0091] 3 grams of Vamac® G (from DuPont) and 12 grams of MEK were mixed in a round bottom flask to form a solution. 3.30 grams of a phenol/formaldehyde resin (GP 5300 from Georgia Pacific), and 15 grams of DMF were added to the round bottom flask, and mixed to form a solution. 3.48 grams of melamine and 3.01 grams of PMDA were added to the solution. The solution was heated under nitrogen for 30 minutes at 100° C., 30 minutes at 120° C., and 60 minutes at 140° C. The mixture was cooled to room temperature. A small sample from the mixture was washed thoroughly in MEK (to remove GP5300 and Vamac-G). IR spectra show the formation of isoimide (peaks at 1836 & 1769 cm −1 ) The anhydride and melamine peaks disappeared while the isoimide peaks appeared, and a small amount of imide was also present as indicated by a very small peak at 1734 cm −1 .
Example 8
[0092] 2.90 grams of carboxyl-terminated butadiene-acrylonitrile rubber (CTBN rubber, 1300×13 from CVC Thermoset Specialties), 3.78 grams of melamine, 3.27 grams of PMDA and 15 grams of dry MEK were mixed in a round bottom flask. The solution was refluxed under nitrogen for 5 hours. The mixture was cooled to room temperature. A small sample from the mixture was washed thoroughly in MEK (remove CTBN). IR spectra of this sample showed the formation of isoimide (peaks at 1836 & 1769 cm −1 ). The anhydride and melamine peaks disappeared. A small amount of imide was present.
Comparative Example A
[0093] In a reaction vessel, 25.22 grams of melamine (0.2 moles), 21.81 grams of PMDA (0.1 moles) and 125 ml DMF were refluxed for 5 hours. The mixture was cooled and quenched with methanol. The solid product was filtered and dried. The IR spectra of the filtered solid product showed the disappearance of the PMDA peaks at 1856 & 1805 cm −1 and of the melamine peak at 1558 cm −1 and the appearance of the imide peaks at 1788 & 1732 cm −1 .
Comparative Example B
[0094] In a reaction vessel, 50.45 grams of melamine (0.4 moles), 43.62 grams of PMDA (0.2 moles) and 400 ml of NMP (N-methylpyrrolidinone) were refluxed for 30 minutes. The mixture was cooled and quenched with methanol. The solid product was filtered and dried. The IR spectra of the filtered solid product showed imide formation (peaks at 1788 & 1732 cm −1 ).
Example 9
[0095] 3.50 grams of the di-isoimide dispersed in 9.5 grams of cyclohexanone, prepared in Example 3 supra, and 11.5 grams of a copolymer of butadiene and acrylonitrile modified to contain free carboxylic groups (Nipol 1072J from Zeon Chemicals) dissolved in 63 grams of MEK, were mixed in a flask. 11.20 grams of melamine phosphate/melamine polyphosphate/melamine pyrophosphate flame retardant (Phosmel 200 Fine from Nissan Chemical Industries) was then added and mixed in, to form a first solution/dispersion. 9.10 grams of an epoxy-rubber adduct (HyPox RK84L from CVC Thermoset Specialties) was dissolved in 9.10 grams of MEK to form a second solution. The second solution was added to the first solution/dispersion thereby forming an epoxy solution/dispersion. The epoxy solution/dispersion so prepared was coated onto 12 micrometer thick Kapton® 50FPC polyimide film using a 7 mil gauge (177.8 micrometer) doctor blade followed by removal of the solvent by placing the thus-cast film and substrate in a vacuum oven at 60° C. for one hour, to form an approximately 25 micrometer thick coating.
[0096] The thus prepared coated Kapton® was then used as a cover-layer on the PWB test sheet. Referring to FIG. 1 , the Kapton® 50FPC film, 1 , coated with the curable composition, 2 , thus prepared was contacted, 5 , to the copper conductive strips, 3 , of the PWB test sheet, 4 , the curable composition, 2 , being in direct contact with the copper conductive strips, 3 . The printed wiring board thereby formed, 6 , was then consolidated, 7 , under vacuum in an OEM Laboratory Vacuum Press by holding the printed wiring board at 175° C. and 2.25 MPa for 80 minutes, thereby forming a flexible printed wiring board, 8, having fully encapsulated copper conductive pathways.
Example 10
[0097] 3.50 grams of the di-isoimide dispersed in 9.5 grams of cyclohexanone, as prepared in Example 3. and 9.80 grams of “Nipol 1072J” rubber dissolved in 55 grams of MEK were mixed in a flask. The mixture was stirred for 30 minutes. 1.40 grams of CTBN (Carboxyl-Terminated Butadiene-Acrylonitrile Rubber, CTBN 1300×13 from CVC Thermoset Specialties) and 11.20 grams of “Phosmel 200 Fine” flame retardant (from Nissan Chemical Industries) were added to the mixture. 9.10 grams of HyPox RK84L were dissolved in 13.7 grams of MEK and the solution so formed was added to the mixture. The thus prepared solution/dispersion was coated onto a 12 micrometer thick Kapton® 50ENS polyimide film using a 7 mil gauge (177.8 micrometers) doctor blade, after which the thus coated Kapton® film was placed into an air circulating oven at 110° C. for 10 minutes to remove the solvent. The dry adhesive film thickness was 27 micrometers.
[0098] The thus prepared coated Kapton® film was used to prepare a fully encapsulated flexible printed wiring board employing the materials and procedures described in Example 9.
Example 11
[0099] 61.60 grams of “Nipol 1072J” rubber were dissolved in 350 grams of MEK in a flask to form a first solution. 9.10 grams of the di-isoimide dispersed in 25 grams of cyclohexanone prepared in Example 3 was mixed into the first solution to form a second solution/dispersion, followed by mixing in 42.25 grams of “Phosmel 200 Fine” flame retardant (from Nissan Chemical Industries) to form a third solution/dispersion. 34.45 grams of HyPox RK84L was dissolved in 34.45 grams of MEK and the resulting fourth solution was mixed into the third solution/dispersion to form a fifth solution/dispersion. 2.6 grams of bisphenol A diglycidyl ether epoxy resin (EPONTM 828 from Hexion Specialty Chemicals) were mixed into the fifth solution/dispersion to form an epoxy solution/dispersion. The thus prepared epoxy solution/dispersion was coated onto a Kapton® 50FPC polyimide film using a 7 mil gauge (177.8 micrometer) doctor blade. The thus coated Kapton® film was placed in an air circulating oven at 110° C. for 10 minutes to remove the solvent. The dry coating thickness was approximately 25 micrometers in thickness.
[0100] The thus prepared coated Kapton® film was used to prepare a fully encapsulated flexible printed wiring board employing the materials and procedures described in Example 9.
Example 12
[0101] 55.8 grams of a cyclohexanone dispersion of melamine-PMDA di-isoimide (26.9 weight % isoimide content) prepared according to the method of Example 3 and 51.0 grams of rubber (copolymer of butadiene and acrylonitrile modified to contain free carboxylic groups—Nipol 1072J from Zeon Chemicals) were dissolved in 289 grams of MEK to form a solution. 36 grams of an epoxy-rubber adduct (HyPox RK84L from CVC Thermoset Specialties) and 48.0 grams of melamine phosphate/melamine polyphosphate/melamine pyrophosphate flame retardant (Phosmel 200 Fine from Nissan Chemical Industries) were mixed into the solution using a mechanical stirrer. When all the ingredients were dispersed into the solution, the mixture so formed was homogenized for 2.5 minutes (Silverson model L5M homogenizer) to a dispersion having a visually uniform appearance. The thus homogenized mixture was then mechanically stirred continuously until coating, described infra, was commenced.
[0102] The dispersion so prepared was coated onto Kapton® 50FPC polyimide film using a 7 mil gauge (177.8 micrometer) doctor blade. The solvent was removed by placing the thus coated Kapton® film in an air circulating oven for 10 minutes at 110° C. The dried coating thickness was approximately 25 micrometers.
[0103] The thus dried coated film was laminated to a PWB test sheet. The printed wiring board, 6 , as shown in FIG. 1 was further prepared with a release film and a rubber pad on each side. The combination thus prepared was inserted into a quick lamination press and pressed at a temperature of 185° C. and a pressure of 9.8 MPa for 2 minutes, followed by a cure in an air-circulating oven at 160° C. for 90 minutes.
[0104] The adhesion of the coated film to the PWB test sheet was determined to be 2.16 N/mm (Newton/millimeter) according to ISO 6133 IPC-TM-650 2.4.9 using a German wheel attached to an Instron machine.
Example 13
[0105] The materials and procedures of Example 12 were employed, except that the quantities were different, as indicated in Table 1, and the procedure was modified as described infra.
[0000] Ex. 12 (g) Ex. 13 (g) Melamine-PMDA isoimide (26.9 55.8 33.85 weight-% isoimide) dispersion in Cyclohexanone Nipol 1072J 51.0 41.6 MEK 289 235.7 HyPox RK84L 36 34.5 Phosmel 200 Fine 48.0 42.25
The melamine-PMDA isoimide cyclohexanone dispersion, Nipol 1072J, and MEK were combined to form a first solution, to which the Phosmel 200 Fine was added to form a first solution/dispersion. The HyPox RK84L was first dissolved in 34.5 grams of MEK to which 2.6 grams of Epon 828 (from Hexion) were added, thus forming a second solution. The second solution was then added to the first solution/dispersion. The remaining procedures and method of Example 12 were then followed. The adhesion of the coated film on the PWB test sheet was determined to be 2.15 N/mm.
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The present invention deals with a novel curable epoxy composition comprising an aromatic di-isoimide chemical compound. The di-isoimide serves effectively as a thermally activated latent catalyst in epoxy curing, thereby increasing shelf life, and avoids premature cross-linking. Novel laminated articles and printed wiring boards, including encapsulated printed wiring boards are also disclosed.
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part of our copending application Ser. No. 10/873,470 filed Jun. 21, 2004, which is a divisional of Ser. No. 10/087,064 filed Mar. 1, 2002, (now U.S. Pat. No. 6,776,838) which claimed priority from Provisional application No. 60/273,176 filed Mar. 2, 2001.
FIELD OF THE INVENTION
[0002] The present invention relates generally to fillers and extenders, and more specifically relates to a white filler and extender derived from glass manufacturing by-products, and to the method for producing the said product. The product is a non-crystalline, vitreous aluminosilicate of low alkali content and high brightness and finds application as a filler and extender in plastics, paints, coatings, and in other common uses for fillers and extenders.
BACKGROUND OF THE INVENTION
[0003] In a representative glass fiber manufacturing facility, typically 10-20 wt % of the processed glass material is not converted to final product and is rejected as industrial by-product or waste and sent for disposal to a landfill. This rejected material represents a substantial cost to the industry and also generates a consequent detrimental impact on the environment. While the rejected by-product referred to may have widely varying physical form, ranging from thick fiber bundles to partially fused fiber agglomerates and shot, it is evident from chemical analyses of various samples recovered at different times, that the material still has a substantially constant chemical and mineralogical make-up. Thus, unlike wastes from many other industrial processes which typically have widely varying chemical and mineralogical properties, the waste from the glass fiber manufacturing process is very consistent in composition and still benefits from the stringent engineering quality control applied to the glass-making process itself. This consistency is a major advantage to any potential utilization of the glass fiber manufacturing waste.
[0004] More specifically, the glass formulations of great relevance to this invention are those of low alkali calcia-alumina-silica compositions (CaO—Al 2 O 3 —SiO 2 or “CAS”) typically used for commercial glass fiber manufactured to comply with ASTM D-578. These formulations are given in Table 1. The compositions are vitreous and by virtue of their components have very low levels of discolorants. These compositions are expressed conventionally in terms of the element oxide and are not meant to imply that the oxides, crystalline or otherwise, are present as distinct compounds in the amorphous glasses:
[0000]
TABLE 1
Composition Range
Component (Element Oxide)
(% by Weight)
Silicon dioxide, SiO 2
52-62
Aluminum oxide, Al 2 O 3
12-16
Iron oxide, Fe 2 O 3
0.05-0.8
Calcium oxide, CaO
16-25
Magnesium oxide, MgO
0-5
Sodium oxide + potassium oxide (Na 2 O + K 2 O)
0-2
Boron oxide, B 2 O 3
0-10
Titanium dioxide, TiO 2
0-1.5
Fluorine, F 2
0-1
Mineralogical Composition (XRD)
Amorphous (glassy)
[0005] Several features are immediately evident from inspection of the data in Table 1. First, the general chemical and mineralogical composition of the glass fiber material is very similar to amorphous (glassy) calcium alumino-silicate materials, such as blast-furnace slag and Class C fly ash, that are commonly used as cementitious or pozzolanic admixtures in portland cement concrete; second, the alkali (Na 2 O+K 2 O) content of the glass is very low (0 to 2%); and third, with their inherently low iron contents (0.05 to 0.8%), the glasses have little or no color. Low alkali content and chemical consistency differentiates the glass fiber manufacturing waste from post consumer waste glass, for example container bottles and flat glass, that have widely varying chemical composition, generally high alkali content, and in the case of container/bottle glass are highly colored.
SUMMARY OF INVENTION
[0006] In the aforementioned parent patent applications the present inventors have found that once it is ground to a powder of suitable fineness, the glass fiber waste discussed above can effectively function as a reactive pozzolanic admixture for use in portland cement-based building materials and products, such as concrete, mortars and grouts. In another distinct aspect of the present invention, however, it has been found that these powder products can also serve as outstanding fillers and extenders in the manufacture of plastics, paints, coatings and in other conventional uses of fillers and extenders.
[0007] The finely ground glass powder of the invention (which retains the vitreous nature and chemical composition of the fiber feed) is white in color having a brightness as high as 90 or more (were measured as discussed below). The product is entirely vitreous, and thus contains essentially no crystalline silica. This is an exceedingly significant property, since it renders the silica based material safe for use in consumer and industrial applications in contrast with the health hazardous crystalline silica fillers of the prior art. These safe properties also assure that recycling of materials containing such filler/extenders will not be hampered by the presence of a hazardous filler. Furthermore the very low alkali content minimizes the accumulation of the alkali bloom phenomenon which is common with many prior art fillers. The products of the invention when used e.g. as fillers in polymers can be loaded in the polymer to typical levels of 20 to over 60% by weight. Depending upon loading and the specific polymer involved, desired mechanical, thermal and/or electrical properties of the filled polymer can be achieved. Because the fillers have low oil absorption, lower viscosities are present during manufacture, facilitating, processing of the filled polymer. Furthermore the low alkalinity of the fillers leads to greater stability in the filled materials.
[0008] According to a process aspect of this invention, glass fiber wastes are converted into high quality filler and extender products, by shredding long entangled strands of glass into short fibers, adjusting the moisture content of the short fibers, grinding the short fiber, and classifying the ground material to produce a uniform high quality product with precise control over the maximum particle size and particle size distribution. Because of its physical characteristics, this product will at times herein be referred to as “white VCAS filler/extenders”, the “VCAS” being a reference to its production from fibers of “vitreous calcium-alumino-silicate” glass. The white VCAS filler/extender has a reflectance value of at least 80 as measured by a Technibrite TB-1C colorimeter according to the ISO 2467, 2471 method, and as already mentioned can have brightnesses of 90 or even higher.
BRIEF DESCRIPTION OF DRAWINGS
[0009] In the drawing appended hereto:
[0010] FIG. 1 is a schematic block diagram illustrating a process which may be used to prepare the fillers and extenders of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0011] According to the process aspect of this invention, glass fiber wastes are converted into high quality filler and extender products, by a shredding long entangled strands of glass into short fibers, adjusting the moisture content of the short fibers, grinding the short fiber, and classifying the ground material to produce a uniform high quality product with precise control over the maximum particle size and particle size distribution.
[0012] The process of glass manufacturing entails melting a mixture of carefully selected oxides, then cooling the molten material to produce the desired size, shape, and characteristics (e.g., container glass, flat glass, optical glass, fiber glass, etc.). The carefully selected ingredients for glass manufacturing are typically based on specific formulations of three material types: i.e., glass formers, glass modifiers or fluxes, and stabilizers. Glass formers comprise the major components of glass and most commonly consist of silicon dioxide in the form of sand and aluminum oxide in the form of alumina. Boron oxide is another common glass former component found in some formulations. Glass modifiers or fluxes lower the melting temperature and alter the viscosity of the glass melt and consist primarily of alkaline earth metal and alkali metal oxides, typically derived from the raw materials calcium carbonate, sodium carbonate and potassium carbonate. Stabilizers are added to make the glass strong and resistant to water and chemical attack. Low alkali glass, such as many of the formulations typically used for the manufacture of high performance glass fiber, is specially formulated for resistance to high temperatures and corrosive substances, in addition to having high physical strength and flexibility.
[0013] The process of glass fiber forming involves feeding molten glass from a high temperature furnace through a series of bushings containing thousands of accurately dimensioned holes or tips. Fine individual filaments of glass with diameters typically in the range 20-60 microns are drawn mechanically downward from the bushing tips, cooled and brought together to form bundles or strands of glass fibers. In the process of forming glass fibers, a significant amount of wastage is generated, mostly in the form of irregular, entangled long strands and bundles, often with nodules from partial fusion. The waste strands and bundles can be many tens of feet in length and are in a form that is not conducive to easy handling and processing by conventional means. This waste material is typically cooled by water and air quenching and shipped to a landfill for disposal. According to this invention a large amount of this waste glass fiber material can be processed and converted into high performance industrial products.
[0014] A typical process useful in the invention is shown schematically in FIG. 1 . In the first step of the present process, the glass fiber waste (feed stock) is collected and placed in a containment area for de-watering and trash removal. Water used to cool the waste fiber stream is allowed to drain off the fibers and is collected and transferred to the wastewater treatment system. Incidental trash objects are manually removed from the bulk waste materials to allow for further processing.
[0015] In the second step of the process, the moist waste glass fiber bundles are processed by a shredder at fiber shredding through a shredder to reduce the fiber length from infinitely long entangled strands to short fibers (typically less than 10 mm) for subsequent processing. The shredding stage consists of processing the entangled strands through a rapid rotating mandrel with protruding cutting knives. Stationary cutting edges are also located opposite the rotating mandrel. The fast cutting action of the knives snaps the entangled glass bundles and strands into the desired short individual fibers. A screen enclosure around the rotating mandrel is used to retain the large entangled strands and ensure shredding into short fibers.
[0016] In the third step of the process (fiber drying), the moisture content of the shredded short fibers is adjusted prior to further processing using dry and heated air. The moisture content is controlled to a predetermined specific range to optimize the subsequent grinding process. Generally the moisture content should be less than 10% by weight, and is preferably less than 2% by weight. In a very typical instance the moisture content is from 0.5 to 1.0% by weight.
[0017] In the fourth step of the process, the shredded short fibers are subjected to fine grinding by being processed through an attrition mill, preferably in a vertical attrition mill such as a stirred or agitated ball mill. The short fibers and the ground glass are very abrasive materials. Abrasion of commonly used stirred mill components not only contaminates the product, it also reduces the grinding efficiency. In the present process the mill uses a rotation shaft and arms that agitate the grinding media and create both impact and shearing action, resulting in efficient product size reduction. The rotating arms are covered with replaceable leading-edge ceramic protectors composed of die cast and heat-fused alumina. The wall of the attrition mill is also lined with abrasion-resistant alumina to further minimize product contamination from the metal components in the mill. The mill uses the highest quality high alumina grinding media consisting of ⅛″ to ⅜″ diameter balls. The effectiveness and efficiency of the attrition mill are greatly enhanced by the die-cast, heat-fused leading edge protector attachments of the agitator arms. Energy inputs used in this grinding process are at least 100 kW-hrs/ton of feed fibers and typically are in the range of 100 to 200 kW-hrs/ton of the feed fibers.
[0018] The attrition mill is typically operated with continuous feed and discharge, although if desired it can alternatively be operated in a batch mode. The discharged grinding media and product are separated in stage five of this process using a vibratory screen with 80 to 100 mesh openings. The grinding media and oversize glass comminution products are returned to the attrition mill for continuous processing. The ground glass product passing the screen is conveyed to an air classification system for product refinement.
[0019] In step six of the invention (fine powder classification), the ground glass product is processed through a high-performance, dual-cyclone, dry air classification system. This stage is used to control the fineness and particle size distribution of the product from fine grind to low-micron range depending on the required specification. Particles larger than the maximum allowable are returned to the attrition mill for further grinding. The use of an air classification system in this stage allows for precise control over the maximum particle size and ensures the production of a uniform product. The air used in classification is vented through a filter fabric dust collector (Air emission control system). Ultra fine particles collected in the filter fabric can be blended with the final product (Blending Packaging).
[0020] The final classified white filler or extender product will generally have a particle size distribution such that at least 95% of the particles by weight have an equivalent spherical diameter (E.S.D.) of less than 45 μm (microns). Typically 95% by weight may be less than 25 μm; (typical median size around 9 μm); and for many applications the milling and classification will provide an end product where 95% by weight of the particles are of less than 10 μm E.S.D. (a typical median size here is around 3 μm); and in other instances the said end product can have P.S.D.'s where 95% of the particles by weight are less than 5 μm, or even less than 3 μm.
[0021] The finely ground white VCAS filler/extenders product as produced by this process is characteristically of a blocky, almost equi-dimensional particle shape, with no evidence of residual high aspect ratio fibers. The aspect ratio of the particles will typically average less than 2:1, with the aspect ratio becoming smaller as the average particle size becomes smaller as a result of the milling and classification as discussed above. The finely ground powder product yielded by the invention can be packaged in bags or sold in bulk for industrial filler and applications. This product can serve as a replacement to high priced white fillers and extenders. The final product from the process contains substantially no particles which NIOSH defines as “respirable fibers,” i.e., particles which are greater than 5 μm in length and less than 3 μm in diameter with an aspect ratio of greater than or equal to 5:1.
[0022] The invention is further illustrated by the following Example, which is indeed to be considered exemplary of the invention, and not definitive thereof.
Example 1
Preparation of VCAS Filler/Extenders
[0023] To facilitate an evaluation of their properties, by-product glass fiber waste materials having compositions as shown in Table 1 were ground to fine powders with a variety of different particle size distributions or finenesses. This was carried out using both laboratory and pilot-scale equipment in a multi-stage process involving drying, comminution, screening, and high efficiency air classification, the object being to have no residual high aspect ratio particles (shards) in the powder products. Representative sub-samples of the ground product materials from this process were characterized for their granulometry properties, some illustrative examples of which are shown in Table 2.
[0000]
TABLE 2
SSA
Median
D95
Pozzolan ID
(m 2 /kg)
(μm)
(μm)
GP1
269
nd
50
GP2
560
12
30
GP3
580
10
30
GP4
686
9
25
GP5
788
6
20
GP6
956
3
10
GP7
>1200
1
3
[0024] The specific surface area (SSA) of the powders was determined by the Blaine air permeability method according to ASTM C-204. The results in Table 3 show that the range of specific surface areas for the prepared VCAS pozzolan powders was 250 to greater than 1200 m 2 /kg. The corresponding particle size distribution, median particle size, and D95 (particle size with 95% of the particles finer) of the products, were determined by the laser interferometer technique in aqueous dispersion using Microtrac® X100 or Coulter LS® particle size analyzers. The median particle sizes of the VCAS filler/extender products ranged from 1 μm (microns) to 12 μm, with corresponding D95 values ranging from 3 μm (microns) to 50 μm. The specific gravity of the VCAS filler/extender powders, as determined by the Le Chatelier method (ASTM C-188), was 2.57 cm 2 /g.
[0025] Examination of the VCAS filler/extender powders at high magnification by scanning electron microscopy (SEM) confirmed that, as is typical of such ground materials, all the VCAS pozzolan samples were substantially blocky in particle shape. There was no sign of residual high aspect ratio particles. X-ray powder diffraction (XRD) analysis of the powders confirmed that that they were all essentially amorphous in structure.
[0026] While the present invention has been described in terms of specific embodiments thereof, it will be understood in view of the present disclosure, that numerous variations upon the invention are now enabled to those skilled in the art, which variations yet reside within the scope of the present teaching. Accordingly, the invention is to be broadly construed, and limited only by the scope and spirit of the claims now appended hereto.
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A substantially white powder for use as a filler and/or extender derived from by-products of manufacturing vitreous low alkali, low iron glass fibers, and a method for producing the powder. The filler has very low alkalinity and by virtue of its being essentially free of crystalline silica is non-hazardous to health and therefore safe for consumer-based and industrial-based uses.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to German Patent Application No. 10164756.5 filed Dec. 19, 2001, which application is herein expressly incorporated by reference.
BACKGROUND AND SUMMARY
[0002] The invention relates to a waste holding tank for a sanitary toilet system, in particular, a mobile sanitary toilet system, the toilet system comprising a base section, a bowl section supported by the base section and a waste holding tank, the tank comprising a housing, the housing defining a tank interior and a tank exterior and comprising a vent opening at a first location of the housing, the opening forming a fluid communication between the interior and the exterior of the tank.
[0003] Furthermore, the invention relates to a sanitary toilet system, in particular, a mobile sanitary toilet system comprising a base section, a bowl section supported by the base section and a waste holding tank.
[0004] Mobile toilet systems of the kind as mentioned above are used in vehicles, e.g. mobile homes, caravans, boats, coaches etc. In such vehicles attempts have been made in the past to reduce the irritation by odors resulting from the formation of bacteria in the waste holding tank by using chemicals. Despite these endeavors, there is generally, and particularly strongly on hot summer days, a very strong and unpleasant irritation due to odors.
[0005] An improved venting system for a mobile toilet system is disclosed in DE 199 25 898 A1. To overcome the problems indicated above, it is proposed to connect the vent opening with a suction device when the tank is inserted in the mobile toilet system. Since the vent opening of commonly used tanks is located on the top side of the tank, a conduit is required to connect the vent opening and the suction device leading through a side wall of the base and also through a sidewall of the vehicle. This individually required adaptation of the mobile toilet system to different vehicle situations involves intensive installation efforts with respect to cost and time.
[0006] Therefore, it is an object of the present invention to provide a waste holding tank for a mobile toilet system and a mobile toilet having an improved and easily installable venting system.
[0007] This object is accomplished in accordance with the invention in a waste holding tank of the type described at the outset in that a vent conduit is provided for connecting the vent opening on the tank exterior at the first location with the exterior of the tank at a second location of the housing, the vent conduit leading at least partly through the interior of the tank without being in fluid communication with the interior of the tank.
[0008] The advantage of the inventive solution is that no additional installation work is required for a perfect venting of the tank. The foul gases can easily be led through the vent opening and through the vent conduit to the second location on the exterior of the tank, e.g., on a side wall or the bottom side of the tank. If the tank is inserted into the mobile toilet system, the vent conduit according to the present invention forms a shortcut for the foul gases from the interior of the tank to the exterior at the second location where the tank could easily be connected with the outside of the vehicle, with or without an optional suction device. If the conduit leads at least partly through the interior of the tank, the conduit could be formed partly by the tank itself and partly by a second member, e.g., a part of the base section forming another part of the vent conduit. Such a construction would allow the foul gases to be led along the exterior of the tank to a location where the vent conduit could easily be connected with the exterior of the vehicle and/or the exterior of the room where the toilet system is located.
[0009] In a preferred embodiment of the invention, it is provided that the vent conduit leads completely through the interior of the tank. Such a construction requires the least sealing efforts compared to a vent conduit leading at least partly through the interior of the tank. Furthermore, the tank according to the present invention is adapted to be introduced into mobile toilet systems which are already in use.
[0010] Preferably, the first location is on the top side of the housing. Such an arrangement reduces the risk of the content of the tank reaching the vent conduit through the vent opening and avoids a contamination of the vent conduit.
[0011] Furthermore, it is advantageous when the second location is on the bottom side of the housing. According to this arrangement, the vent conduit could be formed as short as possible, i.e., having a minimal length. Additionally, no extra installations leading around the tank are required to connect the vent opening with the bottom side of the tank.
[0012] In principle, it would be possible for the vent conduit to be formed by a plurality of conduits. Preferably, the vent conduit comprises a channel having a first end and a second end. A channel of this kind reduces the number of connections which have to be sealed to a minimum.
[0013] According to a preferred embodiment of the invention, the channel is formed by a tube extending vertically through the tank. Such a tank is easy to produce since only two openings have to be formed, one on the top side and another one on the bottom side of the tank. The tube can easily be inserted through the openings so as to form a passage through the interior of the tank and allow the waste air to leave the tank and to be guided through the interior of the tank to the exterior without coming into contact with the waste contained in the tank.
[0014] To prevent waste air from escaping from the tank when the tank is, for example, in a stored position outside the mobile toilet system, a closure is provided, the closure opening the vent opening in an open position and closing the vent opening in a closed position. Such closure additionally holds back the contents of the tank to avoid a splashing of the contents when the vehicle is moved and a contamination of the vent conduit.
[0015] In principle, the closure could be electrically actuatable. According to a preferred embodiment of the invention, however, the closure is mechanically actuatable. This allows opening of the vent opening automatically or manually when a venting of the tank is required.
[0016] Although the closure could be formed by a cover or a screw cap, it is beneficial for the closure to be formed by a valve.
[0017] In principle, the valve could be a simple valve. However, it is advantageous for the valve to be a safety valve. With such a valve, an unintentional opening of the vent opening can be avoided.
[0018] Since it is not guaranteed that the contents of the tank will not pass through the vent opening and contaminate the vent conduit when the closure is in the open position, it is preferable for the closure to comprise a movably supported float for reversibly opening and closing the vent opening in the open position of the closure. Such a float allows closing of the vent opening when the closure is in the open position. For example, the float can be actuated by the contents of the waste tank, i.e., if the tank fills up, the surface of the waste (the upper waste level) inside the tank forces the float to close the vent opening.
[0019] Although the closure could be actuated manually, it is advantageous for an actuation mechanism to be provided for reversibly moving the closure from the open position to the closed position. The actuation mechanism allows opening and closing of the closure automatically. In principle, the actuation mechanism could be actuated manually or automatically, e.g. electrically or by air pressure.
[0020] Although the actuation mechanism could be actuated manually, it is preferable to provide an automatic actuation of the closure. This could be advantageously realized in such a way that the tank is movable from an inserted position to a retracted position, the tank being inserted in the base section in the inserted position and being retracted from the inserted position in the retracted position, the actuation mechanism being actuatable by moving the tank from the retracted position to the inserted position. This allows an automatic opening and closing of the vent opening by inserting or retracting the tank into or out of the base section of the mobile toilet system.
[0021] In a preferred embodiment of the invention, the actuation mechanism comprises a movable actuation member supported by the tank and cooperating with an actuation element supported by the base section during the movement of the tank from the retracted position to the inserted position. Such a construction requires a minimum of movable parts since the actuation element need not be a movable member.
[0022] Preferably, the actuation member is arranged within the vent conduit and extends in the direction of the vent conduit. The arrangement of the actuation member within or at least partly inside the vent conduit provides protection of the actuation member against contamination and destruction. Furthermore, the actuation member could be completely hidden within the tank.
[0023] To improve the stability of the actuation member and also to increase the waste air flow through the vent conduit, the actuation member has a cross-shaped cross section.
[0024] Although the actuation element could be a movable member, e.g. a push button, it is preferable that the actuation element be formed by an inclination. This allows the actuation member to move or glide along a surface of the inclination which results in a movement of the actuation member in a direction transverse to the inclination.
[0025] In order to also provide an outlet for the waste air with a cross section of maximum size, the actuation element is formed by a web extending across a through-opening of the base section. This allows the waste air to pass bthe web and to flow through the through-opening of the base section. Furthermore, waste air flow is maximized.
[0026] Preferably, the closure is in the closed position when the tank is in the retracted position. Therefore, it is advantageous for the actuation mechanism to comprise a biasing member for biasing the closure in the closed position when the tank is in the retracted position. This avoids any leakage of the tank when the tank is in the retracted position, which, for example, could result in a contamination of the vent conduit.
[0027] In another preferred embodiment of the invention, the actuation mechanism comprises a pivotally supported transfer element interconnecting the actuation member and the closure. This allows an actuation force to be transmitted from a first direction to a second direction via the transfer element. For example, if the actuation member extends vertically through the tank and the vent opening is located on the top side of the tank, an up-and-down-movement of the actuation member has to be transmitted to an up-and-down-movement of the closure. This could be easily achieved with the transfer element.
[0028] In principle, the biasing member could be allocated to the closure itself or to the actuation member. However, it is preferable for the biasing member to be allocated to the transfer element. This allocation allows a reduction in the size of the biasing member and also exact adjustment of a biasing force.
[0029] The actuation mechanism could be easily hidden and protected if it is at least partially arranged in a recess formed on the exterior on the top side of the tank.
[0030] In order to conceal the actuation mechanism and form an impervious air passage between the vent opening and the vent conduit or the channel, according to a preferred embodiment of the invention it is provided that the recess is closed with a cover, the covered recess forming a second conduit, the second conduit being in fluid communication with the first end of the channel and the vent opening.
[0031] Preferably, the transfer element is arranged in the recess. This allows formation of a shallow recess, which has the advantage that almost the entire inner height of tank could be used for storing waste without the risk that the waste will splash through the vent opening and contaminate the vent conduit.
[0032] For further improvement of the venting system, a vent line connector is supported by the base section, the vent line connector being connected to the second end of the channel in the inserted position of the tank. This arrangement allows the waste air to be guided further outside the mobile toilet system, i.e. through the base section to the exterior of the toilet room or the vehicle in which the toilet system is located.
[0033] To avoid further unpleasant irritation by odors a sealing member is provided for sealingly connecting the vent line connector with the second end of the channel.
[0034] A very inexpensive and easy way to seal the vent line connector to the second end of the channel is for the sealing member to be formed by a foam sealing arranged around the vent line connector.
[0035] The vent line connector could be formed by a flange to be connected to a tube system leading the waste air to the outside of the toilet room or the vehicle. However, the vent line connector is preferably a hose connector. Hoses are adapted to fit in almost all situations in a vehicle, especially in caravans or motorhomes. Furthermore, hoses are very cheap and can easily be bent into a shape which is necessary to reach around corners and edges.
[0036] According to a further preferred embodiment of the present invention, the base section comprises an opening for passage of a third conduit connectable to the second end of the channel and/or the vent line connector. This offers the advantage that the waste air can be led through the vent opening and the vent conduit formed by the channel to the second end of the channel which can be connected to a vent line connector and through the third conduit to the exterior of the base section and further to the exterior of the toilet room and/or the vehicle.
[0037] In an advantageous embodiment of the present invention, a cavity is provided in the base section and the vent line connector extends into the cavity. This allows an easy connection of a further air guiding line to the vent line connector.
[0038] In special cases where it is not possible to lead the waste air to the exterior of the toilet room or the vehicle and even in cases which allow an air flow to the exterior, unpleasant irritation could be reduced or completely avoided by using a filter element. Preferably, the filter element is connectable to the vent line connector and locatable in the cavity. This allows easy changing of the filter element after retraction of the tank. Furthermore, the filter element is optimally stored and protected.
[0039] Furthermore, the object as mentioned above is achieved in accordance with the present invention with a mobile sanitary toilet system comprising a base section, a bowl section supported by the base section and a waste holding tank in that the system comprises a waste holding tank as described above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0040] The following description of a preferred embodiment of the invention serves to provide a more detailed explanation, in conjunction with the drawings, in which:
[0041] [0041]FIG. 1 is a cross-sectional view through a waste holding tank inserted in a base section of a mobile toilet system.
[0042] [0042]FIG. 2 is a sectional view of a part of a tank in a retracted position.
[0043] [0043]FIG. 3 is a cross-sectional view along line 3 - 3 in FIG. 1.
[0044] [0044]FIG. 4 is an exploded view of elements of an actuation mechanism.
[0045] [0045]FIG. 5 is a cross-sectional view along line 5 - 5 in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] [0046]FIG. 1 shows a part of the mobile toilet system indicated at 10 , namely a base section 12 and a waste holding tank 14 in an inserted position, i.e., completely inserted in a housing 16 formed in the base section 12 .
[0047] The tank 14 comprises a housing 16 having a top side 20 and a bottom side 22 . On the top side 20 of the housing 18 a block-shaped recess is formed and closed by a cover 26 . A bottom plate 28 of the recess 24 is provided with a circular hole 30 which is surrounded by a tubular flange 32 extending into an interior 34 of the tank 14 . A second circular hole 36 which is about three times smaller in diameter than the hole 30 is also provided in the bottom plate 28 . The hole 36 is surrounded by a tubular section 38 extending into the interior 34 .
[0048] The hole 36 serves as a vent opening of the tank 14 and contains a vent pivot 40 which is movable along an axis of the tubular section 38 . The hole 36 and the vent pivot 40 form a valve unit for reversibly opening and closing the vent opening.
[0049] A vent lifter 42 forming a part of an actuating mechanism for lifting and lowering the vent pivot 40 comprises a bearing shaft 44 and a U-shaped first end 46 which is connectable with the vent pivot 40 . For this reason, the vent pivot 40 comprises two vent flanges 48 and 49 . The first end 46 engages between the flanges 48 and 49 .
[0050] As shown in FIG. 5, sidewalls 50 a and 50 b of the recess 24 which comprise receptacles 52 a and 52 b for receiving ends of the shaft 44 form a hinge for the vent lifter 42 . The axis of the shaft 44 extends parallel to the bottom plate 28 and transversely to a line connecting the holes 30 and 36 . Furthermore, the vent lifter comprises a pot-shaped receptacle 54 for receiving a spring 56 which is held in position by a tubular spring locating section 58 . The spring locating section 58 is arranged on the bottom plate 28 and extends in a direction towards the cover 26 . The spring 56 is arranged between the bottom plate 28 and the vent lifter 42 such that the first end 46 of the vent lifter is forced towards the cover 26 for keeping the vent opening in an opened position.
[0051] A hole 60 is formed in the bottom side 22 of the tank 14 and connected with a tube 62 which extends vertically through the interior 34 of the tank 14 and reaches with a diameter-reduced tube section 64 through the hole 30 . An O-ring 66 is fitted between the flange 32 and the tube section 64 for sealingly connecting the tube 62 to the bottom plate 28 . The vent hole 36 in connection with the covered recess 24 and the tube 62 form a vent path for guiding waste air from the interior 34 of the tank 14 to the bottom side 22 of the tank 14 through the interior of the tank 34 without being in fluid communication with the interior of the tank 34 .
[0052] A vent actuator 68 having a cross-shaped cross section is located within the tube 62 and movable along a tube axis 70 . An upper end 72 of the vent actuator 68 comprising an opening 74 is adapted to receive a second end 47 of the vent lifter 42 . A movement of the vent actuator 68 towards the cover 26 lifts the second end 47 of the vent lifter 42 towards the cover 26 and lowers the first end 46 of the vent lifter 42 at the same time against the biasing force of the spring 56 . When the first end 46 of the vent lifter 42 is lowered, the vent pivot 40 is in a lowered position opening an air path through the hole 36 and through the vent pivot 40 . This position, the so-called open or venting position, is shown in FIGS. 1 and 3.
[0053] As shown in FIG. 2 where the tank 14 is in a retracted position, i.e., any position different from the inserted position shown in FIG. 1, the first end 46 of the vent lifter 42 is forced in a direction towards the cover 26 by means of the spring 56 so that the vent opening formed by the hole 36 is closed by the vent pivot 40 . At the same time, the vent actuator 68 is forced into a lowered position.
[0054] For automatically actuating the vent actuator 68 , a base plate 76 of the base section 12 has a circular opening 78 which is formed by a tubular-shaped hose connector 80 . The upper edge 82 of the connector 80 extends towards the tank 14 and is inclined at about 10 to 15°. A web 84 extends over the opening 78 and is connected with the highest and the lowest sections of the edge 82 . The web 84 is inclined in a direction parallel to the opening 74 .
[0055] The connector 80 extends into a cavity 86 formed in the base plate 76 . A hose 88 shown in dotted lines in FIG. 1 may be connected to the connector 80 and led through the bottom of the cavity 86 to the exterior, for example, of a toilet room or a vehicle.
[0056] Alternatively, a filter element 92 may be arranged within the cavity 86 and connected to the connector 80 for cleaning the waste air led through it.
[0057] For obtaining a sealed connection between the tank 14 and the base section 12 , the hole 60 in the bottom side 22 of the tank 14 is prolonged with a tubular connector 94 having an inclined edge 96 . The opening 78 is surrounded by a base plate seal 98 made of foam.
[0058] Before using the toilet system 10 , the tank 14 has to be inserted into the housing 16 of the base section 12 . During insertion, the tank 14 slides along the base plate 76 of the base section until a front edge 100 abuts a stop 102 formed on the base plate 76 . During the insertion of the tank 14 , a lower edge 104 of the vent actuator 68 slides along the inclined web 84 which results in a movement of the vent actuator 68 towards the cover 26 . At the same time, the second end 47 of the vent lifter 42 lifts up and the first end 46 is lowered. In the inserted position of the tank 14 shown in FIG. 1, the vent opening is open and the waste air inside the tank 14 can flow through the hole 36 and the vent pivot 40 , the covered recess 24 , the tube 62 and the connector 80 and, for example, through a hose 88 to the exterior of the vehicle. Since both the edge 82 of the connector 80 and the edge 96 of the connector 94 are inclined, and the seal 98 surrounds the opening 78 , the edge 96 contacts the seal 98 in such a way that air cannot leave the above-described vent path.
[0059] When the tank 14 is retracted from the inserted position, the vent actuator 68 moves away from the cover 26 and the biasing force of spring 56 results in a lifting-up of the first end 46 of the vent lifter 42 . The vent opening is thereby automatically closed.
[0060] For closing the vent opening in the bottom plate 28 of the recess 24 when the vent pivot 40 is in the open position as shown in FIG. 1, a float 106 is provided. The float 106 comprises a float holder 108 which is slidably supported in a central bore 109 of the vent pivot 40 . The float holder 108 carries a float stem 110 in the form of a disk whose one circular side is covered by a disk 112 of foam. In order to close an air path when the vent pivot 40 is in the open position, a vent seal 114 is arranged around the hole 36 having an inner diameter which is about three times larger than the diameter of the hole 36 .
[0061] The float 106 is connected to the vent pivot 40 and forms a safety valve which closes the vent opening when the upper waste level inside the tank 14 rises above a certain level and comes into contact with the disk 112 . As the waste level rises further, the disk 112 connected to the float stem 110 moves towards the cover 26 until the float stem 110 comes into contact with the vent seal 114 . When the float 106 is actuated, it is impossible for waste to pass through the vent opening inside the recess 24 , which would result in a contamination of the actuating member.
[0062] Construction of a waste holding tank 14 as indicated above, i.e., with an improved venting system, has a quadruple function.
[0063] First, it is possible to guide the waste air from the faeces out of the tank 14 through the interior 34 despite the waste located there. The location of the outlet for a waste air guide, e.g. the tube 62 , can be chosen optimally and be adapted to the requirements of the base system, i.e., the vehicle or the toilet room.
[0064] Second, it is possible to install the necessary actuating mechanism for valve control in the vent conduit.
[0065] Third, the tank 14 can be easily transported since the vent opening is closed when the tank is in the retracted position.
[0066] And fourth, it is possible to change the function of the safety valve to a float when the actuating mechanism is activated, i.e., when the tank is in the inserted position.
[0067] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.
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A waste holding tank for a mobile sanitary toilet system includes a base section, a bowl section supported by the base section and a waste holding tank. The tank includes a housing defining a tank interior and a tank exterior. A vent opening is located at a first location of the housing. The opening forms a fluid communication between the interior and the exterior of the tank. A vent conduit connects the vent opening on the tank exterior at the first location with the exterior of the tank at a second location of the housing. The vent conduit leads at least partly through the interior of the tank without being in fluid communication with the interior of the tank.
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BACKGROUND
Technical Field
The present disclosure relates to the field of memory cells, and more specifically of antifuse memory cells, that is, of memory cells having a storage element, which is non-conductive in its initial state and becomes conductive after programming.
Description of the Related Art
FIG. 1 shows an example of an antifuse memory cell 10 . In the upper portion of a P-type semiconductor substrate 1 are delimited active areas 2 , each of which is surrounded with an insulating ring 3 . Insulating ring 3 is for example of the type currently called STI (Shallow Trench Insulation) in the art. The antifuse memory element 10 and its control elements are formed in each active area. The actual memory element 10 is formed of a very thin insulating layer 7 and a conductive pad 9 on the insulating layer 7 . Insulating layer 7 is formed above a portion of the active area or P-type well 2 . Two N-channel access transistors are formed in the active area to connect the region arranged under thin insulator 7 to a terminal called BL, which generally corresponds to a bit line terminal. First transistor 11 , used for transfer, comprises an insulated gate 13 formed above the substrate between drain and source regions 14 and 15 . Second transistor 21 , used for reading, comprises an insulated gate 23 between drain and source regions 15 and 24 . Region 24 is covered with a pad 25 connected to terminal BL.
A metallization 27 coupled with a P + region 29 formed in substrate 1 outside of the active areas has also been shown. Metallization 27 is connected to a generally grounded terminal BULK.
The memory cell has one or the other of two states according to whether insulator 7 effectively insulates conductor 9 from the substrate or to whether this insulator is made conductive by the flowing of a strong programming current. This programming current results from a programming voltage applied between a terminal HV connected to conductive layer 9 and terminal BL while transistors 11 and 21 are set to the on state.
FIG. 2 illustrates current I HV in the antifuse during the programming phase. First, during a time T 1 , which corresponds to the breakdown phase of the antifuse, the current varies slowly. Then, from the end of time T 1 , current I HV increases abruptly, and then remains substantially constant due to the current saturation of access transistors 11 and 21 .
The performed tests show that time T 1 is very variable, for example within a range from 100 ns to 10 μs, from one antifuse to another of a same wafer and for antifuse devices of different wafer batches, even for theoretically identical antifuses. Thus, in practice, many tests are performed and a time at least equal to the longest programming time detected during the tests is selected as the programming time. It can further be observed that the resistivity of antifuses programmed in this manner does not have a minimum and constant value.
BRIEF SUMMARY
An embodiment of the present disclosure is directed to a method for controlling the breakdown of an antifuse formed on a semiconductor substrate, comprising the steps of:
applying a programming voltage; detecting a breakdown time; and interrupting the application of the programming voltage at a time following the breakdown time by a post-breakdown time. This method ensures that a resistivity of a programmed antifuse has a minimum and constant value. In addition, the method is configured to decrease the programming time of antifuses.
According to an embodiment, the post-breakdown time is determined by previous tests for antifuses of determined characteristics.
According to an embodiment, the current generated in the substrate is compared with a first threshold to determine the end of the breakdown.
According to an embodiment, the breakdown voltage is provided by a current source with no current limitation and, after the first threshold has been exceeded, the value of the current generated in the substrate is compared with a second threshold reached in decreasing fashion.
According to an embodiment, the second threshold is selected to be equal to from 30 to 70% of the peak current at the time of the breakdown.
According to an embodiment, the method further comprises the step of interrupting the application of the programming voltage immediately after the crossing of the second threshold has been detected.
An embodiment provides a device for controlling the breakdown of an antifuse formed on a semiconductor substrate, above a well surrounded with a peripheral insulator, the lower surface of the well being laid on a buried layer of a conductivity type opposite to that of the well, comprising a detector of the current on a substrate terminal, and a comparator of the value of said current with a first threshold.
According to an embodiment, the device further comprises a comparator of the value of said current with a second threshold reached in decreasing fashion.
According to an embodiment, the device further comprises means for interrupting the application of the programming voltage after the second threshold has been reached.
The foregoing and other features and advantages will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 , previously described, shows an example of an antifuse memory cell;
FIG. 2 , previously described, shows the current variations in an antifuse during the application of a programming voltage;
FIG. 3 shows an embodiment of an antifuse memory cell;
FIG. 4 shows current variations in an antifuse memory cell during the application of a programming voltage; and
FIGS. 5 and 6 show block diagrams of a devices that include the antifuse memory cell and other components according to embodiments of the present disclosure.
DETAILED DESCRIPTION
The present inventors have found that, to obtain programmed antifuse memory cells having a resistivity of minimum and constant value, said fuses should be applied a programming voltage for a well-determined time adapted to each antifuse. Tests have shown that it was not desirable to interrupt the programming current at the end of above-mentioned time T 1 in the prior art devices, but that the programming phase had to be extended for a post-breakdown time T 2 after phase T 1 to make sure that the antifuse has fully turned into a conductive element of minimum resistivity. Time T 2 , which may experimentally be determined for antifuses of same characteristics, is relatively constant (to within 10%) and is currently on the order of a few microseconds. Further, tests have shown that, if time T 2 is exceeded, for example, by more than 50%, the resistivity of the programmed antifuses increases beyond the minimum value. Given the large above-mentioned dispersion of breakdown time T 1 , conventional methods—where a fixed time at least equal to the longest programming time detected during many tests is selected as the programming time—inevitably provide programmed antifuses which do not have a resistivity of constant and minimum value. This is due to the fact that the total programming time is then shorter (for antifuses having a long breakdown time) or longer (for antifuses having a short breakdown time) than optimal time T 1 +T 2 .
One embodiment of the present disclosure includes detecting the end of period T 1 and applying the programming voltage to each antifuse to be programmed for time T 1 plus time T 2 , which may have been determined experimentally by previous tests or which may have been determined on each programming, as will be discussed hereafter.
According to an embodiment, an antifuse memory cell such as illustrated in FIG. 3 is used. In FIG. 3 , the same reference numerals as in FIG. 1 are used to designate the same elements. Further, in FIG. 3 as in FIG. 1 , as usual in the representation of integrated circuits, the various elements and layers are not drawn to scale.
The same elements as those in FIG. 1 will not be described again. An important difference between the two drawings is that the device of FIG. 3 comprises an N-type buried layer 30 under each active area. The buried layer is contacted by a peripheral N-type wall 31 extending from the surface of the component. An N+ region may separate the surface of the component from the N-type wall. Further, means for measuring, during programming phases, output current I BULK when terminal BULK is grounded are provided.
FIG. 4 is a current-vs.-time curve.
The shape of current I HV flowing in through terminal HV, of current I BL flowing out from terminal BL, and of current I BULK flowing out through terminal BULK has been indicated in this drawing.
Until the breakdown (time T 1 ), as in the case of FIG. 2 , input current I HV and output current I BL are substantially equal while current I BULK on terminal BULK is substantially zero. From the end of time T 1 , considering that there is no element creating a saturation of the current delivered by high-voltage source HV, input current I HV abruptly increases, then uniformly decreases, and the same variation can be observed on current I BULK . During this phase, output current I BL is maintained at a constant value due to the saturation of the access transistors and current I HV is equal to I BL +I BULK .
The variation of current I BULK from a zero value to a positive value of course depends on the specific considered memory cell, but it will be easy to compare current I BULK to a threshold I TH1 , which then enables to easily and accurately determine the breakdown time, and thus time T 1 . Incidentally, it should be noted that the transition detection is easier to perform on current I BULK than on current I HV or on current I BL since the transition on I BULK occurs between zero and a positive value while the transitions of currents I HV and I BL occur between two non-zero values. Further, it is difficult to measure current I HV at the high voltage level since this would require specific measurement devices capable of being connected to the high voltage.
After time T 1 , current I BULK decreases and the downward transition to a second threshold I TH2 greater or smaller than threshold I TH1 can again be detected. Experimental studies have shown that the moment (end of time T 2 ) when the antifuse reaches a minimum resistance in the programmed state corresponds to a time at which current I BULK becomes equal to a percentage approximately ranging from 30 to 70% of its maximum value. It is thus provided to interrupt the application of the programming voltage as soon as threshold I TH2 selected to correspond to this percentage range has been reached. Account can then be taken of possible variations of time T 2 to set the total memory cell programming time.
FIG. 5 is a block diagram of a device for controlling the breakdown of the antifuse memory cell 10 formed on a semiconductor substrate, such as the antifuse 10 shown in FIG. 3 . The device includes a detector 42 configured to detect the current (I BULK ) on a substrate terminal 27 and a comparator 44 configured to compare the value of said current (I BULK ) with a first threshold (I TH1 ) and with a second threshold (I TH2 ) reached in decreasing fashion.
FIG. 6 is a block diagram of a device for controlling the breakdown of the antifuse memory cell 10 formed on a semiconductor substrate, such as the antifuse 10 shown in FIG. 3 . The device includes a detector 42 configured to detect the current (I BULK ) on a substrate terminal 27 and a comparator 44 configured to compare the value of said current (I BULK ) with a first threshold (I TH1 ). The device may also include a comparator 46 configured to compare the value of said current with a second threshold (I TH2 ) reached in decreasing fashion.
Due to the above-described process, the programming time and the power spent for the programming are decreased given that, in practice, time T 1 is greatly variable, for example, from 100 ns to 10 μs, for theoretically identical memory cells which are however different on a wafer or different from one wafer batch to another. Further, this ascertains that the antifuse will have a minimum resistance in the programmed state.
Of course, the foregoing is likely to have many variations.
A specific antifuse memory cell 10 has been described. The present disclosure generally applies to any antifuse memory cell. Different types of antifuse storage elements comprising thin insulating layers of various natures topped with conductive layers of various natures may be used. Similarly, although circuits with two transistors have been described herein as an example, various types of circuits for programming and reading these antifuses may be used.
N- and P-type regions and layers have been mentioned. All conductivity types may be inverted.
No means for measuring current I BULK have been shown or described in detail but it is within the abilities of those skilled in the art to perform a current detection between a terminal and a ground connection of this terminal.
Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and the scope of the present disclosure. Accordingly, the foregoing description is by way of example only and is not intended to be limiting.
The various embodiments described above can be combined to provide further embodiments. These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.
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A method for controlling the breakdown of an antifuse memory cell formed on a semiconductor substrate, including the steps of: applying a programming voltage; detecting a breakdown time; and interrupting the application of the programming voltage at a time following the breakdown time by a post-breakdown time.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a polymeric composite product that resists staining when contacted with moisture, and a method for its production.
2. Discussion of the Background
Lumber, particularly decking lumber, is a multi-billion dollar industry. In the decking lumber industry alone, there are over 30 million existing decks in the United States, with 3 million decks being built, repaired or replaced every year. One primary type of lumber used in the decking industry is pressure treated wood, typically made by impregnating the wood with a composition containing, among other things, arsenic under high pressure.
Synthetic lumber has been used as a substitute for wood, particularly in areas where wood can deteriorate quickly due to environmental conditions. Modern recycling techniques and low cost extrusion processes have greatly increased the market for such synthetic lumber products.
One synthetic alternative to pressure treated wood that has arisen is composite lumber, generally defined as any blend of plastics and wood or other natural fibers. Composite lumber is rapidly becoming the preferred alternative to pressure treated wood, with the market for composite and plastic lumber growing at an annual rate of 11%, with that rate estimated to continue for the next decade. The composite lumber products are preferred over pressure treated wood due to toxicity reasons, as well as the lower maintenance required for composite or plastic products relative to wood decking.
Unfortunately, conventional composite lumber products are not without their drawbacks also. One of the most significant problems associated with conventional composite lumber is that of staining when the product is contacted with moisture. There is a need in the industry for a composite lumber product that retains the advantages of conventional products but which does not show water-spots or staining when contacted with water and allowed to dry.
SUMMARY OF THE INVENTION
Accordingly, one object of the present invention is to provide a composite lumber composition that does not exhibit staining when contacted with moisture.
A further object of the present invention is to provide a method for preparing a composite lumber composition having consistency of appearance and that avoids staining.
These and other objects of the present invention have been satisfied by the discovery of a polymeric composite product comprising about 35-75 wt % of a resinous material, about 25-65 wt % of a tannin containing cellulosic fiber material, calcium carbonate and an amount of a stain preventive agent sufficient to suppress leaching of tannins from the cellulosic material upon application of moisture to a surface of the product.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein;
FIG. 1 provides structures for various compounds found in oak tannins (structures from J. -L. Puech et al, “The Tannins of Oak Heartwood: Structure, Properties, and Their Influence on Wine Flavor”, International Symposium on Oak in Winemaking/Am. J Enol. Vitic ., Vol. 50, No. 4,, pp 469-478 (1999)).
FIG. 2 provides structures for additional compounds found in oak tannins (structures from J. -L. Puech et al, “The Tannins of Oak Heartwood: Structure, Properties, and Their Influence on Wine Flavor ”, International Symposium on Oak in Winemaking/Am. J Enol. Vitic ., Vol. 50, No. 4, pp 469-478 (1999)).
FIG. 3 provides structures for various tannin chemical precursors (structures obtained from Cornell University animal science website, www.ansci.cornell.edu).
FIG. 4 shows the results of water staining tests on PVC/oak flour compositions containing various levels of calcium carbonate.
FIG. 5 shows the results of water staining tests on PVC/oak flour compositions containing various levels of calcium carbonate, to which various levels of succinic anhydride have been added.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention relates to a polymeric composite product comprising about 35-75 wt % of a resinous material, about 25-65 wt % of a tannin containing cellulosic fiber material, calcium carbonate and an amount of a stain preventive agent sufficient to suppress leaching of tannins from the cellulosic material upon application of moisture to a surface of the product.
The polymeric composite product of the present invention is a composite of about 35-75 wt % of resinous materials, such as thermoplastic or thermosetting resins. Suitable resinous materials include, but are not limited to, polyvinyl chloride (PVC), polyethylene, polypropylene, nylon, polyesters, polysulfones, polyphenylene oxide, polyphenylene sulfide, epoxies, cellulosics, and mixtures or blends thereof. The resinous material of the present composition may be virgin material or can be obtained by recycling resinous materials from any of a variety of sources. The resinous material of the present invention can be water-white or pigmented as desired.
The resinous material is most preferably PVC. PVC thermoplastics comprise the largest volume of thermoplastic polymers in commercial use. Vinyl chloride monomer is made from a variety of different processes typically involving reaction of acetylene and hydrogen chloride or the direct chlorination of ethylene. The polymerization is conventionally carried out by radical polymerization of vinyl chloride. The PVC is typically combined with conventional polymer additives, including but not limited to, impact modifiers, thermal stabilizers, lubricants, plasticizers, organic and inorganic pigments, fillers, biocides, processing aids, and flame retardants. The PVC can also be a copolymer of vinyl chloride monomer and one or more other copolymerizable monomers. The copolymer can be any type of copolymer, including but not limited to linear copolymers, block copolymers, graft copolymers, random copolymers, and regular repeating copolymers.
Suitable copolymerizable monomers that can be included in the PVC for the present invention preferred embodiments include, but are not limited to, acrylonitrile; alpha-olefins such as ethylene or propylene; chlorinated monomers, such as vinylidene dichloride; acrylate monomers such as acrylic acid, methyl acrylate, methyl methacrylate, acrylamide, and hydroxyethyl acrylate; styrenic monomers such as styrene, alpha methyl styrene or vinyl toluene; vinyl acetate; or any other ethylenically unsaturated copolymerizable comonomer. Preferably the PVC of the preferred embodiments is at least 50 wt % vinyl chloride monomers with the remainder being one or more of the copolymerizable monomers. The PVC's used in the present composition can have a range of physical properties and can be alloyed or blended with other polymers as desired. Suitable alloying polymers include, but are not limited to ABS, acrylic, polyurethane and nitrile rubber. Such alloys or blends can provide improved impact resistance, tear strength, resilience and/or processability.
In a preferred embodiment of the present invention, the resinous material is rigid PVC, optionally containing a small amount of plasticizer. The PVC is hard and tough and can be compounded to a wide range of properties, including impact resistance and weatherability (i.e. fading color to a wood grey appearance). The PVC preferably has a tensile strength of about 6,000-7,500 psi, a percent elongation of about 40-80%, and a tensile modulus of about 3.5-6.0×10 6 psi. It can be used without chlorination to about 140° F., and with chlorination to about 220° F. It also has a coefficient of thermal expansion of about 3-6×10 −5 inch/inch-° F.
The composition of the present invention can be prepared by any conventional polymer handling technique, including but not limited to, injection or vacuum molding, or extrusion and drawing. In a preferred embodiment, a mixture of PVC regrind and/or virgin PVC is compounded and then heated and extruded through a die to produce boards and other shapes having any desired length, width and thickness, preferably lengths ranging from 4 to 20 feet and widths or thicknesses ranging from 0.05 to 6.0 inches. The extruded products can be further processed by molding, calendering and finishing to add surface textures or wood grain appearance.
The composition of the present invention further comprises a tannin containing cellulosic material, preferably cellulosic fibers or cellulosic flours from recycled paper products, soft woods or hard woods. More preferred cellulosic materials are those obtained from hard woods due to their lower capacity to absorb moisture, with wood flour being more preferred and of these, oak flour being most preferred. The oak flour is preferably of about 10-100 mesh, most preferably about 20-30 mesh.
One or more additional fiber or flour type fillers can also be present in the present invention composite, although in a preferred embodiment, the only such filler is the wood flour, preferably oak flour.
In a preferred embodiment, the resin and wood flour components are combined with a chemical blowing agent, or a gaseous medium is introduced into a molten mixture of the resin and wood fiber to produce a series of trapped bubbles prior to thermo-forming the mixture, for example, by molding, extrusion, or co-extrusion. These thermo-forming processes, as well as the methods for making foamed polymer articles are well known in the art.
In a preferred process for making the composite of the present invention, a quantity of PVC (virgin and/or regrind) in small chunks is mixed with 20-30 mesh wood flour (preferably oak flour), which has been pre-dried to release any trapped moisture as steam. The mixture also can include a melt enhancer, such as a high molecular weight acrylic modifier, which improves melt elasticity and strength and enhances cellular structure, cell growth and distribution.
As noted above, the polymer composite of the present invention can be foamed by use of a chemical blowing agent or gas. Such a chemical blowing agent or gas can be added to the mixture to reduce the density and weight of the composite. The amount of blowing agent or gas is not particularly limited. Preferably the blowing agent is added in an amount of from 0.5 to 1.5 phr (parts per hundred parts of polymer resin), more preferably from 1.0 to 1.5 phr. This density reduction allows the composite product to better simulate wood in its ability to be nailed, drilled, and screwed. If a chemical blowing agent is used, it can be added at any point during the process that is suitable for producing a foamed product. Preferably it is mixed into the compound during blending or at the feed throat of the extruder. In the extruder, the blowing agent is decomposed, disbursing gas, such as nitrogen or carbon dioxide, into the melt. As the melt exits the extrusion die, the gas sites experience a pressure drop, expanding them into small cells or bubbles trapped by the surrounding polymer.
Chemical blowing agents useful in the present composition include any conventional blowing agent which releases a gas upon thermal decomposition. Chemical blowing agents may also be referred to as foaming agents. The blowing agent, or agents, if more than one is used, can be preferably selected from chemicals containing decomposable groups such as azo, N-nitroso, carboxylate, carbonate, heterocyclic, nitrogen-containing and sulfonyl hydrazide groups. Generally, they are solid materials that liberate gas when heated by means of a chemical reaction or upon decomposition. Preferred blowing agents include, but are not limited to, azodicarbonamide, bicarbonates, dinitrosopentamethylene, tetramethylene tetramine, p,p′-oxy-bis(benzenesulfonyl)-hydrazide, benzene-1,3-disulfonyl hydrazide, azo-bis(isobutyronitrile), biuret and urea.
The blowing agent can be added to the polymer in several different ways which are known to those of skill in the art. Suitable methods include, but are not limited to, adding the solid powder, liquid or gaseous agents directly to the resin in the extruder while the resin is in the molten state to obtain uniform dispersion of the agent in the molten plastic or adding to the resin prior to entry into the extruder. Preferably the blowing agent is added before the extrusion process and is in the form of a solid. The temperature and pressure to which the foamable composition of the invention are subjected to provide a foamed composition will vary within a wide range, depending upon the amount and type of the foaming agent, resin, and cellulosic material that is used. Preferred foaming agents are selected from endothermic and exothermic varieties, such as dinitrosopentamethylene tetrameine, p-toluene sulfonyl semicarbazide, 5-phenyltetrazole, calcium oxalate, trihydrazino-s-triazine, 5-phenyl-3,6-dihydro-1,3,4-oxadiazin-2-one,3,6-dihydro-5,6-diphenyl-1,3,4-oxadiazin-2-one, azodicarboamide, sodium bicarbonate, and mixtures thereof.
The foamed composition of the preferred embodiments preferably has a specific gravity of 1.25 g/cc or less, more preferably 1.20 g/cc or less, most preferably 1.07 g/cc or less. The porosity of the preferred embodiments preferably is at least about 1%, more preferably about 5-40% by volume of solids in the composite. Even though these specific gravity and porosity values provide a preferred product that is lightweight, the preferred product has a flexural modulus, tensile modulus, and/or Young's modulus of about 100,000 to 450,000 psi.
In addition to the above, a coloring agent can be added to the compounded mixture, such as dyes, colored pigments, fly ash, carbon black, or a mixture of two or more of these, depending on the resulting color desired and cost considerations. Such additives can provide “weatherability” or a faded greyish coloring or a permanent tint, such as blue, green or brown.
The composite of the present invention further comprises calcium carbonate as filler. The calcium carbonate can be contained in any amount up to the point where the polymer fiber composite product loses its physical properties required for the desired end use. Preferably, the composite comprises up to 50 wt % of calcium carbonate (CaCO 3 ), more preferably up to 15 wt %, most preferably up to about 5 wt %, based on total amount of composite. The calcium carbonate can be specifically added to the composition, or can result from the use of polymer resin regrind having calcium carbonate therein. Most regrind PVC contains calcium carbonate, up to about 5-8 wt %. Regrind sources that contain calcium carbonate include, but are not limited to, recycled vinyl siding, windows and pipes. Such regrind is desirable in the production of polymeric wood substitutes since it lowers the cost, while little or no sacrifice in properties is observed. However, the presence of calcium carbonate in such polymeric wood substitutes, particularly PVC wood substitutes that also contain wood fiber or wood filler, results in staining when the product is contacted with water. The water causes tannins in the wood fiber or wood flour to leach to the surface and cause the appearance of unsightly stains.
Since the fiber material of the present invention contains tannins, it is necessary to add an amount of a stain preventive agent sufficient to prevent leaching and deposition of tannins from the cellulosic fiber to the surface of the composite product upon contacting the product with water. Tannins, within the context of the present invention, include any of the series of compounds contained in cellulosic materials having structures similar to vescalagin, castalagin, grandinin, roburins A-E, portions of tannins such as lyxose, or xylose, as well as chemical precursors thereto, such as gallotannin, gallic acid, ellagitannin, hexahydroxydiphenic acid and ellagic acid (structures of these materials are provided in FIGS. 1 - 3 ). Unfortunately, many tannins (lower molecular weight ones) are soluble in water, thus becoming solubilized and leaching to the surface of polymer-fiber composites when contacted with water. This leaching and deposition on the surface of the product produces unsightly brown stains on the surface of the product, having a negative impact on consumer satisfaction.
The stain preventive agent of the present invention is a compound that has the ability to either couple two or more of these tannin molecules to one another, couple a tannin molecule to a cellulosic unit in the cellulosic fiber itself, or both. This causes the tannins to lose their solubility and not be leached/deposited to the surface of the product, thus minimizing staining. The amount of stain preventive agent required is the amount sufficient to suppress the tannin leaching process. This amount will vary depending on the particular stain preventive agent used. The stain preventive agent is preferably a di (or higher) functional compound wherein the functionality has the ability to readily react with one or more of the hydroxyl groups present in the tannins contained in the cellulosic fiber material. Preferred stain preventive agents include, but are not limited to, organic di or polyacids and their anhydrides, preferably diacids and anhydrides, most preferably succinic acid, succinic anhydride, maleic acid, maleic anhydride, glutaric acid, glutaric anhydride, adipic acid, phthalic acid and phthalic anhydride. The amount of stain preventive agent is limited only by the tendency of the agent to plate out of the composition. This plate-out level varies depending on the particular agent and is readily determined by one of ordinary skill in the art. For example, the most preferred succinic anhydride tends to plate out at about 4 wt % based on total composition. Adipic acid tends to plate out at about 2 wt % based on total composition.
Having generally described this invention, a further understanding can be obtained by reference to certain specific examples which are provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.
EXAMPLES
Varying Succinic Anhydride and Calcium Carbonate
A trial was performed using a 35-mm extruder die and a PVC based polymer composition to which was added varying levels of succinic anhydride and calcium carbonate, to determine the optimum level of succinic anhydride that is effective at lower calcium carbonate levels, corresponding to the use of PVC regrind which usually contains about 5-8 wt % of calcium carbonate. The PVC composition was conventional BOARDWALK® product from CertainTeed Corporation, a Saint-Gobain company, which contains about 62% compounded PVC and about 38% of oak flour. The standard batch (1) was added to the hopper, with all other materials added manually to the extruder. Flood feed conditions were maintained throughout.
Approximately 8-inch samples representative samples from each formula variation were cut and subjected to spot testing with distilled water. About 3 mLs of distilled water were placed on a surface of the sample and permitted to dry for approximately 32 hours, after which the sample was observed for visible staining.
The following compositions were prepared and tested, using Ross and Henschel mixers:
#1—Control, 11 kg boxed batch of PVC containing oak flour as noted above, plus 66 g of Celogen® AZRV modified azodicarbonamide from Uniroyal Chemical Company, a Crompton business, as blowing agent.
#2—Composition #1 plus calcium carbonate equal to 1.3 wt % based on PVC content.
#2A—Composition #2 plus succinic anhydride equal to 0.16 wt % based on total composition.
#2B—Composition #2 plus succinic anhydride equal to 0.32 wt % based on total composition.
#3—Composition #1 plus calcium carbonate equal to 2.5 wt % based on PVC content.
#3A—Composition #3 plus succinic anhydride equal to 0.32 wt % based on total composition.
#3B—Composition #3 plus succinic anhydride equal to 0.6 wt % based on total composition.
#4—Composition #1 plus calcium carbonate equal to 5 wt % based on PVC content.
#4A—Composition #4 plus succinic anhydride equal to 0.6 wt % based on total composition.
#4B—Composition #4 plus succinic anhydride equal to 1.2 wt % based on total composition.
The results are shown in FIGS. 4-5.
The tests showed that the amount of succinic anhydride needed to be effective at stain prevention varies directly as the amount of calcium carbonate in the composition. When the amount of calcium carbonate is low, about 1.3% or less, there is no noticeable staining even without the stain preventive agent. However, when the level of calcium carbonate increased above about 1.3%, the level of succinic anhydride needed to prevent staining by tannins also increased, with about 0.32% succinic anhydride needed with about 2.5% calcium carbonate present, while about 0.6% succinic anhydride was needed with about 5% calcium carbonate present.
Test of Addition of Succinic Anhydride to PVC/Oak Flour Product at 8 wt % Calcium Carbonate
A trial was performed using the same BOARDWALK® composition as in the above example, to which 8 wt % of calcium carbonate (based on PVC content) was added to simulate the “worst case” scenario of using 100% regrind PVC. Three batches were tested—1) a Control batch containing 8 wt % calcium carbonate and no succinic anhydride; 2) a batch in which succinic anhydride was added to the Control to give total succinic anhydride level of 1.3 wt % based on total composition; and 3) a batch in which succinic anhydride was added to the Control to give total succinic anhydride level of 1.92 wt % based on total composition. Samples of each batch at room temperature were subjected to the water staining test. In the test, two puddles were made on each sample. One puddle was formed from a single 3 mL pipette of water, while the second puddle was formed using three 3 mL pipettes of water. After drying for 20 hours the samples were observed for staining. The Control batch showed dark spots for both single and triple squirt locations, with the triple squirt location being nearly black in appearance. The 1.3 wt % succinic anhydride batch showed a very weak spot to no spot at all for the single squirt test, while the triple squirt test showed staining, but considerably less than the Control. The 1.9 wt % succinic anhydride batch showed virtually no stain in the single squirt test, and only minimal staining in the triple squirt test. Accordingly, even at the maximum level of calcium carbonate corresponding to complete use of regrind PVC, the addition of the succinic anhydride showed significant improvements in stain prevention, particularly at levels of above 1.3 wt %.
Obviously, additional 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.
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A polymeric composite is provided which has improved stain preventative properties by virtue of inclusion of at least one compound having multiple functional groups capable of reacting with tannins contained in a tannin containing cellulosic material present in the composite, and a method for its production and prevention of water stains thereon.
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BACKGROUND OF THE INVENTION
This invention relates generally to a method and apparatus for producing a pH change in a solution. More specifically, the invention relates to producing a pH change in a solution by irradiating the solution with visible light. With greater specificity, but without limitation thereto, the invention relates to using light to alter the pH of a solution to thereby cause an expansion and/or contraction of a pH dependent polymer immersed in the solution.
There exist a number of natural and synthetic fibers and gels that are expandable and contractible in volume when activated by an environmental change, such as exposure to a change min solvent composition, temperature, pH, electric field or photo irradiation, for example. As a commercially exploitable technology, the fibers and gels have applications in many fields, such as, for example, use in sensors, switches, motors, pumps, non-metallic operations and use in the medical and robotic fields where it is envisioned that these materials will be able to carry out the function of human muscle tissue.
The work of W. Kuhn and B. Hargitay as described in "Muskelahnliche Arbeitsleistung Kunstlicher Hochpolymerer Stoffe", Z. Elektrochemie 1951, 55(6), 490-502, incorporated by reference herein is one example of a synthesized polymer material capable of expansion and/or contraction. When the Kuhn and Hargitay polyacrylamide fiber, known as polyacrylic acid-polyvinyl alcohol (PAA-PVA), is placed within a solution of appropriately increasing pH, a 10% increase in fiber length is claimed to be observed.
Similarly, the work of T. Tanaka, D. Fillmore, S-T. Sun, I. Nishio, G. Swislow, and A. Shah described in the article "Phase Transitions in Ionic Gels" Phys. Rev. Lett. 1980, 45(20), 1636-1639, incorporated by reference herein discloses an observed 400% volume collapse for a polyacrylamide gel disposed in a 50% acetone-water solvent mixture in which the pH of the solvent is lowered at constant temperature and solvent composition.
The work of Kuhn and Hargitay as well as Tanaka and Fillmore et al use a typical approach to changing the pH of a solution. In this approach, the pH is changed by manually dripping an acid or base into the solution. This technique, known as the "acid drip" method, relies upon the rate of the diffusion of hydrogen ions to a polymer site and is considered undesirably slow for certain polymer applications, such as use in synthetic muscles.
Besides the pH activation method of Kuhn and Hargitay and Tanaka and Fillmore et al, there exist electrical polymer activation schemes in which p-electron conjugated conducting polymers and electronically doped non-conducting polymers are electrically activated (expanded and contracted). An example of this activation method has been characterized by Shahinpoor et al as described in the article of D. J. Segalman, W. R. Witkowski, D. B. Adolf, and M. Shahinpoor titled: "Theory and Application of Electrically Controlled Polymeric Gels", Smart Materials and Structures, Vol. 1 (no. 1), M. V. Gandhi and B. S. Thompson (Eds.), London: Chapman and Hall, 1992, 95-100. Like the pH activation method described above, the Shahinpoor et al method depends on the slow diffusion of ions to the active site of a polymer and therefore is also considered too slow for certain polymer applications such as use in synthetic muscles.
In addition to the activation approaches described above, there exist optical activation methods for causing volume changes in polymer fibers and gels. Noteworthy of these is the work of M. Irie and D. Kunwatchakun described in "Photoresponsive Polymers. 8. Reversible Photostimulated Dilation of Polyacrylamide Gels Having Triphenylmethane Leuco Derivatives", Macromolecules 1986, 19(10), 2476-2480. The Irie-Kunwatchakun studies were among the earliest on photoinduced volume changes in polymer gels. Photosensitive molecules, such as leucocyanide and leucohydroxide, were incorporated directly into a polymer's network. Irradiation with UV light produced a 2.2-fold reversible dimension change, but no significant volume change (phase transition) took place in the polymer studied, as the UV light-induced pH change was far from the pH null point of the polymer gel. Thus the magnitude of the dimension change was not optimized for certain applications such as robotics.
In the work of researchers Mamada and Tanaka as described in A. Mamada, T. Tanaka, D. Kungwatchakun, and M. Irie in "Photoinduced Phase Transition of Gels", Macromolecules 1990, 23, 1517-1519 and as described in A. Mamada, T. Tanaka, D. Kungwatchakun, and M. Irie in U.S. Pat. No. 5,242,491 titled: "Photo-Induced Reversible, Discontinuous Volume Changes in Gels" and issued Sep. 7, 1993, photoinduced phase transitions in gels were observed. The copolymer used was that of Irie-Kunwatchakun described above. At a given temperature, the polymer gel discontinuously swelled in response to UV irradiation and shrank when the UV light was removed. It is hypothesized that this swelling is due to dissociation into ion pairs, thereby increasing internal osmotic pressure within the gel. The shrinking process of this method is governed by ion diffusion and recombination, making the speed of the reverse process impossible to control, thereby hindering its usefulness in many polymer actuator applications.
In either of the UV studies described above, the UV radiation can cause undesired ionization, photolysis and molecular ligation of a utilized polymer.
Finally, in the work of A. Suzuki and T. Tanaka described in the article "Phase Transition in Polymer Gels Induced by Visible Light", Lett. Nature 1990, 346, 345-347, visible light was used to irradiate a gel containing a light-sensitive chromophore located in the backbone of an expandable and contractible copolymer. The chromophore absorbed the light and the light energy was then dissipated locally as heat by radiationless transitions, the result of which increased the "local" temperature of the polymer. Unlike the UV studies, the polymer expansion is a rapid process and is due to the direct heating of the polymer network by light. Yet the process of returning the polymer to its original size requires cooling, which becomes increasingly difficult as the temperature of the surrounding solution approaches the temperature of the polymer. This reverse process is too slow for many polymer uses such as in synthetic muscles.
Because many reactions are based on either acid or base catalyzations, including those of the polymers described above, researchers have investigated various approaches to promoting rapid pH changes. Such has been the case of Anthony Campillo et al as described in the article by A. J. Campillo, J. H. Clark, R. C. Hyer, S. L. Shapiro, K. R. Winn, and P. K. Woodbridge titled: "The Laser pH Jump", Proc. Intl. Conf. Lasers '78, Orlando, Fla., Dec. 11-15, 1978, Chem. Phys. Lett. 1979, 67(2), 218-222; the article by A. J. Campillo, J. H. Clark, S. L. Shapiro, K. R. Winn, and P. K. Woodbridge, titled: "Excited-State Protonation Kinetics of Coumarin 102", Chem. Phys. Lett. 1979, 67(2), 218-222; the article by J. H. Clark, S. L. Shapiro, A. J. Campillo, K. R. Winn, titled: "Picosecond Studies of Excited-State Protonation and Deprotonation Kinetics. The Laser pH Jump", J. Am. Chem. Soc. 1979, 101(3), 746-748; and U.S. Pat. No. 4,287,035 issued to John H. Clark, Anthony J. Campillo, Stanley L. Shapiro, and Kenneth R. Winn on Sep. 1, 1981.
The work of Campillo et al relies on excited-state proton transfer reactions to change the [H + ] of a solution by several orders of magnitude. Campillo et al used a picosecond spectroscopy tool to directly measure excited-state deprotonation-protonation reaction rate constants. To promote a pH change, a UV laser with a pulse width of 20 picoseconds was used to excite 2-naphthol-6-sulfonate to a higher (S 1 ) electronic state. From the measured rate constants, Campillo et al determined that the excited-state PK a value was 1.9, as opposed to the ground-state value of 9.1. This 7-unit change in pK a corresponds to a 7-order of magnitude increase in the acid dissociation constant, K a . Campillo's findings are consistent with earlier studies which show that excited-state K a values can differ from ground-state values by many orders of magnitude, see the disclosure of J. F. Ireland and P. A. H. Wyatt titled:"Acid-Base Properties of Electronically Excited States of Organic Molecules", Adv. Phys. Org. Chem. 1976, 12, 131-221.
Campillo et al claim that a major use of their technique is initiation of acid-base catalyzed ground-state reactions. For example, the reactants A and B are present in solution at pH 7. The ground state reaction, A+B→C, occurs only at pH 4. By exciting the Campillo et al "jump molecule", 2-naphthol-6-sulfonate, a subnanosecond jump from pH 7 to pH 4 can be achieved, thereby enabling the desired ground-state reaction. Referring to FIG. 1, a schematic state energy level diagram illustrates the path by which the "jump molecule" 2-naphthol-6-sulfonate travels to produce the pH change described. The 2-naphthol-6-sulfonate is irradiated with UV light and is excited from ground state S 0 to first excited singlet state S 1 . Radiative decay (florescence) then occurs bringing the molecule back to its ground state.
A major drawback of the Campillo technique is the extremely short duration of the accompanying pH change, typically 10 nanoseconds. While Campillo proposes that the excited state duration, and hence pH change, could be prolonged through use of repetitious irradiation, such an irradiation would require a bombardment of photons on the order of a million times a second. An additional shortcoming of the Campillo technique, when utilized with expandable and contractible polymers such as those described above, is that the utilized UV radiation promotes undesirable polymer ionization, photolysis and other molecular ligation. Additionally, the extremely narrow illumination path (0.1 mm or 5D-6 cubic centimeters) provided by the utilized 266 nanometer laser is considered insufficient to effectively illuminate an expandable/contractible polymer to undergo an appreciable change in volume.
SUMMARY OF THE INVENTION
The invention provides a method and apparatus of rapidly changing the pH of a solution by way of a pH jump molecule that is activated by visible light. An application of the present invention is the ground-state reaction of changing the volume of an expandable and contractible polymer for simulated muscle applications as well as for other applications.
To permit these applications, it is desirable (1) to use a source of excitation energy that is not harmful to a utilized polymer; (2) to produce an in-situ pH change in which hydrogen ions become rapidly present at a polymer site; (3) to sustain the resultant pH change long enough and in a volume large enough for desired ground-state reactions to occur, for example, the fully reversible expansion and contraction of a polymer; and (4) to provide a mechanism for efficient dissipation of heat produced as a result of the source of excitation energy.
Candidate pH "jump molecules" considered suitable for providing sufficient polymer actuation (activation) should possess the following characteristics:
(1) the jump molecules should have long lifetimes at room temperature, e.g 10 milliseconds;
(2) the jump molecule acidity constants should be grossly different in ground and triplet states, e. g., 7 orders of magnitude;
(3) the resultant pH change should go through the midpoint (pH null point) of the utilized polymer; and
(4) either the non-protonated or the protonated form of the jump molecule should absorb in the visible region of the spectrum.
In accordance with the present invention, an apparatus and method incorporating these desirable features are disclosed. The invention includes a pH jump molecule that permits visible light excitation to provide a long lasting pH change to a pH dependent polymer or other pH driven reactant. The attendant pH change occurs rapidly (in nanoseconds) and will last for the excited state lifetime of the jump molecule. Further irradiation by either a continuous wave or appropriately pulsed laser can sustain the pH change indefinitely. Heat resulting from the light activation is efficiently discharged by radiative decay through room temperature phosphorescence lifetimes existing on the order of milliseconds. Thus an expandable and contractible polymer can be made to respond rapidly to a change in pH while the radiant heat-release mechanism of the invention allows the polymer to return to its initial configuration in a millisecond time frame, suitable for a variety of useful applications, including robotics.
Accordingly, it is an object of this invention to provide a method and apparatus for producing a rapid pH change in a solution.
A further object of this invention is to produce a rapid pH change in a solution that is useful in causing the expansion and/or contraction of a polymer.
Another object of this invention is to produce a rapid pH change in a solution that lasts long enough and is prevalent enough to be useful in causing the expansion and/or contraction of a polymer.
Still another object of this invention is to produce a rapid pH change in a solution that is useful in causing the expansion and/or contraction of a polymer while minimizing damage to the polymer.
Still yet another object of this invention is to produce a rapid pH change in a solution by irradiating the solution with visible light.
Yet another object of this invention is to produce a pH change in a solution by irradiating the solution with visible light in which any heat produced by the light is rapidly dissipated.
Other objects, advantages and new features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic state energy level diagram.
FIG. 2 is illustrates the pH expansion and contraction dependence of an exemplary polymer, in this case an acrylamide gel.
FIG. 3 describes ΔpK values for various families of molecules
FIG. 4 illustrates the light absorbance of anthracene versus wavelength.
FIG. 5 illustrates the pH expansion and contraction dependence of another exemplary polymer, in this case a polyacrylic acid-polyvinylalcohol (PAA-PVA) fiber.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the expandable and contractible polymer world, a term of art has evolved that describes the large and easily perceptible change in volume that occurs when such a polymer, whether it be a gel or a fiber, is exposed to a particular change in the pH of a solution in which the polymer is immersed. This term of art is known as a "phase transition", and describes the physical phenomenon that takes place when the polymer is exposed to a narrow change in pH that passes through what is know as the pH null point of the polymer.
Referring to FIG. 2, there is shown a graphical depiction of such a phase transition. This illustration, taken from the 1980 Physical Review Letter of T. Tanaka and D. Fillmore et al referred to above, shows the response of a polymer network of an acrylamide gel that has been hydrologized in a 4% (volume) N,N,N,N-tetramethylethylenediamine (TEMED) solution. The quantity φ/φ* represents the swelling ratio which is the ratio of the final polymer network concentration to the initial polymer network concentration. The smooth curve is for gels immersed in water. The discontinuous curve is for gels in a 50% acetone-water mixture. In either case, as pH is increased, the gel swells; as the pH is decreased, the gel shrinks.
For the acetone-water mixture shown in FIG. 2, the sharp s-shaped curve is characteristic of a phase transition. This behavior is referred to as a phase transition because an enormous amount of polymer swelling-shrinking occurs within a very narrow range of pH values. Capitalizing on this phenomenon, the greatest leverage for polymer activation can be achieved by finding a polymer-polymer activation system that has a pK a at the midpoint of the pH curve (or what is otherwise referred to as the null point of the polymer). The closer that the ground state pK a of a candidate "jump molecule" is to the null point of a polymer, the greater will be the variability of polymer volume for a given quantity of excitation energy. By using such a jump molecule, a small change in pH to either side of the midpoint will expand or contract the polymer by the largest amount possible, optimizing polymer dimensional change for use in robotics or other applications.
The term pK is a shorthand indicating the strength of an acid (pK a ) and is defined as the -log 10 K in which K is the characteristic equilibrium constant K, represented by:
K=[H.sup.+ ][B]/[BH.sup.+ ]
where [H + ] is the hydrogen ion concentration and [B] is the concentration of the conjugate base. When the amount of one of these constituents is varied, the others will adjust to keep K constant.
During the course of scientific research, the inventor constructed kinetic equations for the 3-level system of FIG. 1. Referring again to FIG. 1, an ideal "jump molecule" will be excited from ground state energy level (S 0 ) to first excited singlet state energy level (S 1 ), and return to the ground state via triplet state energy level (T 1 ). The radiationless transition and radiative decay via phosphorescence will function as a "sink" for the molecules and because of their combined long lifetime, a prolonged molecule excited state will exist. The pH change produced by this excitation will last for the life of this excited state.
Repeated runs with many different candidate jump molecules predicted the requirements necessary to sustain a desired pH change:
(1) jump molecules should have long excited state lifetimes at room temperature, e.g., 10 milliseconds;
(2) jump molecule acidity constants must be grossly different in the triplet and ground states, e.g., 7 orders of magnitude;
(3) the resultant pH change should go through the midpoint (pH null point) of a utilized polymer; and
(4) either the non-protonated or the protonated form of the jump molecule should absorb in the visible region of the spectrum.
A great many molecules with functional groups were eliminated based upon being disqualified by the above requirements.
For example, the phenones are considered undesirable because the lifetimes of the protonated and non-protonated forms are very different, providing a rapid excited state deactivation channel. An example of this is benzophenone, having an unprotonated lifetime of 100 milliseconds and a protonated lifetime of 62 nanoseconds.
In addition, a great many functional groups were eliminated based upon small ΔpK values, ΔpK in this instance being the difference between first triplet state pK value minus the ground state pK value (pK(T 1 )-pK(S 0 )), as can be seen in FIG. 3.
In Table 1, characteristics of the carbon acids are described. The carbon acids shown exhibited long excited-state lifetimes τ p (p for phosphorescence) , large ΔpK values, and have ΔpK values that pass through a desired polymer null point, however the excitation wavelength λ 00 necessary to initiate a pH change falls within the ultraviolet. In this table, "obs" means "observed" and "c" means "calculated".
TABLE 1______________________________________ τ.sub.p (msec) pK (S.sub.0) pK (S.sub.1) pK (T.sub.1) .sub.00 (nm)______________________________________fluorene 0.35 23.04 -5.96 7.54 300(c) (c) 9-phenylflourene obs 18.6 -10.7 4.2 305(c) (c) 9-cyanflourene obs 11.4 -12.4 5.0 300(c) (c)______________________________________
Through the process of elimination, several families of molecules satisfied the pH jump molecule requirements stated above. One of these are the polynuclear aromatic hydrocarbons (PAC's) which are bases.
Of these, the PAC, anthracene, fits well with certain well established polymers. Referring to FIG. 4, the protonated form of this molecule is confirmed. In FIG. 4, an absorbance versus wavelength profile shows the zero-time spectrum for protonated anthracene. The peak at 424 nm is the only peak within the visible region of the spectrum which decreases with time, and is the signature of anthracene's protonated form. It is this peak that is used to activate the anthracene polymeric actuator with visible light.
Referring to FIG. 5, the contractile-expansion characteristics of the Kuhn-Hargitay polyacrylic-acid-polyvinylalcohol (PAA-PVA) polymer are shown. The Kuhn-Hargitay polymer fiber undergoes a phase transition between pH levels of 5 and 5.5, having a pH null point of approximately 5.3, as shown by the "Lange des Fadens" or "Length of Fiber" solid line.
Referring now to Table 2, specifications for utilizing protonated anthracene in coordination with the polymer described by Kuhn-Hargitay referred to above are shown.
TABLE 2______________________________________pH change and species concentrations BH+ only absorbing, pH = 5.0, 413.1 nm - #STR1## - Anthracene Jump Molecule______________________________________ Lamda = 413.1 nm Ground Singlet Triplet Log(eps) epsilon______________________________________ pK's 3.8 13.6 10.3 Lifetimes nS 10.0 (10.0) (mS) B 9.7D-4 1.5D-21 3.0D-11 0.04 1 BH+ 6.4D-4 2.0D-11 2.0D-4 4.38 23988______________________________________Initial Concentrations: Final pH:pH 5.0 5.48 Watts 4.2 Photons/sec 9.3D+18 [H+] 1.0D-5 3.3D-6 V cm3 1.0 P/cm3-sec 9.3D+18 [B] 9.8D-4 [BH+] 2.0D-4 Total B 1.0D-3______________________________________ 413.1 nm = Center Kr+ line: 406.7, 413.1, 415.4
By utilizing visible light, the protonated form BH + of anthracene is disassociated into its base (B) and hydrogen ion (H + ) constituents to prompt a pH change from 5 to 5.48. As can be seen, the ΔpK (pK(T 1 )-pK(S 0 )) of anthracene is 10.3-3.8, permitting such a large scale pH change. The calculation in Table 2 is based on a pK(S 0 ) value for anthracene found in Mackor.. E. L., Hofstra, A., and Van Der Waals, J. H., 1958, in an article entitled "The Basicity of Aromatic Hydrocarbons", Trans. Faraday Soc., vol. 54, 66.
For use with the referenced Kuhn-Hargitay polymer, the desired protonated form of anthracene is derived by dissolving enough anthracene in cyclohexane, as described in Table 2, so that the resulting concentration of non-protonated anthracene is 9.8D-4 moles/liter when the pH is adjusted to 5.0 by the addition of sulfuric acid (H 2 SO 4 ). The mixture is then vigorously shaken in a separatory funnel, causing the anthracene to diffuse from the cyclohexane to the sulfuric acid to form a solution of protonated anthracene.
For the polymer-anthracene combination described, a BeamLok 2080 krypton ion laser was used to irradiate the polymer system at 413.1 nanometers and 4.2 watts. The one cubic centimeter irradiation volume is large enough to house a polymer of macroscopic dimensions as the jump molecule provides a pH change from 5.0 to 5.48. Because of the 10 millisecond prolonged excited state of the anthracene jump molecules, the continuous wave laser will permit constant pH elevation until the irradiation is cut-off, at which time the excited-state jump molecules will decay to the ground state and reassociate, causing a return to the original pH in a few milliseconds. Importantly, the heat created by the molecules absorbing the irradiated light is released as light of a longer wavelength. Full polymer reversibility, which is not hindered by the slow dissipation of heat, is therefore made possible for use in many polymer applications, including robotics.
Besides use of a continuous wave irradiation source, a pulsed laser having a repetition rate of 100 times a second at 42 millijoules will also suffice. This repetition rate will prompt a pulse every 10 milliseconds, permitting continuous pH elevation.
Referring now to Table 3, specifications for utilizing protonated anthracene in coordination with the polymer described by Tanaka-Fillmore et al referred to above are shown. The protonated form BH + of anthracene coordinates well with the Tanaka polymer in which the null point of this polymer (3.8 pH) corresponds with the ground state pKa value of the anthracene.
TABLE 3______________________________________pH change and species concentrations BH+ only absorbing, pH = 3.7, 413.1 nm - #STR2## - Anthracene Jump Molecule______________________________________ Lamda = 413.1 nm Ground Singlet Triplet Log(eps) epsilon______________________________________ pK's 3.8 13.6 10.3 Lifetimes nS 10.0 (10.0) (mS) B 6.4D-4 3.2D-21 6.9D-11 0.04 1 BH+ 1.8D-4 2.3D-11 1.8D-4 4.38 23988______________________________________Initial Concentrations: Final pH:pH 3.7 3.9 Watts 6.3 Photons/sec 1.4D+19 [H+] 2.0D-4 1.3D-4 V cm3 1.0 P/cm3-sec 1.4D+19 [B] 7.1D-4 [BH+] 2.9D-4 Total B 1.0D-3______________________________________ 413.1 nm = Center Kr+ line: 406.7, 413.1, 415.4
For use with the Tanaka-Fillmore polymer, the desired protonated form of anthracene is derived by dissolving enough anthracene in cyclohexane, as described in Table 3, so that the resulting concentration of non-protonated anthracene is 7.1D-4 moles/liter when the pH is adjusted to 3.7 by the addition of sulfuric acid (H 2 SO 4 ). The mixture is then vigorously shaken in a separatory funnel, causing the anthracene to diffuse from the cyclohexane to the sulfuric acid to form a solution of protonated anthracene.
For the polymer-anthracene combination described, a BeamLok 2080 krypton ion laser may be used to irradiate the polymer system at 413.1 nanometers and 6.3 watts. The one cubic centimeter irradiation volume is large enough to house a polymer of macroscopic dimensions as the jump molecule provides a pH change from 3.7 to 3.9. The 10 millisecond prolonged excited state, permits the continuous wave laser to maintain a constant elevated pH level. Once the irradiation is cut-off, the excited-state jump molecules will decay to the ground state and reassociate, causing a return to the original pH in a few milliseconds. As before stated, the heat created by the jump molecules absorbing light will be efficiently discharged as light of a longer wavelength.
Obviously, many modifications and variations of the 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 has been described.
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A method and apparatus for initiating a rapid and long-lasting pH change to a pH dependent polymer or other pH driven reactant is provided by a pH jump molecule in solution. Visible light is used to excite the pH jump molecule. The attendant pH change occurs rapidly (in nanoseconds) and can be maintained by continuous wave light or by an appropriately pulsed light. Heat resulting from the light activation is efficiently discharged by radiative decay through room temperature phosphorescence lifetimes existing on the order of milliseconds.
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The present application is a continuation-in-part of PCT application no. PCT/EP02/05810, filed May 27, 2002, which application claims priority from German application no. 101 25 568.3, filed May 27, 2001, and from German application no. 101 58 785.6, filed Nov. 30, 2001. All of these applications are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to a device for treating pathological obesity and especially to a medical implant which is adapted to bypass a natural food passage in the digestive tract.
BACKGROUND OF THE INVENTION
The so-called Body Mass Index (BMI), is used today to define the degree to which one is overweight. BMI is calculated by dividing body weight in kilograms (kg) by the square of the body height in meters (m 2 ). A BMI of more than 40 corresponds to morbid obesity. A BMI of 35-40 is defined as severe obesity and a BMI of 30-35 is defined as obese. Morbid obesity and, to a lesser extent, severe obesity of human beings results in a number of health consequences such as cardiovascular diseases, diabetes and damages of the locomotor system.
As a general rule, in the case of extreme forms of obesity, often only a few kilograms of weight reduction, which is hardly noticeable, is achieved over the long run despite all efforts. In such extreme cases, surgical therapy is often finally indicated.
Nowadays, surgical therapies for the morbidly obese include performing operations for restricting the stomach. Among these, “gastric banding” and the “gastric bypass”, in which appropriate implants are inserted, have been generally accepted.
Gastric Banding
With this operation the inlet area of the stomach is constricted by an implanted synthetic band, thereby forming a smaller upper stomach sac which communicates with the remaining stomach area only through a small outlet.
However, this operation can result in the patient eating more high-caloric food after the operation or the constricted stomach bag bulges and expands so that a certain increase in weight is probable again. Moreover, it is possible for the silicone band to be displaced or break through into the stomach.
Gastric Bypass
By this operation a smaller stomach bag in the inlet area of the stomach is likewise separated from the main portion of the stomach, defined with the aid of clip suture instruments. However, this stomach bag does not communicate with the remaining stomach area, but with an anastomosed loop of the small intestine which is pulled up and fixed to the stomach bag. The food passes through the esophagus and the smaller stomach bag and then flows into the loop of the small intestine, bypassing the remaining larger portion of stomach and much or all of the duodenum. Gastric bypass generally results in a higher reduction of weight than the gastric banding.
However, the operation is deemed to be irreversible, which is a drawback in the case of complications such as malabsorption consequences. Furthermore there is a risk that sutures at the clip suture instruments become leaky, thereby necessitating a further surgical procedure.
SUMMARY OF EXEMPLARY EMBODIMENTS OF THE INVENTION
It is the object of the invention to provide a device for treating pathological obesity which controls the obesity for a long time and permits a reversible operation on the patients.
The object is achieved by the device according to claim 1 . Advantageous further developments are explained in the dependent claims.
The device is a medical implant comprising a storage-like hollow body which can be implanted inside the stomach of a patient as a kind of stomach mock-up for a temporary intake of food having a first tube-like end section and a second tube-like end section, the first tube-like end section being dimensioned so that it can be fitted into the esophagus of the patient and the second tube-like end section being dimensioned so that it can be connected to the loop of the small intestine of the patient in a sealing manner.
According to an advantageous further development a wall of the hollow body has a means for adjusting the volume of the hollow body.
In accordance with a further advantageous development the implant has fixing means at the first and second tube-like end sections for fixing the end sections to parts of the patient's organs. For instance, the fixing means can be braces, or the end sections can be easily sewed at the corresponding parts of the patient's organs.
According to a further advantageous development the implant includes between the first and second end sections a hollow flexible central portion which bulges relative to the end sections and is communicated with the latter.
Preferably, the central portion is made of a suitable flexible material such as polyurethane or another synthetic resin having a similar flexibility. The wall thickness of the central portion can be further adjusted to obtain the desired flexibility of the central portion. Advantageously, the desired flexibility of the central portion corresponds to the flexibility of a human stomach.
Optionally, a wall of the hollow body and especially of the central portion may include a means by which the diameter and thus the maximum volume of the hollow body is adjusted. For instance, the means for adjusting the diameter of the hollow body can be realized by inelastic strips enlacing the hollow body or being embedded therein. Alternatively, the central portion may be in the form of bellows.
The flexible hollow body can comprise an additional aperture directed to the stomach. The aperture is adjusted in its size and allows a natural passage for the food into the stomach. Thereby, the stomach is advantageously bypassed, for instance, for 90%, while 10% of the food comes into contact with the remaining stomach and the duodenum. Furthermore it is possible to observe the remaining stomach through the aperture, for instance, via an endoscope after surgery, which has been impossible in conventional and laparoscopic methods yet.
The aperture can include means for changing its size, such as a lace for contracting the aperture.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention and its advantages become clear from the following description of the embodiment along with the enclosed drawings.
FIG. 1 shows an embodiment of the present invention;
FIG. 2 shows the embodiment of the present invention while being implanted in the stomach of a patient; and
FIG. 3 shows a modified embodiment according to the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
FIG. 1 illustrates a medical implant for treating pathological obesity in accordance with the present invention. This implant is a flexible hollow body 1 .
The hollow body 1 has a first tube-like end section 2 and a second tube-like end section 3 . The first tube-like end section 2 is dimensioned so that it can be fitted into the esophagus of the patient. The second tube-like end section 3 is dimensioned so that it can be fitted into the loop of the small intestine of the patient.
Each of the first and second tube-like end sections 2 , 3 includes a first opening 5 and a second opening 6 , respectively.
Fixing means (not shown) by which the end sections 2 , 3 can be fixed to parts of the patient's organs are provided at the first and second tube-like end sections 2 , 3 . The fixing means can be, for instance, braces which are broadly used in the medical area.
Alternatively, the end sections 2 , 3 can be easily sewed at the corresponding parts of the patient's organs.
The hollow body 1 has a hollow flexible central portion 4 which is bulged relative to the first and second end sections 2 , 3 and is communicated with the first and second end sections 2 , 3 . This central portion 4 defines the later artificial stomach volume of the patient. As the central portion 4 is flexible, the artificial stomach volume is expandable to a certain extent depending on the filling ratio of the central portion 4 . Preferably, the central portion 4 is made of a suitable flexible material such as polyurethane or another synthetic resin having a similar flexibility. The wall thickness of the central portion 4 can be adjusted to obtain the desired flexibility of the central portion 4 . Advantageously, the desired flexibility of the central portion 4 corresponds to the flexibility of a human stomach.
A wall of the hollow body 1 and especially of the central portion 4 may optionally include a means (not shown) by which the diameter and thus the maximum volume of the hollow body 1 is adjusted. For instance, the means for adjusting the diameter of the hollow body 1 can be realized by inelastic strips enlacing the hollow body 1 or being embedded therein. Alternatively, the central portion 4 may be in the form of bellows.
It is also possible, of course, to design the central portion as a rigid receptacle.
FIG. 2 illustrates how the medical implant is used for treating pathological obesity according to an embodiment of the present invention by implantation in the stomach.
Here the arrangement of the implant in the stomach is clearly discernible. The first tube-like end section 2 is fitted into the esophagus 7 , while the second tube-like end section 3 is fitted into a laxative loop of the small intestine 9 . The small intestine loop 9 is prepared in advance by being circularly clipped to the stomach wall by clip suture instruments 10 , after a suitable perforation in the stomach wall was prepared at that location. In this way the implant comprises a bypass between the esophagus 7 and the small intestine 9 which completely bypasses the stomach 8 and the duodenum (not shown). Thus the food path becomes the esophagus 7 , through the first opening 5 , the first tube-like end section 2 , the central portion 4 , the second tube-like end-section 3 and the second opening 6 directly into the small intestine. There is preferably chosen a laxative loop of the small intestine 9 from the lower small intestine area so that the upper area of the small intestine is equally bypassed.
The implant in accordance with the present invention has the following advantages.
The entire operation can be executed by minimally invasive surgery methods, whereby the stresses and risks for the patient are minimized.
In general the implant can be removed from the patient again, whereby the operation is reversible in contrast to the gastric bypass. Consequently later occurring complications can be eliminated by removing the implant.
Moreover a considerable reduction of weight is possible, because the food does no longer pass the stomach and the duodenum, gastric juices from the gallbladder and the pancreas can get into contact with the food later only and moreover the upper small intestine area is bypassed. Thus the active intestine surface is greatly reduced and nutrient absorption is massively reduced.
It is another advantage with respect to the gastric bypass that there is no need to delimit a stomach bag by clip suture instruments. Consequently no sutures which might entail later complications occur by the implant in this place.
The invention can be modified as it is shown in FIG. 3 :
The flexible hollow body 1 can comprise an additional aperture 11 directed to the stomach. This aperture 11 is adjustable in its size and allows a natural passage for the food into the stomach. Thereby, the stomach is advantageously bypassed, for instance, for 90%, while 10% of the food comes into contact with the remaining stomach and the duodenum.
Furthermore it is possible to observe the remaining stomach through the aperture 11 , for instance, via an endoscope after surgery, which has been impossible in conventional and laparoscopic methods yet.
The aperture 11 can include means (not shown) for changing its size, such as a lace for contracting the aperture 11 .
The invention is not restricted by the above embodiments. Rather, the invention can be further modified within the scope of the present invention as defined in the claims.
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A medical implant is disclosed, said implant having a flexible hollow body ( 1 ) which can be implanted inside the stomach ( 8 ) of a patient and which has a first tube-like end section ( 2 ) and a second tube-like end section ( 3 ), wherein the first tube-like end section ( 2 ) is dimensioned such that it can be fitted into the esophagus ( 7 ) of the patient, and the second tube-like end section ( 3 ) is dimensioned such that it can be connected to the small intestine loop ( 9 ) of the patent in a sealing manner.
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BACKGROUND OF THE INVENTION
The present invention relates to niches for remains ashes, designed to suitably contain and preserve the ashes of a person or a pet.
Nowadays a higher number of people wish their bodies to be incinerated in the moment of their death and to have the ashes preserved for relatives or to be deposited in special places.
Persons in charge of administration of this procedure provide areas where the ashes can be correctly and unmistakably deposited with the use of devices which guarantee its reliability and resistance against external agents.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a self-mountable niche for remain ashes which is an improvement of existing niches.
In keeping with these objects and with others which will become apparent hereinafter, one feature of present invention resides, briefly stated, in a self-mountable niche for remain ashes which has a substantially closed box; a receptacle for accommodating ashes and insertable in the box; a supporting element connected with the box and supporting the latter; and a fastening and locking element connected with the supporting element for placing the niche at a corresponding location.
When the niche is designed in accordance with present invention, it is formed as an easy-to-use device, in which the receptacle with the ashes can be quickly arranged and which can be placed in a place designed for its location with full guarantee of reliability of its contents.
The inventive niche for remain ashes which is easy to assembly by correlation of its several elements, so that they take a minimum space and provide outstanding beauty of its design and assembly.
The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, 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
FIG. 1 is a perspective exploded view of a niche in accordance with the present invention;
FIG. 2 is a view showing a sectional exploded view of the inventive niche;
FIG. 3 is a front perspective view of a niche which is partially truncated in accordance with the present invention;
FIG. 4 is a partially sectioned view of the niche in mounted conditions;
FIG. 5 is a view showing a practical use of plurality of the niches in accordance with the present invention, which form a multiple assembly on a supporting element; and
FIG. 6 is a view showing another possibility of a use of the inventive niche by placing the niches on sides a normal funeral block or module.
DESCRIPTION OF PREFERRED EMBODIMENTS
A self mountable niche in accordance with the present invention is formed as a closed element in which the ashes are deposited and preserved, a body or supporting and fastening element, and a base for fastening and locking the niche of the place or location either in a sole funeral assembly for several niches or on a surface of a funeral block or the like.
The closed element of the element niche is formed as a regular presmatic-shaped Box 1 with a front face provided with a large opening 2 . The opening can be rectangular and closed with a glass which is not shown in the drawings. Walls 3 are provided at four sides and limit a space inside the box. A receptacle 4 can be arranged in the thusly delimited space and contains the ashes. Then the box with the receptacle inside is closed by a cover 5 and firmly retained between the cover and the edges which surround the front opening 2 .
The box 1 at the back is provided with cylindrical pins 6 . With the cylindrical pins the box 1 can be placed and locked on a supporting and fastening body 7 . The pins have a slight narrowing 6 a so that they can remain engaged through related key hole-shaped holes 8 in the supporting body 7 at its front face 9 . The holes have a larger upper part which allows the head of the pins 6 to enter, while the narrower part 6 a of the pins is accommodated in the lower narrower area 8 a of the holes. The supporting and fastening element 7 is preferably regular prismatic-shaped. It has at its front face 9 a rectangular opening 10 surrounded by the holes 8 for fastening of the box 1 with the receptacle 4 .
When the box 1 is located and fastened to the supporting body 7 , the front opening 10 remains fully covered, while the closed box 1 is locked by a sliding bolt 11 supported against the cylindrical pin 6 . This prevents upward movement so that the box 1 can not displace upwardly, while the pins 6 can not exit from the holes 8 in which they are introduced. The sliding bolt 11 is accessible from outside. It is actuated by a known tool, such as for example a latch key 12 .
The back face of the supporting body 7 has a large rectangular opening 13 surrounded by a narrow rib 14 . The rib extends along the sides as well as the upper and lower faces of the supporting body. Holes 15 are provided in the rib and arranged symmetrically in correspondence with the holes 8 at the front face 9 . The arrangement of the holes 15 allows to place and fasten and also to lock the supporting body 7 on the locking base 16 of the niche assembly. The locking base 16 is rectangular and has sides which are identical to the sides of the back face of the supporting body 7 . It is provided with holes 17 for bolts, screws or the like, for locking it against a surface where the niche assembly is to be placed.
The locking base is also provided with cylindrical emerging pins 18 similar to the pins 6 of the box 1 . The pins 18 are placed so that they coincide with the holes 15 of the supporting body 7 . Therefore the supporting body can be locked on the locking base 16 by introducing the holes on the corresponding pins 18 .
Finally, the locking base 16 has a retaining means which acts as a locking device. The returning means include a rectangular plate 19 which is locked at the upper part of the locking base 16 and on the face which faces the interior of the niche assembly.
When the supporting body 7 is placed on the pins 18 of the locking base 16 , a locking plate 19 is arranged instead of it, to prevent lifting of the supporting body with subsequent detachment and removal of the pins, since the locking plate 19 locks the upper edge of the rib 14 of the supporting body 7 . The plate 19 remains joined to the base 16 by screws and nuts 19 ′.
The locking base 16 can be connected to a surface of a special module 20 together with the rest of the niche assembly and the supporting body 7 with the closed box 1 . A plurality of the assemblies are locked on the surface of the module close to each other in perfect continuity, with niche side faces of the supporting bodies 7 coinciding with one another. Thereby horizontal and vertical rows are formed. The special module described herein above is shown in FIG. 5 . It has side supporting feets and a protecting and ornamental larmier 22 .
In accordance with another embodiment of the invention, the niches can be located on a free side wall 23 of a normal funeral module 24 which is provided with corresponding rows of niches 24 a. During the placement of the niches on the wall, the corresponding bases 16 are locked in corresponding areas.
When the niche assembly in view of its self mountable nature is placed at the corresponding location, as well as on the special module, they are fastened by bolt or screws of the locking base 16 , then the supporting body 7 is placed on it, its back holes 17 are engaged on the cylindrical pins 18 of the base 16 , and the locking plate 19 is placed to prevent withdrawal of the supporting body 7 . Then with the ashes contained in the closed box 1 the box is located on the supporting body 7 , the cylindrical pius 6 engage in the holes 8 , the latch 11 is driven by the deadlock 12 , one of the cylindrical pins 6 remains fastened, and it is impossible to withdraw the closed box.
The niches for ashes of people and pets have the same construction but just different sizes.
It is possible to provide ornamentation of the assembly For example a drawing sheet, a photograph or the like can be placed on the front face under the glass arranged at the front opening 2 . This can identify the incinerated person or pet. Also, a supporting elemnet 25 for flowers or the like can be provided on the supporting body 7 .
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in self mountable niche for remains ashes, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims:
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A self-mountable niche for remain ashes has a substantially closed box, a receptacle for accommodating ashes and insertable in the box, a supporting element connected with the box and supporting the latter, and a fastening and locking element connected with the supporting element for placing the niche at a corresponding location.
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This is a continuation of application Ser. No. 07/881,990, filed May 12, 1992.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to liquid crystal shutters and more particularly to a method for fabricating liquid crystal shutter displays using a single mode visible laser.
2. Brief Description of Related Art
The fabrication of liquid crystal shutter display devices requires the delineation of multiple parallel horizontal segments of indium tin oxide, separated by narrow spaces, on the surface of a sheet glass substrate. The narrow spaces are typically in the order of 4-10 microns wide and provide electrical isolation of the stripes to facilitate synchronization of the switching of the liquid crystal with the vertical raster of a CRT.
Typical contemporary production techniques in the liquid crystal display industry employ positive working photoresists for reproducing the image of a photomask on the surface of the glass substrate. Briefly, to produce the above-described parallel segments, a glass substrate having a thin indium tin oxide conductive layer on its surface is coated with photoresist. A photomask with the appropriate segment-spacing pattern is brought within close proximity to the photoresist coating and a UV lamp behind the photomask is illuminated. The light striking the photoresist causes a photochemical reaction that allows a developing solution to remove photoresist from all areas exposed to the UV light.
The achievable space dimensions between the segments, and their tolerances within the photoresist, are determined by the optical system used in the fabrication, including: the dimensions on the photomask; the spacing between the mask and substrate; and, the wavelength of the UV lamp. Current high volume exposure tools in the liquid crystal display industry are capable of resolving lines on the order of ≧20μ at their best performance. Typical contemporary proximity aligners could be set up for small exposure gaps on the order of sub 10μ, but this would cause undo pick-up of photoresist particles off of the surface of the substrate and result in repeating defects unless the photomask was frequently cleaned.
An alternative exposure tool for producing the requisite spaces between the parallel segments is a step and repeat aligner. In a step and repeat aligner, a photomask is placed at a predetermined distance from the substrate and an optical system reduces the image of the photomask by some integer number (typically 2x to 5x) onto the surface of the substrate. The substrate is then moved by a stage and the exposure is repeated. In this fashion, exposure is achieved by stepping the substrate and repeating exposure, making sure that, each time, the mask is aligned properly to either the previously exposed layer, or to the adjacent layer. While such tools are capable of resolving the narrow lines needed for defining the horizontal segments in liquid crystal shutters, they suffer from high capital costs and low material throughput, making them unsuitable for lowest cost high volume manufacturing.
SUMMARY OF THE INVENTION
The present invention comprises a method for fabricating liquid crystal shutters using a single mode visible laser. The laser is used to produce a single beam, capable of being split into multiple beams, which is focused onto the surface of a photoresist coated glass substrate. The substrate includes a thin layer of indium tin oxide to provide conductive electrodes for the shutter.
In the preferred method, the substrate is moved via a translation stage across the laser beam path or paths such that a single narrow line or multiple narrow lines of photoresist are exposed. The photoresist is then developed and the indium tin oxide layer is etched from the substrate. After stripping the remaining photoresist from the substrate surface, well defined horizontal electrodes remain in the indium tin oxide with sufficient electrical isolation to ensure proper functioning of the shutter.
In bypassing the use of photomasks, the preferred method provides a low-cost, high throughput technique for exposing multiple lines in the indium tin oxide layer with minimal risk of picking up repeating defects. Additionally, once the beam splitters are positioned and fixed, the only moving part in the exposure system is the substrate transport mechanism. This provides for a very robust, relatively inexpensive system which is amenable to a high volume manufacturing environment.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an elevational view of an exposure system and its interrelationship with the indium tin oxide coated glass substrate, illustrating the preferred method of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, shown is an exposure system 10 for fabricating a liquid crystal shutter in accordance with the preferred method of the present invention. A single mode visible laser 12 provides an unattenuated source beam of light 14 which can be used directly or split into several separate beams. In the embodiment depicted in FIG. 1, a beam splitting system 15 is provided to split source beam 14 into several separate component exposure beams, and a focusing system 17 is provided to focus the individual exposure beams onto a predetermined target, normally a prepared glass substrate 22. Glass substrate 22 includes an indium tin oxide electrode coating 25 and a photoresist coating 23, and is carried by a translation stage 24. The substrate is normally loaded onto translation stage 24 using an appropriate loading cassette type of mechanism well known to one skilled in the art.
Beam splitting system 15 comprises a first beam splitter 16, disposed in a first predetermined position within the system, and effectively splits source beam 14 into a first component beam 18, coaxial with the source beam, and a first exposure beam 20, substantially orthogonal to the source beam. A first focusing element 21 of focusing system 17 is disposed along the path of exposure beam 20 and focuses the beam onto photoresist layer 23 on substrate 22.
A second beam splitter 26 is provided at a second predetermined position within beam splitting system 15 and effectively splits first component beam 18 into a second component beam 28, coaxial with beam 18, and a second exposure beam 30, orthogonal to beam 18 and parallel to beam 20. The distance between beam splitter 26 and adjacent beam splitter 16 is normally determined by the requisite width of the adjacent horizontal segments to be formed within the indium tin oxide electrode coating 25 on substrate 22. Typically, the horizontal segments are approximately 15 mm wide which translates into a spacing of 15 mm between beam splitter 26 and beam splitter 16. As will be described in further detail below, each beam splitter is disposed a substantially equal distance from the adjacent beam splitters. A second focusing element 32 of focusing system 17 is disposed along the path of exposure beam 30 and focuses the beam onto photoresist layer 23.
A third beam splitter 34 is provided at a third predetermined position within beam splitting system 15 and effectively splits second component beam 28 into a third component beam 36, coaxial with beam 28, and a third exposure beam 38, orthogonal to beam 28 and parallel to beam 30. Beam splitter 34 is normally disposed an equal distance from beam splitter 26 as beam splitter 26 is from beam splitter 16. This distance, once again, is determined by the requisite spacing of the electrodes to be formed on substrate 22. A third focusing element 40 of focusing system 17 is disposed along the path of exposure beam 38 and focuses the beam onto photoresist layer 23.
In the embodiment of FIG. 1, a fourth and final beam splitter 42 is provided at a fourth predetermined position within beam splitting system 15 and effectively splits third component beam 36 into a fourth component beam 44, coaxial with beam 36, and a fourth exposure beam 46, orthogonal to beam 36 and parallel to beam 38. Beam splitter 42 is normally disposed an equal distance from beam splitter 34 as beam splitter 34 is from beam splitter 26. A fourth focusing element 48 of focusing system 17 is disposed along the path of exposure beam 46 and focuses the beam onto photoresist layer 23.
The final element along the optical path of source beam 14 is a 100% reflecting mirror 50 which completely reflects any incident light onto photoresist layer 23. Once again, mirror 50 is disposed at an equal distance from beam splitter 42 as beam splitter 42 is from beam splitter 34. Mirror 50 effectively reflects component beam 44 toward substrate 22 along a path parallel to exposure beam 46. A fifth focusing element 52 of focusing system 17 is disposed along the path of reflected beam 44 and focuses the beam onto photoresist layer 23.
As described above, the series of beam splitters act in concert to separate a single source beam from the laser into a number of exposure beams corresponding to the number of lines to be exposed in the photoresist coated substrate. For an N-segment shutter, N minus 1 exposure beams and N minus 2 beam splitters are required. The last element in the optical path of the source beam is a 100% reflecting mirror. The percent reflection vs. transmission of each beam splitter needs to be uniquely tailored to specific design requirements and product characteristics. More specifically, since each beam splitter removes a portion of the incident laser energy and transmits the balance, each splitter must be uniquely fabricated so that their reflection and transmission properties provide equal energy in each beam. A formula for determining the percentage reflection and the percentage transmission by each splitter is provided below for an N segment shutter and for the mth beam forming reflector:
______________________________________Reflecting Element # % Reflection % Transmission______________________________________1 [1/(N-1)]*100 [1-1/(N-1)]*1002 [1/(N-2)]*100 [1-1/(N-2)]*1003 [1/(N-3)]*100 [1-1/(N-3)]*100. . .. . .. . .m [1/(N-m)]*100 [1-1/(N-m)]*100. . .. . .. . .N-2 50% 50%N-1 (mirror) 100% 0%______________________________________
The technology for fabricating beam splitter coatings with this range of reflection vs. transmission is well known to those skilled in the art.
During fabrication of a shutter in accordance with the method of the present invention, translation stage 24 moves substrate 22 within a fixed plane perpendicular to the direction of incidence of the exposure beams and in a direction normal to the plane of the page containing FIG. 1. The substrate is normally driven at a fixed velocity of approximately 1-5 cm/sec, depending upon the intensity of the incident exposure beams.
Focusing system 17 is configured to separately maintain the focus of each exposure beam on the photoresist layer. Each focusing element is designed such that the optics have a large depth of field and high numerical aperture, thus providing for a robust fabrication method which is less susceptible to any inadvertent tilt angle along the axis of the substrate. In a visible laser at 5320 Å a typical laser used in the present method, maintaining a focus of below 10μ is relatively easy and is well known in the art.
Efficient use of the method of the present invention requires the ability to expose multiple lines using sufficient energies in the exposure beams to develop the photoresist. For sub 1 micron thick photoresist layers, most resists specify energies on the order of 80 to 120 mj/cm 2 . He-Cd lasers are available which emit on the order of 50 mwatts of energy. For an N=8 segment shutter, 7 beams are required for complete exposure. For a substrate throughput of one per minute, it is necessary to move the translation stage at a rate of 1 to 2 cm/sec. Thus, in one second, the laser exposes approximately 7*2*10E-4=0.014 sq cm. At the top of the exposure range, with the less sensitive resists, the laser must provide 120*0.014=1.7 mwatts, which is more than an order of magnitude less than the laser actually produces. Even with some light losses, there is plenty of energy to deliver all the light needed to expose the lines in the time required.
After the substrate has completely traversed the line of exposure beams from end to end, the exposed photoresist is removed, and the indium tin oxide electrode is etched. The remaining photoresist is then stripped from the substrate surface, leaving a predetermined number of well defined parallel electrodes. In the embodiment depicted in FIG. 1, six electrodes are formed on substrate 22 using the five exposure beams.
Fabrication of a liquid crystal shutter in accordance with the method of the present invention realizes several significant advantages. The design and fabrication costs for the exposure system used in the present method are relatively inexpensive. The only substantive moving part is a single axis translation stage capable of maintaining a level surface and traversing the length of the glass substrate. Since all of the glass substrates have substantially the same patterns exposed, the positions of the beam splitters normally require no readjustment during fabrication. Additionally, there is no modulation or a need for changing the deflection of the laser beam. Thus, no special galvanic mirrors or acousto-optic cells are required. Finally, the alignment of the substrate requires no special registration technology other than mechanical pins for positioning the substrate within approximately 0.5 mm accuracy.
Of course, there are design alternatives that will be obvious to those skilled in the art after reading the above description of the preferred embodiment. For example, a single exposure beam could be employed to produce the spaces between parallel elements. The translation stage would then have to traverse the length of the substrate several times in order to expose the necessary lines in the photoresist. Additionally, the substrate could be held stationary, and the exposure system could be moved along the length of the substrate to produce the lines. It is intended that the appended claims be interpreted as covering all such alternatives and modifications as fall within the true spirit and scope of the invention.
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A method for fabricating liquid crystal shutters using a laser exposure system. An output beam from the laser is split into multiple exposure beams and a photoresist coated substrate having a metallic layer is caused to traverse the beams. The substrate is then processed leaving multiple parallel electrodes on the substrate surface.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a frame structure for a working vehicle. More particularly, the present invention relates to a simple and low-cost frame structure that is lightweight and has high rigidity.
2. Background Art
A combination of angle pipes and steel I-beams is known for a frame structure for a working vehicle (for example, see the Japanese Patent Laid Open Gazette No. 2004-1769).
BRIEF SUMMARY OF THE INVENTION
Problem to Be Solved by the Invention
Generally, it is difficult to work with a frame that consists of the combination of angle pipes and steel I-beams. Further, the assembly of such frames is labor intensive. An object of the present invention is to improve the rigidity of the frame and to reduce costs required for production by a simple construction.
Solution
The present invention provides a frame structure for a working vehicle, comprising: a side frame having a boat form in a side view; and a front frame attached to the side frame. In the frame structure, a mast plate member, serving as a part of a mast for supporting a front loader, and a front axle support member for supporting a front axle are integrally constructed in the front frame.
Preferably, the mast plate member is disposed to overlap the side frame, and is fixed to the side frame.
Preferably, a mast is constructed by means of fixing the mast plate member to a mast member for supporting a front loader, the mast member is provided at a back face thereof with a partition plate, and a piping for a working machine is passed through an opening of the partition plate into the mast.
Preferably, left and right sets of the side frame and the front frame attached to the side frame are provided in parallel, and a front plate is provided between front edges of the front frames so that the front plate and the left and right sets of side and front frames are constructed in U-shaped in a top view, a front axle installation plate is fixed to the front axle support member and two plates extended in the longitudinal direction from the upper portion of the front axle installation plate are attached to the front plate, and a box-shaped arrangement is constructed by the two plates and the front axle installation plate.
Preferably, left and right sets of the side frame and the front frame attached to the side frame are provided in parallel, and the distance between a lower edge of the left set of side and front frames and a lower edge of the right set of side and front frames is narrower than that between a vertical central portion of the left set of side and front frames and a vertical central portion of the right set of side and front frames.
A method of connecting the mast plate and the side frames in the present invention is plug-welding by providing a hole at the overlapping section of the mast plate and the side frames. Thus, piping in a chassis can be passed without a decrease of strength.
In the frame structure, a plate for connecting the frame at a bottom face of a mast section projects outside the frame, and a tank installed in the working vehicle is hung therefrom, so that the tank capacity can be enlarged.
Said two plates also work as a stopper against oscillating of the front axle. In the frame, a hole for tie-down is provided at a front plate connecting front edges of the frames, so that the number of parts can be reduced and the working vehicle is fixed strongly at a low cost.
EFFECTS OF THE INVENTION
According to the present invention, the number of parts constructing the frame of the vehicle can be reduced, and a contact area of the side frame and the mast plate member attached to the front frame can be enlarged, whereby the rigidity of the joint section of the side frame and the mast plate member can be improved.
According to the present invention, required parts can be reinforced effectively.
According to the present invention, by a simple construction, space saving and protection of the piping can be achieved.
According to the present invention, the rigidity of a front section of the chassis can be improved, and load given to a loader connected to the mast etc. can be smoothly transmitted.
According to the present invention, the rigidity of the working vehicle can be secured, and at the same time, the interference with steering wheels can be prevented.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a side view of a working vehicle.
FIG. 2 is a top view of a frame structure of a working vehicle.
FIG. 3 is a side view of the frame structure of the working vehicle.
FIG. 4 is a front view of the frame structure of the working vehicle.
FIG. 5 is a perspective view of the frame structure of the working vehicle seen from the upper front.
FIG. 6 is a perspective view of the frame structure of the working vehicle seen from the lower back.
FIG. 7 is a side view partly in section of a connection structure of a front frame and a side frame.
FIG. 8 is a perspective view partly in section of a structure of a front part of the working vehicle.
FIG. 9 is a perspective view of a structure of a left front part of the frame.
FIG. 10 is a perspective view of a structure of front lower part of the frame.
FIG. 11 is a bottom view of the structure of front lower part of the frame.
FIG. 12 is a side view of the side frame.
FIG. 13 is a sectional view taken on line B-B in FIG. 12 .
FIG. 14 is a perspective view of rear structure of the frame.
FIG. 15 is a schematic view of an attachment structure for attaching a transmission to the frame.
FIG. 16 is a schematic view of an attachment structure of a rear axle.
FIG. 17 is a side view partly in section of an inner structure of a mast member.
FIG. 18 is a view of a reinforcement structure of a boss.
FIG. 19 is a perspective view of an attachment structure of a tank.
FIG. 20 is a side view of the attachment structure of the tank.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a frame structure for a working vehicle by means of combining bent plates.
First Embodiment
A working vehicle as a mode for carrying out the invention will be described below.
FIG. 1 is a side view of a working vehicle.
A working vehicle 1 shown in FIG. 1 is a tractor loader backhoe, equipped with a loader 2 and a digger apparatus 3 . An operation part 4 is provided at a center portion of the vehicle 1 , and the loader 2 is provided in front of the operation part 4 , and the digger apparatus 3 is provided in a rear of the operation part 4 . Front wheels 7 and rear wheels 8 are equipped with the vehicle 1 , so as to enable driving of the vehicle 1 with the loader 2 and the digger apparatus 3 .
A steering wheel 5 and a seat 6 are provided in the operation part 4 , and an operation apparatus for driving direction and an operation apparatus for the loader 2 are provided at the side of the seat 6 . Thus, a driving direction of the vehicle 1 and the loader 2 can be operated at the operation part 4 . The loader 2 that is one of the loading devices is connected beside the vehicle 1 and extended forward, and a bucket is provided at a head of the loader. An engine is provided at a front portion of a frame 9 that is a chassis of the vehicle 1 , and the engine is covered in a bonnet 30 provided on the frame 9 . The loader 2 is provided outside of the bonnet 30 .
The digger apparatus 3 is detachably attached to a rear portion of the vehicle 1 , and the digger apparatus 3 is operated by an operation apparatus provided in a rear of the seat 6 .
A hydraulic oil tank 90 is provided beside the operation part 4 , which works as steps for getting on and off the operation part 4 . The step formed on a fuel tank is provided at the opposite side to the operation part 4 .
Next, a frame structure of the working vehicle will be described below.
FIG. 2 is a top view of a frame structure of the working vehicle.
FIG. 3 is a side view of the frame structure of the working vehicle.
FIG. 4 is a front view of the frame structure of the working vehicle.
FIG. 5 is a perspective view of the frame structure of the working vehicle seen from the upper front.
FIG. 6 is a perspective view of the frame structure of the working vehicle seen from the lower back.
The frame 9 for the working vehicle mainly comprises two side frames 62 which are extended in the longitudinal direction and provided parallel to each other, two front frames 63 which are respectively connected to front portions of the side frames 62 , and a front plate 61 which connects front portions of the front frames 63 to each other. A mast member 64 is constructed on an outer face of each of the front frames 63 , and a rib 65 connects between the front frames 63 .
A partition 74 working as a connection member is provided between the side frames 62 , thereby providing the frame 9 as a rudder structure. The partition 74 is a cross member provided at a substantially center portion of the frame 9 so as to divide a space between the side frames 62 into an engine arrangement part and a transmission arrangement part.
In the side frame 62 , a beam 62 b is extended outward. The beam 62 b is extended in the transversal direction, so that the beam 62 b is substantially right-angled to the side frame 62 . The section form of the beam 62 b is a C-shaped form, thereby supporting a base member of the operation part 4 .
The front frame 63 is extended backwardly upward slantwise from the front lower portion of the frame 9 . The front frame 63 is extended upward from the connection section thereof connected to the side frame 62 , and the mast member 64 is attached to the part of the front frame 63 extended upward. The engine and the bonnet 30 are provided between the front frames 63 . Lift units of the loader 2 are connected to the mast member 64 , which support the loader 2 .
A lower mast portion 64 b , which is a lower portion of the mast member 64 , is configured as a member projected to the side. The lower mast portion 64 b is configured as a member whose side form is L-like characters pushed down horizontally, thereby receiving the vertical force applied to the mast member 64 . With respect to the frame 9 , which is a chassis of the working vehicle, the lower mast portion 64 b is extended outward, thereby connecting a base of the mast and a side face of the frame. Namely, the lower mast portion 64 b is connected to the base of the mast member 64 and to the outer face of the front frame 63 .
In the working vehicle 1 , a fuel tank and a hydraulic oil tank 90 are hung on the lower mast portion 64 b and the beam 62 b . The fuel tank and the hydraulic oil tank 90 are respectively connected and supported onto the sides of the lower mast portion 64 b and the beam 62 b that are provided at the same side in the working vehicle. Thus, the support structure of the fuel tank and the hydraulic oil tank 90 can be simple and the number of parts can be decreased. Another tank having a different capacity can be easily attached there only if the tank has a similar upper portion to be connected. Furthermore, the frame with high rigidity can be used to support the tanks. The tanks are attached to the base of the lower mast portion 64 b which constructs the base of the mast connected to the lift units of the loader 2 , so that the space below the projection of the mast can be used effectively and the working vehicle can be constituted compactly.
The front plate 61 connects the front portion of the front frames 63 and constructs a front face of the frame 9 which is a chassis of the working vehicle. Two holes 61 b for tie-down are provided at lower portions of the front plates 61 . A rope for fixation or the like is attached to the hole 61 b in carrying the working vehicle 1 . The front plate 61 whose left and right sides are provided with the holes 61 b is durable enough against the tie-down of the vehicle 1 using the holes 61 b . The holes 61 b are extended in the longitudinal direction, so that the rope passed through the hole 61 b rarely twists. It is unnecessary for making the tie-down holes to have an additional member welded to the front plate 61 , so that no projection is constructed on the front plate 61 and a front appearance of the working vehicle is improved.
A notch is provided at the central upper part of the front plate 61 , whereby a hold mechanism of the bonnet 30 can be easily attached to the notch.
The front plate 61 is formed at side portions thereof along the side form of the front frame 63 , and formed so that as it goes downward, the front plate 61 becomes narrow in the lateral width.
A frame structure will be described below in detail.
FIG. 7 is a side view partly in section of a connection structure of a front frame and a side frame.
FIG. 8 is a perspective view partly in section of a structure of a front part of the working vehicle.
FIG. 9 is a perspective view of a structure of a left front part of the frame.
FIG. 10 is a perspective view of a structure of front lower part of the frame.
FIG. 11 is a bottom view of the structure of front lower part of the frame.
The frame 9 , which is a chassis of the working vehicle 1 , is mainly constructed as a joint of a flat plate and a bent plate. The frame 9 is reinforced at several parts, so that the frame of the working vehicle can be produced easily and at low cost. The bent plate can be easily constructed by bending, so that the working vehicle can be processed easily and produced at low cost in comparison with the case where the I-steels are used.
The lower portion of the frame 9 is formed to be boat-shaped so that when seen from the front, the narrower the frame 9 becomes when viewing the frame 9 from top to bottom along a vertical plane. Namely, each of both sides of the lower portion of the frame 9 inclines inward. The frame 9 is constructed as above mentioned, so that the space around the front wheels 8 can be sufficiency taken and the steerable angle of the front wheels 8 can be widely taken.
With respect to the frame 9 , the lower portion of the side frame 62 is bent inside, and the upper and lower ends are horizontally bent inside. As the side frame 62 is bent inside, the effective area of the side frame 62 can be increased in section when viewed in the longitudinal direction, whereby the rigidity of the side frame 62 can be improved. Thus, improving the rigidity of the frame and, at the same time, preventing interference of the frame with the steerable wheels can be achieved.
The lower portion of the front frame 63 is also bent inside, similar to the side frame 62 . The inner side of the front frame 63 is jointed to the outer side of the side frame 62 , which constructs the front part of the frame 9 . The front frame 63 is connected at a rear upper portion thereof to the mast member 64 , and connected at a front lower portion thereof to attachment plates 75 and 76 (see FIGS. 10 and 11 ) provided laterally on a front axle. The upper surface of the attachment plate 75 is connected with two plates 77 , which are extended longitudinally in parallel. The upper surfaces of the plates 77 are connected with the respective side frames 62 , the lower surfaces of the plates 77 are connected with the attachment plate 75 , and the front surfaces of the plates 77 are connected with the front plate 61 . The plates 77 are provided between the front frames 63 .
The attachment plate 75 is connected with the plates 77 and the front frames 63 , and the plate 76 is connected with the front plate 61 and the front frames 63 , thereby improving the rigidity of the front lower part of the frame 9 to which the front axle can be attached. In the front lower portion of the frame 9 , the plates 77 , and the attachment plates 75 and 76 are assembled into a form like a curb, which is connected with the front plate 61 , the front frames 63 , and the side frames 62 . As mentioned above, a box structure is constructed, so that the rigidity of the front portion of the frame is improved by the simple construction.
The attachment plates 75 and 76 to which the front axle is attached also serve as an oscillation stopper (lateral rolling stopper) of the front axle, which restricts the rolling amount of the front axle by touching the front axle. Accordingly, the number of members in the vicinity of the front axle is reduced.
The upper portion of the front frame 63 works as a part of the mast supporting the loader 2 . The lower portion of the front frame 63 works as a support member for the front axle. Thus, the front frame 63 works as a mast support member and a front axle support member, so that the stress is dispersed and the load capacity performance is improved.
The mast member 64 and the front axle are connected by the front frame 63 , so that the load given to the mast member 64 can be directly transmitted to the front axle, and the frame of the working vehicle can be rarely strained.
As shown in FIG. 7 , the front frame 63 and the side frame 62 are cross-jointed. The front frame 63 and the side frame 62 are jointed in a lateral T shape or the like, and the side frame 62 is connected to the inner side of the front frame 63 . At a substantially center part of one of the frames 62 and 63 (in this embodiment, a portion the side frame 62 overlapping the front frame 63 ), holes 62 c and 62 d are provided, and the side frame 62 is welded at the inner margins of the holes 62 c and 62 d with the front frame 63 . Namely, the front frame 63 and the side frame 62 overlapping each other are plug-welded. Thus, the front frame 63 and the side frame 62 are easily connected and the increase of the width caused by the connection can be prevented.
The front frame 63 and the side frame 62 are joined by the plug welding, so that the hole used for the welding can be used as a piping. As shown in FIG. 8 , the front frame 63 has a hole 63 c through which an exhaust pipe 12 b connected to a silencer 12 is extended outside of the frame. As shown in FIG. 9 , the hole 62 c of the side frame 62 coincides to the hole 63 c of the front frame 63 , so that a hole communicating inside and outside of the frame is provided. At the front portion of the working vehicle 1 , the bonnet 30 is provided on the frame 9 . The bonnet 30 is hollow and made of resin. The bonnet 30 covers the engine provided on the frame 9 . In the bonnet 30 , the engine and the engine accessories such as a radiator, the silencer 12 , an air cleaner 34 and so on are provided. The bonnet 30 is constructed to enable opening and closing with respect to the frame 9 , whereby the bonnet is opened by rotating the front portion of the bonnet 30 upward. Seals 32 and 33 fitted on the rib 65 are provided between the bonnet 30 and the frame 9 . At the front portion of the working vehicle 1 , a cover 36 is provided, thereby covering the notch of the front plate 61 .
The hole 63 c is provided in the front frame 63 disposed at the left side of the vehicle. The position of the hole 63 c coincides to the hole 62 c of the side frame 62 . The margins edges of the holes 62 c and 63 c are welded by plug welding, whereby the side frame 62 and the front frame 63 are jointed. Through the hole 63 c , the exhaust pipe 12 b connected to the silencer 12 is extended, whereby the exhaust gas can be exhausted outside the bonnet 30 . Therefore, a space for piping without interference with the frame 9 is ensured in the plug-welded portion of the frame 9 .
Reinforcement structure of the frame at the center part of the vehicle will be described below.
FIG. 12 is a side view of the side frame.
FIG. 13 is a sectional view taken on line B-B in FIG. 12 .
FIG. 14 is a perspective view of rear structure of the frame.
The side frame 62 is formed in narrow C shape seen from front. The side frames 62 are provided thereon with reinforcement members, including pipes 66 , rear reinforcement members 68 and triangle reinforcement members 67 , respectively. Each of the side frame 62 is provided on an upper portion thereof with the pipe 66 , at a rear portion thereof with the rear reinforcement member 68 , and at a rear lower portion thereof with the triangle reinforcement member 67 . On the lower face of center part of the side frame 62 , a lower reinforcement member 69 is attached and extended in the extended direction of the side frame 62 .
Onto the upper portion of the side frame 62 , the pipe 66 is attached. The pipe 66 has a square shape in sectional view, and it is extended from the engine arrangement part to the transmission attachment part. The pipe 66 is attached to the inner face of the return part in the upper part of the side frame 62 , and is extended on the side frame 62 from the front end of the upper portion of the side frame 62 to the rear reinforcement member 68 . The pipe 66 penetrates the partition 74 provided at the center part of the side frame 62 . Thus, the part of the chassis frame of the working vehicle receiving a lot of stress can be effectively reinforced, which is reinforced by the angle pipes, so that the long-range attachment can be easily achieved.
On the rear portion of the side frame 62 , the rear reinforcement member 68 is provided, and the rear axle is fixed below the rear reinforcement member 68 . The side frame 62 has an opening at the portion thereof onto which the rear reinforcement member 68 is provided, whereby the rear axle is attachable through the opening from the outside of the side frame 62 .
The triangle reinforcement member 67 is provided between the rear reinforcement member 68 and the partition 74 , and the triangle reinforcement member 67 is connected with the rear reinforcement member 68 and the partition 74 . The triangle reinforcement member 67 is formed in the inverse L shape in the sectional view. The triangle reinforcement member 67 is connected with the lower bent part and the inner face of the side frame 62 , and the opening side of the member 67 is turned to the side frame 62 .
The part of the side frame 62 attached to the triangle reinforcement 67 is formed in a square shape in the sectional view. Thus, the reaction of the side frame 62 against the driving force or the rigidity of the part loaded by the hitch is improved. The part to which a lot of stresses are given in the chassis frame of the working vehicle can be effectively reinforced.
The lower reinforcement member 69 is formed in the inverse L shape in the front view, and has a lower extended part into the inside of the vehicle (the opening side of the side frame 62 ). The lower reinforcement member 69 is extended in the working vehicle from the engine arrangement part to the transmission attachment part. The lower reinforcement member 69 is attached to the lower face of the side frame 62 , whereby the part to which a lot of stresses are given can be effectively reinforced, and the frame that is easily assembled and has high rigidity is achieved.
The attachment structure for attaching a transmission to the frame 9 will be described below.
FIG. 15 is a schematic view of an attachment structure for attaching a transmission to the frame.
FIG. 16 is a schematic view of an attachment structure of a rear axle.
A transmission 10 is attached through a stay 73 of a rear extended part 72 fixed at the rear portion of the side frame 62 . The transmission 10 is fixed at a lower or side face, thereof not only by the rear axle, but also by the stay 73 extended from the side frame 62 and foamed in the L shape in the front view. In the embodiment shown in FIG. 15 , the lower end of stay 73 is connected to the lower face of the transmission 10 . As mentioned above, the transmission 10 is fixed to the side frame 62 through the stay 73 , so that the variation of transmissions attachable to the frame is expanded and the frame can be standardized. The stay 73 can receive a part of the force given by the transmission 10 by the deformation or the like. When the transmission 10 gives the excess load, the stay 73 is deformed plastically so as to protect the side frame 62 .
The transmission 10 and each of the rear axle cases, constituting a transfer path of the driving force, are arranged in a gate shape in the top view, as shown in FIG. 16 . In the transfer path, a driving case 10 b extended in the lateral direction is connected at an outer side end thereof to the front portion of the rear axle case 11 connected with the shaft of the rear wheel 7 , and is connected at an inner side end thereof to the transmission 10 , so as to constitute the gate-shaped arrangement in the top view. The gate-shaped arrangements are laterally symmetrically provided in the vehicle 1 . The rear axle case 11 is a terminal of the change gear mechanism, and the rear axle case 11 is connected to the side frame 62 through a stay 71 . The stay 71 is fixed at an upper end thereof to the outside of the side frame 62 , and is fixed at a lower end thereof to the rear portion of the rear axle case 11 . The rear axle case 11 is supported as mentioned above, so that the stay 71 can absorb a part of the force generated from the rear axle case 11 by the deformation or the like. When the rear axle case 11 gives excessive load, the stay 71 is deformed plastically so as to protect the side frame 62 . The supporting rigidity of the rear axle case 11 is changeable by the characteristic of material of the stay 71 .
The structure of the mast 64 will be described below.
FIG. 17 is a side view partly in section of an inner structure of the mast member 64 .
The mast member 64 is formed in the L shape in the top view and is connected to the outside of the front frame 63 and the upper face of the lower portion 64 b . A partition 64 f is provided between the mast member 64 and the front frame 63 . The partition 64 f constructs a space inward from the mast member 64 , whereby the rigidity of the mast member 64 is improved. A piping 79 is provided in the space.
Bosses 80 are provided on the inside of the mast member 64 , and bosses 80 are provided on the outside of the front frame 63 so as to correspond to the respective bosses 80 , whereby the lift units of the loader 2 are twin-supported. The partition 64 f is attached along the bosses 80 , thereby improving the rigidity of the bosses 80 . At the upper portion of the partition 64 f , an opening 64 g is provided at an upper portion of the partition 64 f , and an opening 64 h is provided at an upper face of the lower mast portion 64 b . The piping through the space between the partition 64 f and the mast member 64 is extended outward from the opening 64 g and the opening 64 h . The partition 64 f is provided between the twin-supporting mast structures, the piping 79 is inserted from the lower face into the backside of the partition 64 f , and is passed out through the opening 64 g provided at the front face of the partition 64 f . As a result, the piping 79 is protected by effectively use of the space around the mast member 64 , and the working vehicle can be miniaturized.
The reinforcement structure of the boss 80 will be described below.
FIG. 18 is a view of a reinforcement structure of the boss. FIG. 18( a ) is a perspective view of a reinforcement structure of the boss. FIG. 18( b ) is a front view of a reinforcement structure of the boss.
The bosses 80 are gently convex, and are connected at their base portions to a reinforcement member 81 . The reinforcement member 81 connecting the base parts of the bosses 80 is formed in the U shape in the front view. The bosses 80 and the reinforcement member 81 are connected by welding, so that the bosses 80 and the reinforcement member 81 are constructed integrally. It can be also available that the bosses 80 and the reinforcement member 81 are formed integrally in advance.
The reinforcement member 81 is attached to the front face of the partition 64 f in the mast member 64 and is connected to the left and right bosses 80 . The reinforcement member 81 can be attached to other bosses 80 above and below the bosses 80 provided at the vertical center part.
The bosses 80 are connected with the reinforcement member as mentioned above, so that the bosses 80 and the mast member 64 are easily reinforced.
A tank structure provided in a working vehicle will be described below.
FIG. 19 is a perspective view of an attachment structure of tanks.
FIG. 20 is a side view of the attachment structure of the tanks.
At the sides of the operation part 4 in the working vehicle 1 , the hydraulic oil tank 90 and the fuel tank 91 are provided respectively. Some projection members are extended sideward from the frame 9 so as to hang the hydraulic oil tank 90 and the fuel tank 91 . In this embodiment, the lower mast portions 64 b and the beams 62 b serve as the projection members. The hydraulic oil tank 90 and the fuel tank 91 are provided below them.
Both the lower mast portion 64 b and the beam 62 b are extended sideward from each of the side frames 62 as components of the frame 9 . The lower mast portion 64 b is connected with the side frame 62 and the mast member 64 , thereby contributing for the improvement of the rigidity of the mast member 64 .
On an upper face of each of the hydraulic oil tank 90 and the fuel tank 91 , two connection members 96 each of which has a tapped hole are provided. A bolt is screwed into the connection section of each of the tanks through the bottom faces of the lower portion 64 b and of the beam 62 b . Thus, each of the tanks is fastened on the bottom faces of the lower portion 64 b and of the beam 62 b . The connection members 96 are extended in the lateral direction on the upper faces of each of the hydraulic oil tank 90 and the fuel tank 91 . Each of the connection members is provided with plural bolts to be screwed. As mentioned above, the connection members 96 are extended in the lateral direction on the upper face of each of the tanks, so that high rigidity and the durability against getting on and off of an operator are ensured even if each of the tanks is loaded on the outside thereof.
In this embodiment, the hydraulic tank 90 is provided at the right side of the frame 9 , and the fuel tank 91 is provided at the left side of the frame 9 . Each of the hydraulic tank 90 and the fuel tank 91 is formed in the step shape (L shape) in the front view, so as to have the lower part thereof more extended sideward (to the outside of the vehicle) than the vertical extension of the upper part thereof. Thus, even if the height of the tank is small, the tank has enough capacity, and the hydraulic tank 90 and the fuel tank 91 are miniaturized around the operation part 4 .
Furthermore, the step-shaped face can be used as the steps to get on and off the operation part 4 . At each of the corners of the hydraulic tank 90 and the fuel tank 91 , an anti-slip member 94 is provided, whereby the safety when getting on and off is secured.
At the fuel tank 91 , an upwardly inclined inlet 93 is protruded toward outside. The inlet 93 is provided between the upper part 91 a and the lower part 92 b of the fuel tank 91 and at an angled corner part formed at the outside of the fuel tank 91 . A battery 98 is provided at the upper face of the fuel tank 91 . The battery 98 is provided between the lower mast portion 64 b and the beam 62 b.
The hydraulic tank 90 and the fuel tank 91 are provided as mentioned above, so that they can be used as steps for getting on and off the operation part 4 . When getting on and off, either the hydraulic tank 90 or the fuel tank 91 is stepped on and causes a sound, so that the change of an amount of the hydraulic oil or the fuel are known by means of hearing the sound. The battery 98 can be provided in the clearance of the frame 9 , whereby the space around the frame 9 can be effectively used.
Additionally, the battery 98 provided on the fuel tank 91 is covered by the cover installed in the working vehicle 1 , and is protected from rainwater or earth and sand.
INDUSTRIAL APPLICABILITY
The present invention is applicable to a frame structure for working vehicle. Especially, it is applicable to a frame structure for a working vehicle that needs light weight and high rigidity.
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Production of a working vehicle frame consumes high costs because it requires high rigidity. A simple construction improves the rigidity of the frame and reduces costs required for the production. In a structure of a frame ( 9 ) for a working vehicle ( 1 ), side sections of the frame ( 9 ) are constructed in a boat form, and, in a front view, the width of a lower section of the frame ( 9 ) is set smaller than that of the central section in the vertical direction of the frame ( 9 ). Further, a mast plate ( 63 ) for supporting a front loader ( 2 ) and a front axle installation plate section ( 75 ) are integrated, and side frames ( 62 ) constructing the side section of the frame ( 9 ) and the mast plate ( 63 ) are jointed in a lateral T shape in a side view.
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FIELD OF THE INVENTION
The present invention relates to high pressure spark ignition direct injection (SIDI) fuel delivery, and more particularly to an attachment system for high pressure fuel injectors in an isolated SIDI fuel delivery system.
BACKGROUND OF THE INVENTION
Spark ignition direct injection (SIDI) combustion systems (and other direct injection combustion systems) for internal combustion engines provide improved fuel economy and increased power over conventional port fuel-injected combustion systems. A SIDI engine includes a high pressure fuel injection system that sprays fuel directly into a combustion chamber. The fuel is directed to a specific region within the combustion chamber. As a result, a homogeneous or stratified charge may be created in the combustion chamber as desired. Throttling requirements are less restrictive and fuel combustion characteristics are improved, thereby improving fuel economy and engine output.
Referring now to FIG. 1 , an exemplary SIDI engine 10 includes an engine block 12 that includes one or more cylinders 14 . A spark plug 16 extends into a combustion chamber 18 . The combustion chamber 18 is defined by a piston 20 , the cylinder 14 , and a cylinder head 21 . The cylinder 14 includes one or more exhaust ports 22 and corresponding exhaust valves 24 . The cylinder 14 includes one or more intake ports 26 and corresponding intake valves 28 . A fuel injector 30 extends into the combustion chamber 18 . One or more of the fuel injectors 30 are connected to a fuel rail 32 .
Referring now to FIGS. 1 and 2 , the fuel rail 32 provides fuel to the fuel injectors 30 . The fuel injectors 30 deliver fuel to the combustion chamber 18 according to performance requirements of the SIDI engine 10 . Typically, a low pressure (e.g. approximately 45-75 psi) fuel supply pump 40 is located within a fuel tank 42 . The low pressure fuel supply pump 40 delivers fuel to a high pressure injection pump 44 . The injection pump 44 pressurizes the fuel at approximately 750 to 2250 psi, depending on demand. The injection pump 44 provides the pressurized fuel to the fuel rail 32 . The fuel rail 32 is rigidly fastened to the cylinder head 21 of the cylinder 14 . For example, the fuel rail 32 is fastened to the cylinder head 21 via a fuel rail attachment assembly (not shown). The fuel injector 30 is rigidly fastened (e.g., clamped) between the fuel rail 32 and the cylinder head 21 , or another suitable fixture of the SIDI engine 10 . A location of the fuel injector 30 relative to the combustion chamber 18 , as well as a design of a fuel injector nozzle 46 , are optimized to achieve desired combustion characteristics.
SUMMARY
A fuel injector isolation system in a high pressure fuel injection system comprises an isolated fuel rail assembly. At least one cylinder has a cylinder head. A fuel injector is coupled to and in fluid communication with the fuel rail assembly, extends axially through an opening in the cylinder head, and is moveable within the opening in relation to the cylinder head.
In other features, a vehicle comprises an engine block that includes at least one combustion cylinder having a cylinder head and a combustion chamber. A high pressure fuel injection system delivers fuel directly into the combustion chamber. The high pressure fuel injection system includes an isolated fuel rail assembly and a fuel injector coupled to and in fluid communication with the fuel rail assembly that extends axially through an opening in the cylinder head and is moveable within the opening in relation to the cylinder head.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
FIG. 1 is a cross-sectional view of a spark ignition direct injection (SIDI) engine cylinder according to the prior art;
FIG. 2 is a functional block diagram of a SIDI fuel rail assembly according to the prior art;
FIG. 3A is a graphical representation of SIDI fuel system noise according to the prior art;
FIG. 3B is a graphical representation of SIDI fuel system noise according to the prior art;
FIG. 4 is a cross-sectional view of a SIDI fuel injector arrangement according to a first implementation of the present invention;
FIG. 5 is a cross-sectional view of a SIDI fuel injector arrangement according to a second implementation of the present invention;
FIG. 6A is a cross-sectional view of a SIDI fuel injector mounting system according to a third implementation of the present invention;
FIG. 6B illustrates a retainer clip used in a SIDI fuel injector mounting system according to the present invention;
FIG. 6C is a cross-sectional view of an assembled SIDI fuel injector mounting system according to the present invention;
FIG. 7 is a cross-sectional view of a SIDI fuel injector mounting system according to a fourth implementation of the present invention;
FIG. 8A is a cross-sectional view of a SIDI fuel injector mounting system according to a fifth implementation of the present invention;
FIG. 8B is a cross-sectional view of an assembled SIDI fuel injector mounting system including a retainer plate according to the present invention; and
FIG. 8C is a fuel injector retainer plate according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements.
A typical SIDI system generates undesirable noise during normal operation. As used herein, the term noise refers to any unwanted or undesirable noise that is generated during normal operation of electrical, mechanical, and/or electromechanical devices. The noise is not indicative of present and/or potential damage to these devices. As shown in FIGS. 3A and 3B , pressure pulsations (i.e. disturbances) on a right fuel rail and a left fuel rail are indicated at 60 and 62 , respectively. Pressure fluctuations are indicated at 64 for the fuel inlet line. The pressure pulses 60 , 62 , and 64 are synchronous with the electronic solenoid command signal 66 (e.g., from a Powertrain Control Module, or PCM) which controls the high pressure injection pump 44 . These system pressure disturbances 60 , 62 , and 64 excite various components of the SIDI engine to radiate unwanted noise pulses as indicated at 68 , 70 , 72 , and 74 , for example. Sharp pressure pulses generated within the high pressure pump 44 at each pump stroke contribute to unwanted audible noise. Conventionally, the high pressure injection pump is controlled electronically. For example, the high pressure injection pump includes a reciprocating plunger in communication with an electronic governed solenoid valve that maintains the desired fuel rail (injection) pressure. The electronic signal pulses 66 control the pump's solenoid valve as dictated by the PCM. Similarly, secondary high frequency rail pressure pulses 60 and 62 are generated at each injector firing as high pressure fuel is discharged (injected) into the combustion chamber 18 . Together, the pressure impulses generated by both the pump and injectors constitute the majority of impulsive noise excitation to the engine.
Additionally, operation of the fuel injectors cause the SIDI system to generate noise. An impulse is generated each time the fuel injector “fires” (i.e. delivers fuel to the combustion chamber), which can be seen to be coincident with the electronic PCM signal pulses 76 . These impulses are simultaneously comprised of both electromechanical (solenoid) and electro-hydraulic forces. The fuel injectors include electronically-controlled needle valve openings. The opening and closing actuation (e.g. electromechanical and/or hydraulic actuation) of the needle valve openings cause the noise pulses 78 .
As described above, operation of the injection pump and the fuel injectors contribute significantly to the impulsive noise that the SIDI system generates. In particular, rigid mechanical contact between the fuel rail and the cylinder head, as well as between the fuel injector and the cylinder head, transfer noise energy between the SIDI system and various components of the engine. The present invention provides a fuel injector attachment system for high pressure SIDI fuel delivery systems that incorporate noise isolation technology. More specifically, the present invention provides a SIDI system that directly couples the fuel injectors to the fuel rail assembly and isolates elements of the fuel injectors from the cylinder head to interrupt transmission paths of noise energy. With the injector fastened to the rail in the manner described herein, the rail isolation limits vibration energy from being transmitted into the engine.
Referring now to FIG. 4 , an isolated SIDI fuel injector system 100 according to the present invention is shown. A fuel injector 102 delivers fuel from an isolated fuel rail assembly 104 through a cylinder head 106 to a combustion chamber 108 . Conventionally, SIDI fuel injectors (as well as SIDI fuel rail assemblies) are rigidly mounted and/or affixed to the cylinder head 106 . In the present implementation, the fuel injector 102 is suspended from the fuel rail assembly 104 and is substantially mechanically isolated from the cylinder head 106 , especially in the axial direction. The fuel injector 102 is directly coupled to the isolated fuel rail assembly 104 via an injector cup boss 110 , an injector locating base 112 , an injector seat 114 , and a snap ring 116 . The injector seat 114 supports a posterior spherical portion 118 of the injector locating base 112 . The injector seat 114 (e.g. a split spherical seat or other suitable device) secures and maintains a desired position of the fuel injector 102 relative to the injector cup boss 110 . An O-ring 120 provides a wet seal.
The snap ring 116 provides additional support to maintain the desired position of the fuel injector 102 . The snap ring 116 may be removable to allow the fuel injector to be insertably coupled to and/or removed from the injector cup boss 110 . The SIDI fuel injector system 100 may also include an anterior injector seat (not shown) that contacts an upper portion of the fuel injector 102 within the injector cup boss 110 .
As described above, the fuel injector 102 is directly coupled to the fuel rail assembly 104 without rigid mechanical contact between the injector cup boss 110 and the cylinder head 106 . The injector seat 114 limits the axial position of the fuel injector 102 with respect to the injector cup boss 110 . In the present implementation, the injector seat 114 may be formed from an elastomeric material. Those skilled in the art can appreciate that the present invention is not limited to using elastomeric materials. Other materials, including, but not limited to, nylon, composites, and/or metals are anticipated. For example, thermal conductivity of an elastomeric material forming the injector seat 114 may be increased by the addition of aluminum particles.
The cylinder head 106 includes an opening 122 that accommodates the fuel injector 102 and a fuel injector nozzle 124 . In conventional SIDI systems (as described in FIG. 1 ), there is rigid mechanical contact between the cylinder head 106 and the fuel injector 102 to maintain a position of the fuel injector. As a result, noise is transferred between the fuel injector 102 and the cylinder head 106 via contiguous axial contact. In the present implementation, the fuel injector 102 floats in the opening 122 , isolating the fuel injector 102 from the cylinder head 106 . The fuel injector 102 includes a combustion seal (e.g. a nylon or Teflon combustion seal) 126 located near the fuel injector nozzle 124 . The combustion seal 126 seals combustion gases from the combustion chamber 108 and is the only contact between the fuel injector 102 and the cylinder head. Thus, there is no metal-to-metal (i.e., rigid) contact of the injector with the cylinder head. In this manner, the isolated SIDI fuel injector system 100 eliminates substantial axial contact between the fuel injector 102 and the cylinder head 106 .
A biasing element, such as a spring 128 , may be included. The spring 128 provides a downward biasing force to position the fuel injector 102 within the cylinder head 106 . However, it is to be understood that a biasing element is not required for proper positioning of the fuel injector 102 . For example, an internal fuel rail pressure is typically sufficient to bias the fuel injector against the injector seat 114 . Further, although the spring 128 is shown disposed between the injector cup boss 110 and an intermediate portion 130 of the fuel injector 102 , those skilled in the art can appreciate that the spring 128 may be otherwise located. For example, the spring 128 may be located between an upper interior surface 132 of the injector cup boss 110 and an upper portion 134 of the fuel injector 102 as shown in FIG. 5 .
As described above, a longitudinal position of the fuel injector 102 is maintained. In this manner, proper positioning of the fuel injector nozzle 124 for optimized combustion is maintained. Further and as indicated at 136 , the configuration of the SIDI fuel injector system 100 allows angular rotation of the fuel injector 102 relative to the cylinder head 106 . For example, the spherical portion 118 of the injector locating base 112 and the injector seat 114 allow a degree of angular latitude to compensate for misalignment and/or slight positional errors. The opening 122 is sufficiently large to accommodate angular rotation of the fuel injector 102 while maintaining isolation between the fuel injector 102 and the cylinder head 106 . A gap between the fuel injector 102 and the cylinder head 106 as indicated at 138 allows for limited longitudinal movement of the fuel injector 102 . For example, if the injector seat 114 compresses and/or the snap ring 116 is damaged, the fuel injector 102 will not necessarily contact the cylinder head 106 . For example, a controlled clearance between the bottom of the injector base and the cylinder head port acts as a failsafe in the event of a improperly-positioned or snap ring 116 . The injector is trapped between the rail and head thereby maintaining the integrity of the wet seal (i.e., the O-ring 120 ), with increased noise being the only degradation to the system.
The isolated fuel injector arrangements of previous implementations may be combined and/or integrated with a fuel injector mounting system 150 as shown in FIGS. 6A , 6 B, and 6 C. A fuel injector 152 is inserted into an injector cup boss 154 of a fuel rail assembly 156 . A retainer clip 158 , shown in FIG. 6B and cross-sectionally in FIG. 6A , retains the fuel injector 152 within the injector cup boss 154 . The retainer clip 158 engages a stepped collar 160 disposed on the fuel injector 152 . As shown, the retainer clip 158 is a split-segmented snap retainer. However, those skilled in the art can appreciate that other types of retainer clips may be used. The fuel injector mounting system 150 allows for angular rotation and misalignment compensation as described in previous embodiments and facilitates attachment of the fuel injector 152 to the fuel rail assembly 156 . Any suitable tool may be applied to release the retainer clip 158 and remove the fuel injector 152 .
An alternative implementation of a fuel injector mounting system 170 is shown in FIG. 7 . A fuel rail assembly 172 includes one or more fuel injector retaining interfaces (e.g. injector cup bosses) 174 . The interface 174 includes a retainer clip groove 176 that is configured to receive a retainer clip 178 a (shown in profile at 178 b ). A fuel injector 180 is inserted within the interface 174 . An injector sleeve 182 is inserted over the fuel injector 180 and the interface 174 . The retainer clip 178 a is inserted into one or more retainer clip slots 184 and through the retainer clip groove 176 .
In this manner, the retainer clip 178 a , in combination with the injector sleeve 182 , maintains an axial/longitudinal position and a radial position of the fuel injector 180 . A clearance gap 188 between the injector and cylinder head provides isolation as described in previous implementations. The features of the fuel injector mounting system 170 may be combined and/or integrated with previous implementations of the isolated fuel injectors as described in FIGS. 4-6 .
Another implementation of a fuel injector mounting system 200 is shown in FIGS. 8A , 8 B, and 8 C. A fuel rail assembly 202 includes one or more injector retaining interfaces 204 . The interface 204 includes a retainer plate groove 206 . A fuel injector 208 is inserted into the interface 204 through an opening 210 in a retainer plate 212 . When the fuel injector 208 is suitably positioned, the retainer plate 212 slides in a direction 214 parallel to the fuel rail assembly 202 to lock the fuel injector 208 in position within the interface 204 . More specifically, a locking portion 216 of the opening 210 engages an injector retaining groove 218 of the fuel injector 208 .
The retainer plate 212 includes retainer clips 220 . When the retainer plate 212 is positioned to lock the fuel injector 208 in place, the retainer clips 220 engage the retainer plate grooves 206 . In this manner, the retainer plate 212 maintains a position of the fuel injector 208 as described in previous implementations. In an alternative implementation, a plurality of individual retainer plates (not shown) that correspond to a plurality of retaining interfaces 204 may replace the continuous retainer plate 212 .
Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification and the following claims.
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A fuel injector isolation system in a high pressure fuel injection system comprises an isolated fuel rail assembly. At least one cylinder has a cylinder head. A fuel injector is coupled to and in fluid communication with the fuel rail assembly, extends axially through an opening in the cylinder head, and is moveable within the opening in relation to the cylinder head.
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CROSS-REFERENCES
This application is related to currently co-pending U.S. Application Ser. No. 10/010,993 filed Nov. 12, 2001, and titled “Method For Presenting Related Items For Auction.”
The present application claims priority from U.S. Provisional Application Ser. No. 60/230,375, filed Sep. 6, 2000, entitled “System and Method for Automating Listing and Re-Listing of Auction Items”, and U.S. Provisional Patent Application Ser. No. 60/219,596, filed Jul. 20, 2000, entitled “System and Method for Automating Listing and Re-Listing of Auction Items”.
BACKGROUND
1. Field of the Invention
The present invention relates generally to auction systems over a computer network and more specifically to assisting users to more efficiently list and re-list items for auction over a computer network, such as the Internet.
2. Description of the Related Art
FIG. 1A shows a system setting in which on-line auction systems currently operate. A computer network 10 , such as the Internet, connects the computer systems of sellers and bidders 12 – 14 to one or more auction servers 16 – 18 . The auction servers 16 – 18 host an auction site, which receives items for sale, lists them for access by the computer systems of the sellers and bidders 12 – 14 , and conducts an auction to determine the winning bidder.
FIG. 1B shows a representative computer system such as those depicted in FIG. 1A . The various components, such as the central processor 23 , the memory subsystem 24 , the disk interface 25 , the I/O subsystem 26 and the communications interface 27 , of the computer system are interconnected via system bus 22 . The central processor 23 executes programs that are stored in memory subsystem 24 . The disk interface 25 is instrumental in transferring information between permanent storage (such as a disk) and the memory subsystem 24 . The communications interface 27 is instrumental in transferring data between a network (such as the public switched telephone network and/or a local network) and the memory subsystem 24 via the system bus 22 . The I/O subsystem 26 is instrumental in transferring data from a keyboard or pointer device (such as a mouse) to the central processor 23 or the memory subsystem 24 via the system bus and in transferring data from the memory subsystem 24 or central processor 23 to a display device.
Returning to FIG. 1A , sellers list items for sale on the auction system 16 – 18 of FIG. 1A and set auction parameters such as the starting time and date of the auction, the duration of the auction, the starting bid and bid increments. Buyers bid on items during an open auction for the item and are notified whether or not their bid is the highest bid. At the end of the auction the winning bidder, if any, is notified by email via the computer network and the seller and buyer then contact each other directly to complete the transaction. The seller must deliver the item to the buyer and the buyer must pay for the item in accordance with the terms of the auction.
FIG. 2 shows a flow chart of the listing process of current on-line auction systems. Given the setting shown in FIG. 1A , a seller lists an item for sale on the auction site, in step 30 , by first registering seller information at the site including a user id and password. Next, in step 32 , the seller accesses an item listing form from the auction site and provides, in step 34 , item information and auction parameter information. Item information that the seller provides to the form includes a title and a standalone description of the item; the auction parameter information includes the duration of the auction and the minimum bid, and forms of acceptable payment if a sale occurs. A standalone description of the item means that the description does not have any links to any other item currently listed by the seller. In step 36 , the seller obtains an item verification document from the auction site. This document contains a summary of the information provided by the seller in the listing form along with an item id and an item key. For one auction site, the item id is a nine digit number and the item key is a unique sequence of 35 characters. After checking the item verification document, the seller then submits a listing confirmation, in step 38 . This action causes the auction site to list the item, in step 40 , using the assigned item number and item key and then to charge the seller's account, in step 42 , determined from the user id, a listing fee for the item. The listing fee is typically in the range of about $0.25 to $2.00 per item. Thus, it is apparent that listing an item for sale on the auction site is a manual process, involving several, time-consuming interactive steps with the auction site.
If a listed item does not sell during the auction period, the seller has the choice of re-listing the item for sale. The seller is charged a listing fee to re-list the item, however, a credit is applied against this fee if the item is re-listed using the item number and unique key that were used when the item was first listed and the item is sold after being re-listed.
FIG. 3 shows a flow chart of the re-listing process of current on-line auction systems. In step 50 , the seller accesses a previously listed item at the auction site. This causes the auction site to send a re-listing form with filled-in information to the seller, in step 52 , where the filled-in information is obtained from the information provided when the item was originally listed. In step 54 , the seller makes changes to the item description and possibly to the auction parameters. For example, the seller may change the minimum bid or bid increments and improve the description of the item. Upon submitting the listing form back to the auction site, the seller obtains an item verification document, in step 56 , from the auction site. The item verification document now contains the item description and auction parameters along with the original item number, the original key, a new item number and new key for re-listing the item, the user id, and password. Submitting the listing confirmation to the auction site, in step 58 , causes the site to list the item, in step 60 , and charge the listing fee to the seller's account, in step 62 . If the re-listed item is sold, as determined in step 64 , then the auction site issues a listing fee credit to the seller's account in step 66 .
While the process described above is simple and convenient for sellers who list a few items for sale, there are serious deficiencies for sellers who wish to list hundreds or even thousands of items. One deficiency is the time it takes to manually list an item, say a few minutes. To list a thousand items would take about 16 hours. This is too great an expenditure of time to be practicable for the seller. Another aspect of this deficiency is that it is extremely difficult to synchronize the advertising of the items for sale in a trade publication or other advertising medium with their listing on the auction site because the time to list the items on the site may stretch over such a long time period as to make unpredictable the date and time any item is up for sale.
Another deficiency concerns the re-listing of items that did not sell. Not only is there is an extraordinary expenditure of time required to re-list the many items but the seller must use the same item number and key or lose the re-listing fee credit, which for thousands of items can amount to thousands of dollars.
Yet another deficiency is that, when the seller has multiple items listed for sale, the standalone description prohibits links to other items that the seller has listed. This prevents the seller from notifying a potential buyer of the other items for sale, when the buyer finds one of the seller's items.
Therefore, there is a need for an auction assistance system that allows a seller to list and re-list items without spending inordinate amounts of time doing so and without losing credit for re-listed items. Furthermore there is a need for an auction assistance system that allows the seller to inform the buyer of other items the seller has listed.
BRIEF SUMMARY OF THE INVENTION
The present invention is directed to meeting the above needs. In accordance with the present invention, a computerized method of listing an item on an auction site includes selecting an actual item to be listed on the auction site and obtaining actual item description data and actual item auction parameter data for the actual item to be listed; then retrieving a previously obtained and stored item number and item key. Next, confirmation data that includes actual item description data, actual auction parameter data, the retrieved item number, retrieved item key, a user id and a user password is submitted to the auction site to post the item for sale.
Another method, in accordance with the present invention, is used to obtain the item numbers and item keys. First, listing input data containing generic item description data, generic auction parameter data, a user id and a user password is submitted to the auction site. Next, verification data is received from the auction site in response to the listing input data, where the verification data includes the listing input data and an item number and an item key. The item number and item key are then extracted from the verification data and saved for later use. Many item numbers and keys can be obtained prior to listing items for sale at the auction site, thus creating a repository of item numbers and item keys for later use.
A similar process is used to obtain re-listing numbers for items that are listed on the auction site but did not sell during the auction period. The process of listing an item on the auction site can use either a new listing number or a re-listing number, meaning that any item can be listed using a re-listing number. Items that sell using a re-listing number allow the seller to save a listing fee. Many re-listing numbers can be saved in a repository for later use.
Yet another method in accordance with the present invention is a method of presenting to a user on an auction site one or more auction items related to a linking auction item, where the method includes the steps of (i) embedding a pointer in an item description of a linking auction item available by a seller, where the item description when accessed at the auction site causes an access to a facilitating server by means of the embedded pointer, and the linking auction item and the one or more related auction items are items available by the same seller, said auction item being an item available on an auction site, (ii) upon accessing the item description having the embedded pointer, obtaining at the facilitating server a list of item descriptions and item numbers that represent the currently active auction items of the same seller, and (iii) presenting to the user the list of the seller's currently active auction items.
Yet another method in accordance with the present invention includes the steps of (i) encoding search information for one or more related auction items available by a seller, (ii) embedding the encoded search information into a pointer to a facilitating server, where the linking auction item and the one or more related auction items are items available by the same seller, said auction item being an item available on an auction site, (iii) embedding said pointer in an item description of the linking auction item, (iv) upon selection of the linking auction item at the auction site by a user, receiving the encoded search information embedded in the pointer to the facilitating server, (v) automatically decoding the encoded search information embedded in said pointer into a keyword, and (vi) invoking a search engine of the auction site with the keyword as a search parameter to find and present to the user item documents for the one or more related auction items.
An aspect of the present invention is that item descriptions can contain information that enables potential bidders to find other items for sale by the seller without interfering with the search engine of the auction site.
An advantage of the present invention is that a great number of items can be listed on an auction site in a short period of time.
Another advantage of the present invention is that items that did not sell on the first listing can be easily re-listed. Additionally, when re-listing an item, the item, the item description and the auction parameters can be changed regardless of the origin of the first listing. Thus, re-listing item numbers become a resource and the use of this resource can be more easily planned to assure that a re-listed item is one that will sell, thereby assuring the recovery of the re-listing fee.
Another advantage is that listing and re-listing of items can occur at a time that is convenient to the seller. This permits the seller purchase advertisements in trade magazines and to include the item numbers in those advertisements. Thus, when the items are actually listed on the auction site, a demand for the items will already exist.
Yet another advantage of the present invention is that a bidder can be informed of other items that a particular seller has for sale on the auction site without using the auction site search engine for such purposes. This permits the bidder to find related items the seller may have available and increases the likelihood that the bidder will submit a bid for those items.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1A shows a system setting in which the present invention operates;
FIG. 1B shows a representative computer system such as is depicted in FIG. 1A ;
FIG. 2 shows a flow chart of the listing process of current on-line auction systems;
FIG. 3 shows a flow chart of the re-listing process of current on-line auction systems;
FIG. 4A shows a flow chart of the listing process in which an item number and item key are obtained in accordance with the present invention;
FIG. 4B shows a flow chart of the listing process in which an item is listed using a stored item number and item key;
FIG. 4C shows a flow chart of a scheduling process for listing a large group of items;
FIG. 4D illustrates aspects of the scheduling process of FIG. 4C ;
FIG. 5A shows a flow chart of the re-listing process in which a new item number and item key are obtained in accordance with the present invention;
FIG. 5B shows a flow chart of the listing process in which an item is listed using a stored re-listing item number and item key;
FIG. 6 shows flow chart for creating a linked description in accordance with the present invention;
FIG. 7 shows a flow chart in which a search of the auction site uses the linked description created in FIG. 6 ;
FIG. 8 shows a flow chart for creating an alternate linked description in accordance with the present invention; and
FIG. 9 shows a flow chart in which a search of the auction site uses the linked description created in FIG. 8 .
DETAILED DESCRIPTION OF THE INVENTION
An additional server system 20 in FIG. 1 is connected to the Internet and hosts the software of the present invention.
FIGS. 4A and 4B show a flow chart of the listing process in which an item number and item key are obtained in accordance with the present invention. These figures show that the process of obtaining the item number and item key in FIG. 4A is separated from the process of actually listing the item for sale in FIG. 4B . In one embodiment of the present invention, the process of FIG. 4A and the process of FIG. 4B occur concurrently, the process of FIG. 4A operating as a separate task, possibly on a separate computer system, from the task for carrying out the process of FIG. 4B .
The process, shown in FIG. 4A , starts with step 70 , in which an input form having generic item description data and generic auction parameter data, a valid user id and password is submitted to the auction site. The auction site responds, in step 72 , with a verification form that includes the item number and item key the auction site has assigned for the item. In step 74 , the item number and item key are extracted from the verification form and stored, in step 76 , in a database 22 of an auxiliary server 20 such as is shown in FIG. 1 . Database 22 contains a table having a plurality of rows, each of which has an item numbers, an item key, the user id and password. The process of FIG. 4A stores as many item numbers and item keys, as determined in step 78 , as are needed to supply the process of FIG. 4B and is run, in one version of the present invention, if the number of items numbers in the database falls below a prescribed limit. In this version of the invention, a preset number of items numbers is obtained and stored after which the process of FIG. 4A is suspended until the number in the database falls again below the prescribed limit. In another version of the invention, the process of FIG. 4A runs continuously while the process of FIG. 4B runs.
Independently of the process in FIG. 4A , the process shown in FIG. 4B operates to access the stored item number and item keys. In step 84 , a stored item number, item key, user id and user password are retrieved and, in step 86 , a confirmation form is submitted to the auction site. This confirmation form includes actual item description data, actual auction parameter data, the user id, password, and the item number and item key which were retrieved from the database. Submitting the confirmation form to the auction site causes the item to be listed on the site. In one version of the invention, the submission is by means of an HTTP post command. Finally, a listing fee is charged to the user id account, in step 90 .
The above steps are repeated as determined in step 92 for each item to be listed. Once a record in the database has been used to actually list an item, the database must mark the record as used.
If a seller has a large group of items to list to an auction site, a problem arises in that the loop shown in FIG. 4A causes the items to be listed at nearly the same time. This means that the all of the auctions for this large group of items also end at the same time. Because a large fraction of the total number of bids occur within the last 2 minutes of an auction, the chances of maximizing the final bid price for each item in the large group is diminished when all of the auctions for the large group end nearly simultaneously.
The present invention has a process for handling the listing of a large group of items. This process is the scheduling process shown in FIG. 4C . The scheduling process first presents the seller with a list of items scheduled to be listed to an auction site along with the total number of items in the list in step 94 . Next, the seller selects the a time period over which these items are to be listed, called the listing time span in step 95 . Typical time periods are 1 hour, 2 hours or 3 hours. Next, in step 96 , the process computes the number of items to be listed each minute of the selected listing time span. For example, if there are a 90 items scheduled to be listed and the listing time span is 3 hours (180 minutes), then 1 item will be listed every 2 minutes of that 3 hours, thereby staggering the starting times and ending times by 2 minutes for each of the auctions. (Each auction on the auction site has a fixed duration.) After choosing the listing time span, the process next presents, in step 97 , the seller with a choice of time slots during a 24 hour cycle that the listing time span should start and informs the seller of the ending time slot for any previously posted large group of items. Thus, if 3 hour listing time span is chosen, that time span could be selected to start at 11:00 a.m. and end at 2:00 p.m., which defines a 3 hour time slot during the day. This latter choice of time slots during the day is especially helpful to the seller because the choice of time slot helps the seller prevent a new large group of items from ending at the same time as the already posted large group of items. Finally, in step 98 , the items are listed in accordance with the computed number of items to be listed in a unit time (say, a minute) and the selected time-of-day time slot.
FIG. 4D shows a possible scenario under the scheduling process of FIG. 4C . A time-of-day time slot of 11:00 a.m. to 2:00 p.m. is chosen (perhaps because it does not conflict with another time slot) and ninety items are listed during that three hour period. During the first 18 minutes items 1 – 9 are listed. During the last 18 minutes, items 82 – 90 are listed.
Thus the above scheduling process therefore helps to improve the number of bids that a seller may receive on any particular auction because fewer auctions expire at the same time.
FIG. 5A shows a flow chart of the re-listing process in which a new item number and item key are obtained for re-listing an item. In this case, the listed item form is accessed from the auction site in step 100 , the listed item being one that was originally listed but did not sell in an auction for that item. In some cases, such items can be retrieved from the auction site up to about 30 days after the auction in which they failed to sell. The listed item form has the original item number and original item key. Next, in step 102 , the listed item is again submitted to the auction site The item description in the input-listing form can be either the original item description information or generic item description information. In step 104 , the auction site responds with a verification form having a new item number and item key for re-listing the item. The original item number, original item key, new item number and new item key are then extracted in step 106 from the form and, in step 108 , are stored in a table of the database with the user id and password. The table in the database for the re-listing item numbers (i.e., the new item numbers for re-listing) is kept separate from the table in the database for the first listed item numbers. The process is repeated until all the items listed that did not sell have been accessed, as determined in step 110 . Using re-listing item numbers for items that are sure to sell helps save listing fees so it is important to keep re-listing item number separate from original listing numbers. In one version of the invention, the process of FIG. 5A runs when the number if re-listing numbers in the database falls below a prescribed limit and is suspended after obtaining a preset number of re-listing numbers, if possible. In another version of the invention, the process of FIG. 5A runs continuously while the process of FIG. 5B runs.
FIG. 5B shows a flow chart of the listing process in which an item is listed using a stored re-listing item number and item key. Again, as above, this process can occur concurrently with the process of FIG. 5A for acquiring the re-listing item numbers. First, in FIG. 5B , an re-listing record is retrieved from the table in the database in step 112 . This record contains the original item number, the original item key, the new item number and item key, user id and password. Next, in step 114 , an confirmation form with actual item description data, actual auction parameter data, the user id and password, original item number, original item key, new item number and new item key, is submitted causing the item to be listed at the auction site under a re-listing number. It should be noted that the item being re-listed does not have to be the same item as the original item that did not sell. All that is required is that the item numbers, item keys, user id and password be consistent with each other. In step 118 , a listing fee is charged to the user id account and the process is repeated, as determined in step 120 , for each item to be listed using re-listing numbers. Finally, if an item listed under a re-listing number is sold, a credit is applied to the user id account under which the item was listed.
FIG. 6 shows flow chart for creating a linked description in accordance with the present invention. In step 86 of FIG. 4B and step 114 of FIG. 5B , a linked description of an item is permitted instead of a standalone description. FIG. 6 and FIG. 8 show alternatives for creating linked descriptions. In FIG. 6 , if a link to other items is desired, as determined in step 130 , search keywords are placed in the item description using their ASCII code equivalents, in step 132 . This keeps these keywords out of the auction site's search index, thus preventing a bidder who searches for a keyword from seeing the other keywords in the item description of the item returned in the search results.
FIG. 7 shows a flow chart in which a search of the auction site uses the linked description created in FIG. 6 . In step 140 , a potential bidder searches the auction site for an item and in step 142 , the site returns a match. In step 144 , an URL (uniform resource locator) with an ASCII coded keyword takes the potential bidder to the auxiliary site 20 in FIG. 1 and that site converts the ASCII coded keyword to its text equivalent and, in step 148 , automatically, invokes the search engine of the auction site with the key word as the search parameter, in step 150 . The potential bidder thus sees the item(s) that matches the converted text when the search engine returns with its search results, in step 152 .
FIG. 8 shows a flow chart for creating an alternate linked description in accordance with the present invention. In FIG. 8 , if a link to other listed items is desired, as determined in step 160 , rather than change the keyword to ASCII in the item description, an HTML tag for an in-line frame is inserted into the item description in step 162 .
FIG. 9 shows a flow chart in which a search of the auction site uses the linked description created in FIG. 8 . In FIG. 9 , the potential bidder searches the auction site, in step 166 , for an item. The auction site, in step 168 , finds the item searched for and, in step 170 , returns a document having an in-line HTML tag to the potential bidder's computer system which interprets the tag. Interpreting the tag causes, in step 172 , the potential bidder's computer system to create an in-line frame and to obtain from the auxiliary site 20 and display a list of keywords in the in-line frame, in step 174 . The potential bidder now selects a keyword in the in-line frame, in step 176 , to cause a new search at the auction site, which, in step 178 , will find and retrieve the linked item on the auction site.
As an alternative to using linked item descriptions to help the potential bidder find items related to an item searched for and to avoid the waste of time in performing repeated similar searches after the item searched for is reviewed in detail, the present invention also contemplates the use of background searches of the auction site. These background searches are conducted by a Web browser “plug-in”, stand-alone client side application, or framed Web page, which is triggered when the potential bidder conducts an original search for a particular item on the auction site. Generally, the original search produces hundreds or thousands of results and these results are lost when the user examines one of the items in detail. The background search, when triggered, corrects this problem by searching for items up for auction on the auction site that are similar to the item shown on the potential bidder's screen and by preparing a list of hyperlinks for the potential bidder from this background search information. The potential bidder then selects one of the hyperlinks and is taken to the auction relating to the item whose hyperlink was selected. When the potential bidder views that item, the process repeats itself, conducting another search in the background for items related to the one currently being viewed by the potential bidder.
Search results from the background search are either narrowed or expanded. To narrow the search results a filter is set up based pre-defined search parameters that the potential bidder has stored at the Web site which conducts the background search. This permits the site to filter out search results that do not interest the potential bidder.
The search can be expanded by having auction sellers register at an auxiliary Web site (i.e., a site which is not the auction site). Using this registration information a background search is conducted over the entire World Wide Web for items that the registered seller is selling and a database for that seller is compiled. This database is presented to the potential bidder when the bidder selects an auction of that seller.
Filters for the background search data include but is not limited to selecting search data that matches a category of item, a specific seller such as the seller for the originally sought item and specific auction starting and ending times.
It is contemplated that an auxiliary Web site receive instructions for performing a search from the computer of the potential bidder. The auxiliary Web site conducts the search for the potential bidder and returns the results to the potential bidder. The auxiliary Web site maintains a database that stores these background search results, cumulatively, for possible later use, until the potential bidder ends the session.
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible.
One alternative method for linking item descriptions includes encrypting the other items' information including descriptions, phrases, and titles. In one method, the encrypted information is inserted into an URL that takes the user to an auxiliary site at which a client-side program, such as a Java script program, runs to decrypt the other item descriptions and present the user with a selection list in readable text. Making a selection causes the user to return to the search engine of the auction site which will find and display the item selected. Instead of residing on an auxiliary site, the program for decrypting the keyword information can reside at the auction site, or even in the item description itself in the case of self-decryption. If the auction site encrypts and decrypts the other item information, there is no need to leave the auction site. The auction site encrypts the other item description data to prevent the auction site search engine from interfered with during a search for an item selected by the user. When the item requested by the user is found, the encrypted data in the item description of the found item is found automatically decrypted and presented to the user, giving the user the choice of selecting the other items for searches.
Another alternative method for linking item descriptions includes creating a keyword in the item description data, wherein the keyword's letters are separated by a delimiter such as a space, underline, comma or period so that the auction site's search engine cannot find the keyword when a search is requested. For example, if the requested item was “U.S. Automobile classics” and the seller want to inform the potential buyer of a related item such as a Jaguar that he has listed on the auction site, a delimited sequence, “J-a-g-u-a-r” is embedded in the item description for the “U.S. Automobile classics”. This prevents the auction site search engine from finding the Jaguar item in a search because the delimiters prevent a match. A program resides either on the auction site or on another site to remove the delimiters from the keyword and then pass the non-delimited keyword back to the search engine of the auction site. The auction site search engine then displays the item related to the keyword.
Yet another alternative method for linking item descriptions includes entering keywords into an item's description data and then inserting those keywords into the auction site's database in a table (or in pre-designated fields of an existing table) set up for storing keywords. The table maintains an associative link with the item data in the auction site's database. When a search is performed at the auction site and the item is found, the table of keywords is called up and the related keywords are displayed along with the found item's description data. The searcher selects one of the keywords and is re-directed to the auction site's search engine with the selected keyword as the search parameter.
Yet another alternative method for linking item descriptions includes embedding other item keywords between HTML tags or other protected area specifically designed for keywords. The auction site's search engine is configured to ignore information in the protected area. The keyword information is stored in a keyword table (or in pre-designated fields of an existing table) set up for keywords. When a search is performed at the auction site and the item is found, the table of keywords (or keyword fields) is called up and the related keywords are displayed along with the found item's description data. The searcher selects one of the keywords and is re-directed to the auction site's search engine with the selected keyword as the search parameter.
Yet still another alternative method for linking item descriptions includes placing a pointer, such as an URL inside the item description, where the pointer is used to access an auxiliary host connected to the Internet. When a Web page containing the item description having the pointer is accessed by the potential bidder's browser (or equivalent interpreter), the pointer accesses the auxiliary host to produce an auxiliary list of keywords, item descriptions and/or item numbers that represent all of the currently active auctions for the sellers items and displays the list inside the auction description. The list from the auxiliary host can also be displayed in a pop-up window generated when the URL is selected and displayed over the Web page containing the item description from the auction site.
The auxiliary list is preferably dynamic in that it can be changed at any time so that the list is always up-to-date when viewed. This means that when an auction for one or more items ends, the list is updated to only show currently active auctions. Because the list resides on the auxiliary host, the information in the list is not visible to and so does not interfere with the auction site search engine. A variation of the above alternative is that the auction site has Java, Java-Script or similar code inside the item description on the auction site. This code when executed allows the potential bidder's browser to have access to the dynamic list of items on the auxiliary site. Thus, code for displaying the dynamic list of items can reside on the client side, i.e., with the browser or on the auxiliary site.
Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained herein.
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A method of promoting for bid or sale of auction items of a seller on an auction site. In an item description of an item available from a seller on the auction site, a pointer is embedded. The pointer points to a related item offered for bid or sale on the auction site. When the user accesses the item description, the auction site causes an access to a facilitating server using the pointer. This, in turn, causes the facilitating server to produce a list of related items available by the same seller on the auction site. The list is presented to the user so that the user can bid on or purchase the related items. In this way, a specific seller's items can be promoted to bidders or purchasers using the auction site.
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FIELD OF THE INVENTION
The invention relates to control of impulse-generated (sometimes termed shock-generated) vibration for diagnostic testing and/or controlled fragmentation. Applications include vibration testing of geological strata or mechanical structures to characterize how inherent strengths and weaknesses affect their use. In the oil and gas industry, information from down-hole equipment develops control data which guides well completion. Particularly demanding applications include combining impulse-generated swept-frequency stimulation vibration with cyclically-varying hydraulic pressure (herein: adaptive stimulation) on intervals along horizontal wellbores in ultralow-permeability (unconventional) formations. The invention is related to U.S. Pat. Nos. 8,939,200, 8,944,409, 9,027,636, 9,080,690, and 9,169,707. The application is a continuation-in-part of co-pending U.S. patent application Ser. No. 14/919,848 (filed 22 Oct. 2015), and is related to co-pending U.S. patent application Ser. No. 15/645,430 (filed 10 Jul. 2017).
INTRODUCTION
New designs described herein incorporate innovative applications of well-known technical principles for improved data collection to support design improvements and optimize stimulation system performance. Adverse and beneficial aspects of the technical principles are represented in relationships between mechanical shocks and their broad-spectrum impulse-generated vibration. For example, adverse aspects of these relationships are strikingly manifest in the troubling fluid-end failure rates of even the most modern conventional high-pressure well-stimulation pumps (termed frac pumps herein). On the other hand, beneficial aspects can be employed both to increase frac pump reliability and to enhance well productivity through more efficient and localized adaptive stimulation of geologic material surrounding a wellbore. That is, well completion is informed by analysis of backscatter vibration data from the stimulated material.
Note that alternative configurations of adaptive stimulators of the present invention may be placed in selected wellbores for purposes other than well completion (e.g., to test for local seismic activity using timed bursts of diagnostic stimulation vibration). And a well system undergoing either test or completion may be preloaded by its hydraulic head and/or supplemental pump pressurization. Performance testing is yet another application of adaptive stimulators, wherein they may be hydraulically coupled to structures such as bridges or railroad track beds to detect fatigue cracking, settling, corrosion and other phenomena likely to affect performance. As in the case of well completion applications and seismic studies, static and/or dynamic preloading may be desirable in performance testing to more completely characterize the structures tested.
Creation of adaptive stimulation for any purpose begins with broad-spectrum impulse-generated vibration (i.e., vibration bursts simultaneously comprising a plurality of vibration frequencies). Such bursts are sometimes termed shock-generated vibration, and they are commonly seen in oil field operations to be either beneficial or detrimental. For a detrimental example, consider the mechanical shock of valve closure under pressure in a high-pressure pump fluid end. The shock creates a plurality of vibration frequencies that can lead to excitation of destructive vibration resonances in the fluid end or the entire frac pump. These excited resonances predispose various pump parts to fatigue-related cracking and ultimate failure. A variety of designs shown and described in the following materials explain how such damaging vibration resonances can be controlled (e.g., suppressed) using a hierarchy of tunable systems, tunable subsystems, tunable components and design elements. Controlling destructive resonance excitation vibration, in turn, limits vibration-induced cracking.
Specific examples are cited in the following paragraphs to illustrate how frac pump reliability improvements have evolved from a better understanding of causes and effects of shock and vibration in fluid ends. First, remarkably strong and repetitive energy impulses (associated with mechanical shocks) commonly originate in frac pump fluid end valves. Second, both the bandwidth and amplitude of impulse-generated vibration produced by repetitive high-pressure closure of conventional fluid end check valves can be reduced through innovative design changes. Third, without such design changes, fatigue-related damage (due to resonance excitation by impulse-generated vibration) is exacerbated and frac pumps are predisposed to fluid end failures (an increasingly common problem).
But resonance vibration excitation shouldn't always be limited in well stimulation systems; sometimes it should be enhanced! In the present invention, broad-spectrum impulse-generated vibration originates in adaptive down-hole hydraulic stimulators, being transmitted via each stimulator's fluid interface to surrounding geologic material. Transmitted vibration can be tailored, and tailoring is initiated by alternately up-shifting and down-shifting (i.e., cyclically shifting) the power spectral densities (PSD's) of the vibration frequency spectra in a predictable manner. Cyclical PSD shifting produces vibration frequency sweeps originating in the predictably-varying PSD's. The frequency sweeps thus embedded in adaptive stimulation vibration can facilitate maximization of stimulation efficiency through analysis of backscatter vibration originating in stimulated (e.g., fractured) geologic material.
The simultaneous presence of cyclically-varying down-hole hydraulic pressures in predetermined phase relationships (e.g., in-phase) with cyclically-shifted PSD's predictably increases rock fracturing, with associated fragmentation, throughout a range of rock particle sizes at varying distances from a wellbore. The varying distances are functions of both the cyclically-varying down-hole hydraulic pressures and the inherent dynamic response of the stimulated geologic material.
Summarizing, adaptive stimulation systems as described herein effectively address frac pump fluid-end fatigue failures by (1) altering check valve closure mechanics to reduce mechanical shock; and/or (2) down-shifting the PSD's of valve-generated (i.e., impulse-generated) vibration spectra to reduce the deleterious effects of resonance excitation. Further, adaptive stimulation systems modify, electively in phase relation (e.g., in-phase), cyclically-varying down-hole hydraulic pressures and cyclically shifted stimulation vibration PSD's to improve stimulation efficiency. *** Thus, adaptive stimulation systems can tailor frequency sweeps of impulse-generated vibration to preferentially cause resonance vibration excitation (i.e., stimulation) of geologic material at varying distances from a wellbore. Backscatter vibration emanating from the stimulated geologic material supports dynamic analysis of widely-variable unconventional geologic formations. Further, such backscatter vibration can inform adaptive modification of the swept-frequency down-hole stimulation vibration and/or the cyclically-varying down-hole hydraulic pressures. ***
By combining cyclically-varying down-hole hydraulic pressures in predetermined phase relation with alternating up-and-down shifts of stimulation vibration PSD (i.e., cyclical PSD shifts), adaptive well stimulation can accomplish four complementary functions: (1) to fracture geologic material at varying distances from a wellbore (thereby opening channels in it); (2) to prop the channels open with rock fragments that are self-generated in situ by stimulation vibration that is tailored during the fracturing process; (3) to characterize the stimulated geologic material as to the degree of stimulation achieved (e.g., the quantitative beneficial results of actual geologic fracture and particle fragmentation) in comparison with that desired; and (4) to adaptively modify cyclically-varying down-hole hydraulic pressures and/or cyclically-shifted PSD's of impulse-generated swept-frequency stimulation vibration to improve stimulation efficiency.
To optimize these complementary well-stimulation functions, the extent of geologic fracturing is periodically assessed in near-real time. Assessment begins with detection of band-limited backscatter vibration corresponding to the frequency sweeps of stimulation vibration. Such backscatter vibration emanates from the stimulated geologic fragments as they are formed by fracture, and backscatter assessment analysis proceeds continuously. In particular, signals representing the backscatter vibration are processed in programmable controllers to produce feedback data and control signals for one or more tunable down-hole hydraulic stimulators (i.e., timed stimulator signals) and the frac pump(s) providing cyclically-varying down-hole hydraulic pressure (i.e., timed pressure signals). Note that signal processing and analysis in programmable controllers is carried out using empirically-derived software algorithms (broadly termed herein: frac diagnostics).
The controller, in turn, ensures that swept-frequency stimulation vibration arises in part from cyclical up-shifts and down-shifts of PSD achieved by electromechanical adjustment of rebound cycle time associated with hammer strikes in a shock wave generator. And swept-frequency stimulation vibration also arises in part from cyclical up-shifts and down-shifts of PSD achieved by magnetostrictive adjustment of shock-wave generator fluid interface resonant frequencies. The latter adjustment is achieved by step-wise changing of the steady-state flux density of one or more longitudinal magnetic fields applied to one or more magnetostrictive amorphous ferromagnetic alloy disc-shaped thin members comprising a vibration generator fluid interface. See, e.g., U.S. Pat. No. 8,093,869, incorporated by reference.
Among other remarkable properties of the above magnetostrictive amorphous ferromagnetic alloy disc-shaped thin members (comprising, e.g., the amorphous ferromagnetic alloy Metglas 2605SC), the disc-shaped thin members can be configured to resonate at a predetermined frequency and/or to convert applied mechanical energy to vibration electrical signals (as in, e.g., a vibration detector). See, e.g., U.S. Patent Application Publication 2005/0242955.
Magnetostrictive materials can also be configured as a magnetostrictive lens operable in response to a coil-generated magnetic field (see, e.g., U.S. Pat. No. 5,458,120, incorporated by reference). Metglas 2605SC exhibits a change up to about 80% of effective Young's Modulus (i.e., effective elastic modulus) with magnetization to saturation in bulk. Young's Modulus is an indicator of stiffness, and changes in stiffness can thus be used to tune the resonance frequency of a shock wave generator fluid interface. See, e.g., U.S. Pat. Nos. 5,381,068 and 9,339,284 incorporated by reference.
In addition to feedback data from the above signal processing, supplemental geologic data may be obtained from frac diagnostics using signals from conventional well-logging apparatus and/or measurement-while-drilling (MWD) tools. Further, data-science techniques applied to studies of differences between swept-frequency stimulation vibration and corresponding band-limited backscatter vibration can reveal structural information on stimulated geologic material that is both highly-desirable and otherwise unobtainable.
Note particularly that use of swept-frequency impulse-generated stimulation vibration confers substantial advantages in characterizing geologic material adjacent to the wellbore. First, the overall broad spectrum of applied vibration ensures that a broad range of rock particle sizes will resonate (and hence tend to fragment) with each burst of stimulation vibration energy. Backscatter vibration accurately reflects the extent of this desired fragmentation. Second, due in part to the electro-mechanical mode of stimulation vibration generation described herein, the bandwidth, phase and amplitude of vibration frequency sweeps will vary slightly from burst-to-burst. Inherently then, the likelihood of missing critical geologic resonance vibration frequencies within successive frequency sweeps of stimulation vibration is reduced. Third, the down-hole stimulation vibration generators described herein can be tailored: e.g., their output PSD's (and thus their frequency sweeps) can be adjusted via closed-loop control systems. Stimulation energy may therefore be electively stepwise concentrated in progressively higher frequency ranges as stimulation-induced geologic fragmentation progresses through a range from large pieces to smaller (proppant-sized) fragments. And Fourth, the substantially real-time concentration of stimulation energy in frequency ranges likely to induce desired degrees of geologic fragmentation results in higher efficiency. Energy thus applied minimizes unproductive heat loss because the relative amount of stimulation energy transmitted in less productive frequency ranges is reduced.
The above-described advantages of tailored stimulation stem in part from the fact that backscatter vibration, processed via frac diagnostics to yield feedback data, provides geologic information that is otherwise unobtainable. Functions of feedback data, in the form of control signals from programmable controllers, allow tailoring of the process of closed-loop geologic stimulation to the requirements of individual (unconventional) formations. Such closed-loop stimulation control incorporates feedback of a portion of the controlled-system output (i.e., backscatter vibration from stimulated geologic material) to the controlled-system input (i.e., adaptive stimulation vibration generated via mechanical shock). In other words, backscatter vibration data are used to alter the mechanical shocks themselves, thereby fine-tuning stimulation vibration as needed for quick convergence on optimal stimulation vibration frequency end-points.
Closed-loop control of mechanical shocks in a vibration generator as described herein implies control of the kinetic energy impulses corresponding to a moving hammer (or mass) element striking, and rebounding from, a fluid interface having an adjustable effective elastic modulus. This apparatus is termed herein a tunable down-hole hydraulic stimulator. At least a portion of the initial kinetic energy for each hammer strike is converted to broad-spectrum impulse-generated vibration energy through vibration of the stimulator's fluid interface. So with each hammer strike and rebound, the vibration spectrum's PSD can be detected and adjusted as desired under closed-loop control in near-real time.
Closed-loop PSD control for tunable down-hole hydraulic stimulators means that transmitted vibration spectra from a tunable hydraulic stimulation vibration generator are tuned at their source (e.g., by altering the rebound cycle time for each hammer element strike and/or stepwise alteration of the fluid interface's effective elastic modulus). Such tuning effectively shapes a transmitted vibration spectrum's PSD to concentrate stimulation vibration power in predetermined frequency ranges. The predetermined frequency ranges for any stage of stimulation are (1) ranges that maximize transmission of vibration resonance excitation power to the adjacent geologic materials and/or (2) ranges that facilitate characterization of the geologic materials through analysis of backscatter vibration. As stimulation proceeds, each predetermined frequency range necessarily changes (through the mechanism of PSD shifts), thereby generating frequency sweeps as described herein.
The stimulated geologic materials themselves, after a short time delay, report their actual absorption of tailored stimulation vibration energy (i.e., resonance excitation) in the form of backscatter vibration. Feedback data are then derived from the backscatter vibration. Calculated control signals (which are based on the feedback data) close the loop in closed-loop impulse-generated vibration control. Like the feedback data, control signals are also calculated using a programmable controller running frac diagnostic software. And the control signals are then applied (e.g., via feedback control link) to one or more tunable hydraulic vibration generators and/or frac pumps to optimize down-hole stimulation in near-real time.
Note that evaluation of backscatter vibration data detected via one or more down-hole stimulators may optionally be enhanced in light of, e.g., corresponding down-hole temperature and/or hydraulic pressure data. These parameters, electively combined with associated well-logging data, may be sensed at one or more down-hole stimulators. And enhanced evaluation may then be carried out, e.g., via frac diagnostics in a programmable controller for the relevant tunable down-hole stimulation system.
To acquire the benefits of backscatter vibration data as described above, tunable down-hole stimulators must transmit sweeps of impulse-generated stimulation vibration to geologic materials adjacent to their wellbore stages or location(s). Geologic access is via, e.g., casing perforations and/or slots (i.e., ports or access openings). Since optimal resonance excitation frequencies necessarily change as stimulation progresses, closed-loop control in the stimulator(s) causes the PSD of stimulation vibration energy to be correspondingly shifted in near-real time to optimize stimulation of, and thus generate the corresponding backscatter vibration from, individual producing zones or stages within a wellbore. (See, e.g., U.S. patent application number 2014/0041876 A1, incorporated by reference). *** Optimization thus means: (1) more effective stimulation; (2) for more productive wells; (3) achieved with higher energy efficiency; (4) in less time. ***
The following background materials support the above introduction by discussing the vibration spectrum of an impulse in greater detail, highlighting its importance with examples of deleterious effects of mechanical shock and vibration in conventional applications. Building on the background, subsequent sections describe selected alternative designs for adaptive stimulation system components to transform the overall process of well completion through substantive improvements in reliability, efficiency, and efficacy.
BACKGROUND
The necessity for modified check valve designs (e.g., as described herein and in related patents) may be better appreciated after first considering: (1) the remarkably high failure rates of conventional reciprocating high-pressure pumps (especially their fluid ends), and (2) the substantial uncertainties (e.g., in cost/benefit analysis and technical complexity/reproducibility) associated with multistage well stimulation in unconventional formations. Pump-related issues will be considered initially.
Frac pumps (also commonly called fracking or well-service pumps) are typically truck-mounted for easy relocation from well-to-well. And they are usually designed in two sections: the (proximal) power section (herein “power end”) and the (distal) fluid section (herein “fluid end”). Each pump fluid end comprises at least one subassembly, and commonly three or more, in a single fluid end housing. Each subassembly comprises a suction valve, a discharge valve, a plunger or piston, and a portion of (or substantially the entirety of) a pump fluid end subassembly housing (shortened herein to “pump housing” or “fluid end housing” or “housing”, depending on the context).
For each pump fluid end subassembly, its fluid end housing comprises a pumping chamber in fluid communication with a suction bore, a discharge bore, and a piston/plunger bore. A suction valve (i.e., a check valve) within the suction bore, together with a discharge valve (i.e., another check valve) within the discharge bore, control bulk fluid movement from suction bore to discharge bore via the pumping chamber. Note that the term “check valve” as used herein refers to a valve in which a (relatively movable) valve body can cyclically close upon a (relatively stationary) valve seat to achieve substantially unidirectional bulk fluid flow through the valve.
Pulsatile fluid flow results from cyclical pressurization of the pumping chamber by reciprocating plunger or piston strokes within the plunger/piston bore. Suction and pressure strokes alternately produce wide pressure swings in the pumping chamber (and across the suction and discharge check valves) as the reciprocating plunger or piston is driven by the pump power end.
Such pumps are rated at peak pumped-fluid pressures in current practice up to about 22,000 psi, while simultaneously being weight-limited due to the carrying capacity of the trucks on which they are mounted. (See, e.g., U.S. Pat. No. 7,513,759 B1, incorporated by reference).
Due to high peak pumped-fluid pressures, suction check valves experience particularly wide pressure variations between a suction stroke, when the valve opens, and a pressure stroke, when the valve closes. For example, during a pressure stroke with a rod load up to 350,000 pounds, a conventionally rigid/heavy check valve body may be driven longitudinally (by pressurized fluid behind it) toward metal-to-metal impact on a conventional frusto-conical valve seat at closing forces of about 50,000 to over 250,000 pounds (depending on valve dimensions). A portion of total check-valve closure impulse energy (i.e., the total kinetic energy of the moving valve body and fluid at valve seat impact) is thus converted to a short-duration high-amplitude valve-closure energy impulse (i.e., a mechanical shock). As described below, each such mechanical shock is associated with transmission of broad-spectrum vibration energy, the range of vibration spectrum frequencies being an inverse function of valve-closure energy impulse duration.
Repeated application of dual valve-closure shocks with each pump cycle (i.e., one shock from the suction valve and another shock from the discharge valve) predisposes each check valve, and the pump as a whole, to vibration-induced (e.g., fatigue) damage. (Recall the well-documented progressive cracking of the Liberty Bell with repeated strikes of the clapper, particularly noting the sites of crack progression being significantly distant from the sites of clapper impact). Thus, cumulative valve-closure shocks significantly degrade frac pump reliability, proportional in part to the rigidity and weight of each check valve body.
The increasing importance of fatigue-related frac pump reliability issues has paralleled the inexorable rise of peak pumped-fluid pressures in new fracking applications. And insight into fatigue-related failure modes has been gained through review of earlier shock and vibration studies, data from which are cited herein. For example, a recent treatise on the subject describes a mechanical shock in terms of its inherent properties in the time domain and in the frequency domain, and also in terms of its effects on structures when the shock acts as the excitation. (see p. 20.5 of Harris' Shock and Vibration Handbook , Sixth Edition, ed. Allan G. Piersol and Thomas L. Paez, McGraw Hill (2010), hereinafter Harris ).
References to time and frequency domains appear frequently in descriptions of acquisition and analysis of shock and vibration data. And these domains are mathematically represented on opposite sides of equations generally termed Fourier transforms. Further, estimates of a shock's structural effects are frequently described in terms of two parameters: (1) the structure's undamped natural frequency and (2) the fraction of critical structural damping or, equivalently, the resonant gain Q (see Harris pp. 7.6, 14.9-14.10, 20.10). (See also, e.g., U.S. Pat. No. 7,859,733 B2, incorporated by reference).
Digital representations of time and frequency domain data play important roles in computer-assisted shock and vibration studies. In addition, shock properties are also commonly represented graphically as time domain impulse plots (e.g., acceleration vs. time) and frequency domain vibration plots (e.g., spectrum amplitude vs. frequency). Such graphical presentations readily illustrate the shock effects of metal-to-metal valve-closure, wherein movement of a check valve body is abruptly stopped by a valve seat. Relatively high acceleration values and broad vibration spectra are prominent, because each valve-closure impulse response primarily represents a violent conversion of a portion of kinetic energy (of the moving valve body and fluid) to other energy forms.
Since energy cannot be destroyed in a conventional valve, and a valve can neither store nor convert (i.e., dissipate) more than a small fraction of the valve-closure impulse's kinetic energy, a portion of that energy is necessarily transmitted to the pump housing in the form of broad-spectrum vibration energy. This relationship of (frequency domain) vibration energy to (time domain) kinetic energy, is mathematically represented by a Fourier transform. Such transforms are well-known to those skilled in the art of shock and vibration mechanics. For others, a graphical representation (i.e., plots) rather than a mathematical representation (i.e., equations) may be preferable.
For example, in a time domain plot, the transmitted energy appears as a high-amplitude impulse of short duration. And a corresponding frequency domain plot of transmitted energy reveals a relatively broad-spectrum band of high-amplitude vibration. *** The breadth of the vibration spectrum is generally inversely proportional to the impulse duration. ***
Thus, as noted above, a portion of the check valve's cyclical valve-closure kinetic energy is converted to relatively broad-spectrum vibration energy. The overall effect of cyclical check valve closures may therefore be compared to the mechanical shocks that would result from repeatedly striking the valve seat with a commercially-available impulse hammer, each hammer strike being followed by a rebound. Such hammers are easily configured to produce relatively broad-spectrum high-amplitude excitation (i.e., vibration) in an object struck by the hammer. (See, e.g., Introduction to Impulse Hammers at http://www.dytran.com/img/tech/a11.pdf, and Harris p. 20.10).
Summarizing then, relatively broad-spectrum high-amplitude vibration predictably results from a typical high-energy valve-closure impulse. And frac pumps with conventionally-rigid valves can suffer hundreds of these impulses per minute. Note that the number of impulses per minute (for example, 300 impulses per minute) corresponds to pump plunger strokes or cycles, and this number may be converted to impulses-per-second (i.e., 300/60=5). In this example, the number 5 is sometimes termed a frequency because it is given the dimensions of cycles/second or Hertz (Hz). But the “frequency” thus attributed to pump cycles themselves differs from the spectrum of vibration frequencies resulting from each individual pump cycle energy impulse. The difference is that impulse-generated (e.g., valve-generated) vibration occurs in bursts having relatively broad spectra (i.e., simultaneously containing many vibration frequencies) ranging from a few Hz to several thousand Hz (kHz).
In conventional frac pumps, nearly all of the (relatively broad-spectrum) valve-generated vibration energy must be transmitted to proximate areas of the fluid end or pump housing because vibration energy cannot be efficiently dissipated in the (relatively rigid) valves themselves. Based on extensive shock and vibration test data (see Harris ) it can be expected to excite damaging resonances that predispose the housing to fatigue failures. (See, e.g., U.S. Pat. No. 5,979,242, incorporated by reference). If, as expected, a natural vibration resonance frequency of the housing coincides with a frequency within the valve-closure vibration spectrum, fluid end vibration amplitude may be substantially increased and the corresponding vibration fatigue damage made much worse. (See Harris, p. 1.3).
Opportunities to limit fluid end damage can reasonably begin with experiment-based redesign to control vibration-induced fatigue. That is, spectra of the equipment vibration frequencies measured after application of test shocks can reveal structural resonance frequencies likely to cause trouble in a particular fluid end. These revealed frequencies are herein termed critical frequencies. For example, a test shock may comprise a half-sine impulse of duration one millisecond, which has predominant spectral content up to about 2 kHz (see Harris, p. 11.22). This spectral content likely overlaps, and thus will excite, a plurality of a fluid end's structural resonance (i.e., critical) frequencies. Excited critical frequencies are then identified with appropriate instrumentation, so attention can be directed to limiting operational vibration at those critical frequencies. This process is tailored to each fluid end, with an appropriate test shock and instrumentation to provide at least one “tested fluid end vibration resonant frequency” to support further reliability improvements.
Limiting vibration at critical frequencies through use of the above shock tests can be particularly beneficial in blocking progressive fatigue cracking in a structure. If vibration is not appropriately limited, fatigue cracks may grow to a point where fatigue crack size is no longer limited (i.e., the structure experiences catastrophic fracture). The size of cracks just before the point of fracture has been termed the critical crack size. Note that stronger housings are not necessarily better in such cases, since increasing the housing's yield strength causes a corresponding decrease in critical crack size (with consequent earlier progression to catastrophic fracture). (See Harris, p. 33.23).
It might be assumed that certain valve redesigns proposed in the past (including relatively lighter valve bodies) would have alleviated at least some of the above fatigue-related failure modes. (See, e.g., U.S. Pat. No. 7,222,837 B1, incorporated by reference). But such redesigns emerged (e.g., in 2005) when fluid end peak pressures were generally substantially lower than they currently are. In relatively lower pressure applications (e.g., mud pumps), rigid/heavy valve bodies performed well because the valve-closure shocks and associated valve-generated vibration were less severe compared to shock and vibration experienced more recently in higher pressure applications (e.g., fracking). Thus, despite their apparent functional resemblance to impulse hammers, relatively rigid/heavy valves have been pressed into service as candidates for use in frac pump fluid ends. Indeed, they have generally been among the valves most commonly available in commercial quantities during the recent explosive expansion of well-service fracking operations. Substantially increased fluid end failure rates (due, e.g., to cracks near a suction valve seat deck) have been among the unfortunate, and unintended, consequences.
Under these circumstances, it is regrettable but understandable that published data on a modern 9-ton, 3000-hp well-service pump includes a warranty period measured in hours, with no warranty for valves or weld-repaired fluid ends.
Such baleful vibration-related results in fluid ends might usefully be compared with vibration-related problems seen during the transition from slow-turning two-cylinder automobile engines to higher-speed and higher-powered inline six-cylinder engines around the years 1903-1910. Important torsional-vibration failure modes suddenly became evident in the new six-cylinder engines, though they were neither anticipated nor understood at the time. Whereas the earlier engines had been under-powered but relatively reliable, torsional crankshaft vibrations in the six-cylinder engines caused objectionable noise (“octaves of chatter from the quivering crankshaft”) and unexpected catastrophic failures (e.g., broken crankshafts). (Quotation cited on p. 13 of Royce and the Vibration Damper , Rolls-Royce Heritage Trust, 2003). Torsional-vibration was eventually identified as the culprit and, though never entirely eliminated, was finally reduced to a relatively minor maintenance issue after several crankshaft redesigns and the development of crankshaft vibration dampers pioneered by Royce and Lanchester.
Reducing the current fluid end failure rates related to valve-generated vibration in frac pumps requires an analogous modern program of intensive study and specific design changes. The problem will be persistent because repeatedly-applied valve-closure energy impulses cannot be entirely eliminated in check-valve-based fluid end technology. So the valve-closing impulses must be modified, and their associated vibrations damped, meaning that at least a portion of the total vibration energy is converted to heat energy and dissipated (i.e., the heat is rejected to the surroundings). A reduction in total vibration energy results in reduced excitation of destructive resonances in valves, pump housings, and related fluid end structures.
SUMMARY OF THE INVENTION
Adaptive stimulation systems combine impulse-generated swept-frequency stimulation vibration with cyclically-varying hydraulic pressure to provide adaptive down-hole stimulation. Swept-frequency stimulation vibration arises from cyclical up-shifts and down-shifts of the power spectral density (PSD) of impulse-generated stimulation vibration. The cyclical PSD shifts, in turn, are achieved via closed-loop control of the impulse-generated vibration produced by one or more down-hole stimulators. Adaptive down-hole stimulation can be produced by a single tunable down-hole stimulator or by a plurality of such stimulators spaced apart in a spatial array. A linear array, as schematically illustrated herein (see FIG. 18 ), is one type of spatial array.
Whether singly or in a spatial array, each stimulator is under closed-loop control. And each stimulator responds to timed stimulator signals (e.g., timed stimulator transmission signals and stimulator shift signals). Each stimulator transmits (in response to a timed stimulator transmission signal) an impulse-generated vibration burst comprising a plurality of vibration frequencies. And each such vibration burst has a power spectral density (PSD) which may be up-shifted or down-shifted under closed-loop control (via a timed stimulator shift signal) to create a swept-frequency spectrum. Connected array stimulators may be controlled by a periodic signal group comprising one or more signals for each stimulator in the array. That is, timed stimulator transmission signals and/or timed stimulator shift signals may be sent as timed signal groups from a programmable controller, at least one signal (either a transmission signal or a shift signal or both) for each stimulator. Signals within a timed signal group may be either simultaneous or sequential. Sequential stimulator signals are separated from each other by discrete time intervals within a signal group.
Timed stimulator shift signals control each stimulator's adjustable PSD for tuning via that stimulator's adjustable rebound cycle time. For example, adjustable PSD is up-shifted (i.e., increasing relative power in higher vibration frequencies) by reducing rebound cycle time and/or by increasing the resonant frequency of a stimulator's fluid interface. Down-shifting decreases higher vibration frequencies and occurs with increased rebound cycle time. Shifting of an adjustable PSD means that relative transmitted vibration power within a vibration burst may be shifted toward relatively higher or lower frequencies for tuning a single stimulator. Such tuning of one or more stimulators in a spatial array thus tunes the down-hole stimulation array as a whole. Stimulator vibration burst adjustable PSD's are typically adjusted in order to fine-tune a stimulation array for resonance excitation and fracturing of adjacent geologic materials.
Note that changes in rebound cycle times and/or fluid interface resonant frequencies also affect vibration interference among stimulators within an array (see “interference” below), while changes in stimulator transmission signal times (e.g. either simultaneous or sequential) can affect directional propagation of combined vibration wave fronts from a stimulator array (resulting in, e.g., a directionally-propagated array vibration wave front).
Note further that the hydraulic pressure environment in which down-hole stimulators operate can be altered by timed pressure signals sent from a programmable controller to one or more frac pumps providing the down-hole hydraulic pressure. Such timed pressure signals are phase-related (e.g., in-phase) with bursts of swept-frequency vibration from one or more down-hole stimulators. Cyclically-varying down-hole hydraulic pressure creates cracks of varying width and depth at varying distances from a wellbore. The hydraulic fluid (e.g., water) filling the cracks thus conveys swept-frequency vibration to excite resonances in geologic material at varying distances from the wellbore. Backscatter vibration from the excited resonances (i.e., feedback) can then be processed in one or more programmable controllers to provide localized estimates of the dynamic response of the geologic material to guide further stimulation.
As fracturing proceeds to smaller (proppant-sized) fragments having higher resonant frequencies, adjustable PSD's are up-shifted, increasing relative power in higher vibration frequencies (e.g., by reducing rebound cycle time as a function of increases in the backscatter vibration's higher frequency content). Progressive geologic stimulation is thus optimized, with inherent potential for plain-water (or liquefied propane) fracs completed with self-generated proppant.
A relatively broad vibration frequency spectrum (e.g., comprising a plurality of transmitted frequencies) is characteristic of the impulse-generated swept-frequency stimulation described herein. Combined with cyclically-varying hydraulic pressure, the broad vibration spectrum facilitates adaptive stimulation.
Adaptive stimulation, in turn, may be subject to controlled directional propagation (of combined vibration wave fronts) from a stimulator array. For example, predetermined sequences of simultaneous and/or sequential timed stimulator signals allow repeated scanning and characterization (via analysis of backscatter vibration) of geologic materials adjacent to a stimulator spatial array in a wellbore. Adaptive stimulation may then be tailored to local down-hole geologic conditions in near-real time. And the tailoring may comprise adjustment of phase relations among (1) timed stimulator shift signals (related to cyclical PSD shifts and swept-frequency vibration), and/or (2) timed stimulator array transmission signals (related to directional control of vibration bursts from the stimulator array), and/or (3) cyclically-varying down-hole hydraulic pressure (related to creating and assessing stimulation vibration effects at varying distances from the wellbore. The result is a parameter-rich control options environment for adaptive stimulation as described herein.
Further, stimulus tailoring is beneficially applied early in the well completion process because initial geologic fracturing is associated with relatively high down-hole hydraulic pressures and relatively large geologic fragment sizes. In view of the relatively low resonant frequencies of relatively large geologic fragments, the PSD of adaptive stimulation vibration energy may be down-shifted (i.e., fine-tuned). This will increase the relative power (within a vibration burst) of vibration transmitted at those relatively lower frequencies. Such vibration tuning is possible in the impulse-generated feedback-controlled swept-frequency stimulators described herein. Such stimulators feature closed-loop (feedback-controlled) hammer strike and rebound and/or fluid interface resonant frequencies which facilitate localized and near real-time adjustment of transmitted stimulation vibration PSD.
The need for localization of broad-spectrum impulse-generated stimulation vibration energy means the vibration must be generated and modified down-hole (i.e., in the wellbore) in part to minimize transmission losses as the energy travels to adjacent geologic material. On striking geologic material adjacent to the wellbore, portions of the broad vibration energy spectrum immediately excite resonant vibrations in geologic features whose resonant frequencies were not precisely known initially. By the mechanism of resonance, the variously-sized geologic fragments themselves automatically extract their own portions of vibration energy from the broad range of impulse-generated stimulation vibration frequencies available. The extracted energy, in turn, leads to further vibration-induced geologic fractures and fragmentation.
Backscatter vibration originating from the stimulated geologic materials reveals the stimulation status and the nature of those materials. Backscatter vibration is sensed in near-real time by detectors on one or more tunable down-hole stimulators. Analysis of backscatter vibration (in one or more programmable controllers) is followed by transmission of one or more control signals to one or more down-hole hydraulic stimulators. Beneficial geologic stimulation is thus obtained using a combination of: (1) minimum applied vibration energy, plus (2) resonance vibration effects assessed via detection of backscatter vibration from the stimulated geologic material.
It is known by those skilled in the art that accurately characterizing the overall geologic composition of shale reservoirs is difficult. Such reservoirs are substantially different from conventional and other types of unconventional reservoirs. (See, e.g., U.S. Pat. No. 8,731,889 B2, incorporated by reference). Thus various embodiments of the present invention reflect choices among a variety of different functional relationships relating the stimulation vibration parameters.
Further, certain tunable down-hole stimulation array embodiments may comprise one or more relatively higher-pressure pumps for fluid (e.g., plain water or liquefied propane) that contains no proppant (schematically illustrated and labeled herein as frac pumps). One or more such frac pumps may be combined with one or more relatively lower-pressure pumps for fluid containing exogenous proppant (schematically illustrated and labeled herein as proppant pumps). Such system embodiments facilitate pulsed proppant placement or PPP in previously fractured geologic material. PPP minimizes the total amount of exogenous proppant needed to supplement in situ or self-generated proppant resulting from tunable down-hole stimulation. Thus, the task of stimulation (including proppant placement) is performed step-wise, with each step under closed-loop control for fast convergence on one or more optimal end points.
Note certain differences between PPP as described herein and the industry practice of pumping different types of slurries or fluids in discrete intervals, that is, as slugs or stages. (See, e.g., U.S. Pat. No. 8,540,024 B2, incorporated by reference). First, proppant addition in PPP is under closed-loop control; it is a function, in part, of backscatter vibration sensed down-hole in near-real time by one or more detectors on each tunable down-hole stimulator. Second, in PPP the proppant-laden fluid may be injected into a wellbore (via one or more separate proppant pumps) at lower pressures than proppant-free fluid associated with the frac pump(s). And Third, proppant provided via the PPP closed-loop system is supplemental to self-generated proppant which is continuously created anew through stimulation vibration transmitted by one or more tunable down-hole stimulators.
An adaptive down-hole stimulation system embodiment to accomplish such PPP is schematically illustrated herein to emphasize certain advantages stemming from separation of the relatively high-pressure frac pump from the (optionally) relatively lower-pressure proppant pump.
In the following paragraphs, both generation of broad-spectrum vibration in tunable down-hole stimulators, and incorporation of the stimulators in tunable down-hole stimulation systems, are considered before control of valve-generated vibration in tunable fluid ends. This is to emphasize the role of induced-resonance-excitation vibration and fragmentation in geologic materials for maximizing well productivity.
Suppression of resonance excitation in tunable fluid ends, on the other hand, limits the destructive effects of valve-generated vibration (for maximizing fluid end reliability). Comparisons will be noted between the related-in-part methods for inducing or suppressing a desired range of resonance-related power spectral densities in systems comprising both tunable down-hole stimulators and tunable fluid ends.
The desirability of tunable down-hole stimulators in tunable down-hole stimulation systems stems in part from the well-known vertical and horizontal heterogeneity of unconventional reservoirs. Wide variability of geologic materials adjacent to wellbores is common, meaning that consistently-beneficial stimulation design has been difficult to achieve. In current practice, some fracture stages are typically found to be substantially more productive than others, while the cost of fracking varies little from stage-to-stage. Thus, stimulation design currently reflects compromises between the efficiency of a single customized fracture stage and the degraded performance of multiple one-size-fits-all stages that include a variety of geologic materials having different productive potentials.
Such currently unavoidable inefficiencies are substantially reduced by the advent of new tunable down-hole stimulation systems as described herein. With the new systems, progressive series of customized fracture stages can be realized in near-real time through productive integration of: (1) pumps (optionally having tunable fluid ends), (2) tunable down-hole stimulators, and (3) programmable controllers. Each fracture stage is electively customized in turn, through use of frac diagnostics operating on near-real-time backscatter vibration. Relatively productive stages can be readily identified for optimal stimulation, followed by combination of such stages into strategically important productive clusters.
And the twin keys to creation of productive clusters in horizontal wellbores are (1) sensing backscatter vibration to generate feedback data collected in different portions of a tunable down-hole stimulation system and (2) processing these and related data (e.g., pressure and/or temperature) in the system's programmable controller to create control signals. Control signals, in turn, direct the operations of subsystems for pumping and/or impulse-generated broad-spectrum vibration to optimize stimulation. Control signals can also (optionally) facilitate accurate placement and adjustment of inflow control devices within a tunable down-hole stimulation system.
An illustration of such closed-loop control is seen in a first embodiment of a tunable down-hole stimulation system. The system comprises at least one frac pump for creating down-hole hydraulic pressure, together with at least one tunable down-hole stimulator, each stimulator comprising a tunable impulse vibration generator for transmitting vibration hydraulically to adjacent geologic material. The system further comprises a programmable controller for creating a plurality of control signals and transmitting at least one control signal to each frac pump and at least one control signal to each tunable down-hole stimulator. Additionally, each tunable down-hole stimulator comprises at least one accelerometer for sensing both transmitted and backscatter vibration and for transmitting an electrical signal derived therefrom (i.e., for transmitting an electrical signal which is a function of the vibration as sensed by the accelerometer through change in one or more accelerometer electrical parameters such as capacitance, inductance and/or resistance). And the programmable controller is responsive to that electrical signal (i.e., the programmable controller creates at least one control signal as a function of that electrical signal).
Each tunable down-hole hydraulic stimulator comprises a hammer (or mass) element longitudinally movable within a hollow cylindrical housing having a longitudinal axis, a first end, and a second end, the first end being closed by a fluid interface, and the second end being closed by a driver element. The driver element comprises at least one field emission structure for moving the hammer (or mass) element to strike, and rebound from, the fluid interface during a rebound cycle time to generate broad-spectrum vibration. The fluid interface vibration is in part a function of the fluid interface's effective elastic modulus, and hence its resonant frequencies (which are magnetostrictively responsive to a step-wise adjustable steady-state longitudinal magnetic field applied via current in a peripheral transverse coil).
Hammer strike and rebound are substantially influenced by the driver element and the fluid interface effective elastic modulus. Driver elements may comprise, e.g., one or more magnetic field emission structures and/or one or more electric field emission structures. A hammer element (i.e., a mass) is longitudinally movable within the cylindrical housing between the driver element and the fluid interface. Such movement is influenced (i.e., controlled in an open-loop or closed-loop manner) by forces exerted on the hammer via the magnetic and/or electrical fields of the field emission structure(s). (See, e.g., U.S. Pat. No. 8,760,252 B2, incorporated by reference). To facilitate hammer element movement, the hammer element may comprise, e.g., one or more permanent magnets, and the driver element's field emission structure(s) may comprise, e.g., one or more electromagnets, at least one with reversible polarity and variable field strength. See the '252 patent for other examples of field emission structures.
Note that the hammer element is responsive to the driver element both for striking, and rebounding from, the fluid interface. That is, the hammer element may be, e.g., subject to magnetic attraction during certain portions of its longitudinal travel, and subject to magnetic repulsion during other portions of its longitudinal travel. Responsiveness of the hammer element may be achieved via open-loop control (using empirically-derived predictions of hammer element direction and velocity based, e.g., on field emission strength) or closed-loop control (using, e.g., feedback data on hammer element position to calculate direction and velocity of hammer element movement). The latter data may be obtained, e.g., via an electric field sensor on the fluid interface interacting with an electret electric field emission structure on the hammer element.
Regardless of a stimulator's configuration, stimulation vibration energy may preferably be transmitted from down-hole stimulators in relatively short bursts that are spaced apart in time. Time-delayed backscatter vibration energy may then be sensed at the same or different down-hole stimulators in the periods between bursts of transmitted vibration. But both transmitted and backscatter vibration energy can thus be detected at the fluid interface because they will be present at different times. And one or more accelerometers may provide data on both transmitted and backscatter vibration energy, as well as on the delay time inherent in backscatter vibration.
Delay time, in turn, may be interpreted (e.g., using frac diagnostics) to indicate the stimulation depth or total distance traveled by the backscatter vibration energy. Further, changes in the backscatter vibration's power spectral density (see below) may also (again using frac diagnostics) be used to characterize the geologic material along a wellbore. Thus, vibration information detected by one or more detectors at a fluid interface, as well as estimates of related parameters (e.g., Doppler shift) that can be extracted therefrom, may be particularly useful when determining the preferred directions, depths and lengths of multiple wellbores to be placed in a relatively confined geologic space.
Since backscatter vibration emanates from particles experiencing vibration resonance excitation (i.e., stimulation), changes in the backscatter vibration's PSD can reveal changes in the particles' resonance frequencies. And since particles' resonance frequencies are functions of, among other things, particle size and composition (e.g., hardness), analysis of PSD data can directly indicate the local effects of stimulation. In other words, frac diagnostics applied during the stimulation process can provide near-real time information on the changing nature of the stimulated geologic material. *** Specifically, the extent and range of stimulation generated fragmentation can be estimated through analysis of sequential PSD shifts in band-limited backscatter vibration energy. ***
Responsiveness of a hammer element to a driver element of a tunable down-hole stimulator may be achieved via, e.g., a field emission structure comprising an electromagnet/controller having programmable magnetic field polarity reversal and variable magnetic field strength, as seen, e.g., in linear reversible motors. Control of magnetic field strength is optionally via open-loop and/or closed-loop networks associated with the electromagnet/controller. Note that such magnetic field strength control allows the driver to influence hammer element movement before, during and after each impact via attractive or repelling forces. See. e.g., the '252 patent for further discussion of such forces.
Note that cyclical changes in magnetic field strength may be characterized by a polarity reversal frequency responsive to the accelerometer signal mentioned earlier and/or to a control signal from a tunable down-hole stimulator system programmable controller. Longitudinal movement of the hammer element is thus responsive in part (e.g., via electromagnetic attraction and repulsion) to the driver element's cyclical magnetic polarity reversal. For example, longitudinal movement of the hammer element striking, and subsequently rebounding from, the fluid interface may be substantially in-phase with the polarity reversal frequency to generate vibration transmitted by the fluid interface.
Thus, for example, each hammer strike is at least in part a function of magnetic field polarity and strength, and it is followed by a rebound, the cycle time of which is at least in part a function of flexure due to elastic properties (e.g., the effective elastic modulus fluid interface). The rebound may also be a function of the driver element's magnetic field polarity and strength. The duration of the hammer element's entire flexure-rebound cycle (termed herein rebound cycle time) is measured in seconds. The inverse of rebound cycle time has the same dimensions as frequency (e.g., cycles per second) and is termed “characteristic rebound frequency” herein.
Each hammer strike & rebound applies a mechanical shock to the fluid interface which generates a (relatively-broad) spectrum of stimulation vibration frequencies that are transmitted hydraulically via the fluid interface (and the surrounding down-hole fluid) to the adjacent geologic material. (See the Background section above). The breadth of the generated stimulation vibration spectrum is a reflection of a mechanical shock's duration (i.e., the rebound cycle time). Shortening the rebound cycle time broadens the generated-vibration spectrum (i.e., the spectrum extends to include relatively higher frequencies). The power spectral density is therefore up-shifted, meaning that more of the total power of the transmitted spectrum is represented in the higher frequencies. In this manner, additional stimulation energy (i.e., rock-fracturing energy) may be directed to relatively smaller rock fragments because these fragments have resonances at the relatively-higher stimulation vibration frequencies. Thus, a tunable down-hole stimulator's transmitted stimulation vibration energy may be controlled so as to encourage continued geologic fragmentation to a predetermined fragment size (e.g., to a size for effective function as a proppant).
Summarizing the above example, hammer rebound movement may be either augmented or impeded by the driver element's magnetic field polarity and strength. The fluid interface effective elastic modulus is a function of step-wise adjustable steady-state current in the peripheral transverse coil. Rebound cycle time is thus controllable, allowing changes in the character of each stimulation vibration burst spectrum generated. Such tuning may comprise, for example, altering a transmitted vibration spectrum's bandwidth and/or changing the relative magnitudes of the vibration spectrum's frequency components (i.e., changing the spectrum's power spectral density). In other words, stimulation energy in the form of vibration spectra transmitted by a tunable down-hole stimulator's fluid interface may be subject (in near-real time) to alterations in response to ongoing results of frac diagnostic calculations operating on backscatter vibration to generate feedback data.
Note that alternative embodiments of a down-hole stimulation vibration generator may be described as having the form of a linear electrical motor, the hammer element acting as an armature. One such form is seen in railguns, with the armature providing the conducting connection between (parallel) rails. In this case, opposing currents in the rails (and thus the hammer movement) would be controlled by the driver to achieve the desired characteristic rebound frequency. (See, e.g., U.S. Pat. Nos. 8,371,205 B2 and 8,677,877 B2, both incorporated by reference).
The invention thus facilitates a form of closed-loop (feedback) control of the stimulation process that may be optimized (i.e., to yield better results from less stimulation). Individual tunable down-hole stimulators of the invention can support such an optimization strategy inherently because they naturally produce relatively broad vibration spectra (rather than single-frequency vibration like an aviation black-box pinger). Should a greater frequency range be desired than that obtainable from a single tunable down-hole stimulator, a plurality of such stimulators may be interconnected in a *** tunable down-hole stimulation array ***. (See, e.g., U.S. Pat. Nos. 8,764,661 B2 and 8,571,829 B2, both incorporated by reference).
An alternate first embodiment of an adaptive stimulation system comprises a frac pump for creating cyclically-varying down-hole hydraulic pressure in response to a timed pressure signal. The system further comprises a plurality of down-hole hydraulic stimulators connected in a spatial array, each said down-hole hydraulic stimulator hydraulically transmitting, in response to a timed stimulator transmission signal, vibration having an adjustable power spectral density. A programmable controller is included for periodically transmitting one said timed pressure signal for said frac pump, one said timed stimulator transmission signal for each said down-hole hydraulic stimulator, and one timed stimulator shift signal for each said down-hole hydraulic stimulator, each said timed pressure signal being in-phase with at least one said timed stimulator transmission signal. Each said down-hole hydraulic stimulator comprises a hollow cylindrical housing having a longitudinal axis, a first end, and a second end, said first end being closed by a fluid interface for transmitting and receiving vibration, and said fluid interface comprising at least one accelerometer for producing an accelerometer feedback signal representing vibration transmitted and received by said fluid interface. A driver element reversibly seals said second end, and a hammer element is longitudinally movable within said housing between said driver element and said fluid interface, said hammer element being responsive to said driver element for striking said fluid interface and rebounding therefrom during an adjustable rebound cycle time to hydraulically transmit a vibration burst comprising a plurality of transmitted frequencies.
A transverse coil is peripheral to and surrounds said fluid interface, said transverse coil for generating a step-wise adjustable steady-state longitudinal magnetic field intersecting said fluid interface, and said fluid interface being magnetostrictively responsive to said longitudinal magnetic field for altering its effective elastic modulus.
Note that each said driver element comprises an electromagnet/controller having cyclical magnetic polarity reversal characterized by a variable polarity reversal frequency. Note further that longitudinal movement of each said hammer element is responsive to said cyclical magnetic polarity reversal, and that longitudinal movement of each said hammer element striking, and rebounding from, one said fluid interface is in-phase with one said variable polarity reversal frequency. Additionally note that each said adjustable power spectral density is responsive to one said adjustable rebound cycle time, and each said adjustable rebound cycle time is responsive to one said timed stimulator shift signal.
Adaptive stimulation system embodiments may incorporate timed stimulator shift signals responsive to one or more accelerometer feedback signals. Further, each adjustable power spectral density may change in-phase with one adjustable rebound cycle time. And a down-hole stimulation array may be tunable via shift of at least one adjustable power spectral density which moves relative transmitted vibration power within transmitted frequencies of at least one said vibration burst. Decreasing at least one adjustable rebound cycle time causes up-shift of at least one adjustable power spectral density to shift relative transmitted vibration power within at least one vibration burst to relatively higher frequencies for tuning the down-hole stimulation array
An alternate second embodiment of an adaptive stimulation system comprises a frac pump for creating cyclically-varying down-hole hydraulic pressure in response to a timed pressure signal, and a plurality of down-hole hydraulic stimulators connected in a linear stimulation array, each said down-hole hydraulic stimulator hydraulically transmitting a vibration burst in response to a timed stimulator transmission signal. A programmable controller periodically transmits one said timed pressure signal for said frac pump, and a plurality of timed stimulator signals as a signal group, each said signal group including one said timed stimulator transmission signal for each said down-hole hydraulic stimulator and one timed stimulator shift signal for each said down-hole hydraulic stimulator, each said timed pressure signal being in-phase with one said timed stimulator transmission signal. Each said down-hole hydraulic stimulator comprises a hollow cylindrical housing having a longitudinal axis, a first end, and a second end, said first end being closed by a fluid interface for transmitting and receiving vibration, and said fluid interface comprising at least one accelerometer for producing an accelerometer feedback signal representing vibration transmitted and received by said fluid interface. A driver element reversibly seals said second end; and a hammer element is longitudinally movable within said housing between said driver element and said fluid interface, said hammer element being responsive to said driver element for striking said fluid interface and rebounding therefrom during an adjustable rebound cycle time to hydraulically transmit one said vibration burst comprising a plurality of transmitted frequencies as part of a directionally propagated array vibration wave front.
A transverse coil is peripheral to and surrounds said fluid interface, said transverse coil for generating a step-wise adjustable steady-state longitudinal magnetic field intersecting said fluid interface, and said fluid interface being magnetostrictively responsive to said longitudinal magnetic field for altering its effective elastic modulus.
Note that each said driver element comprises an electromagnet/controller having cyclical magnetic polarity reversal characterized by a variable polarity reversal frequency, and longitudinal movement of each said hammer element is responsive to said cyclical magnetic polarity reversal. Note further that longitudinal movement of each said hammer element striking, and rebounding from, one said fluid interface is in-phase with one said variable polarity reversal frequency, and that said timed stimulator transmission signals within each said signal group are simultaneous signals. Note additionally that said directionally propagated array vibration wave front is responsive to said simultaneous signals, and that each said variable polarity reversal frequency is responsive to one said timed stimulator transmission signal. And note finally that each said adjustable rebound cycle time is responsive to one said timed stimulator shift signal, and that each said timed stimulator shift signal is responsive to one said accelerometer feedback signal.
Further in alternate embodiments of adaptive stimulation systems, the frac pump may comprise a fluid end having at least one tested fluid end vibration resonant frequency. The fluid end may additionally comprise at least one tunable vibration damper, each tunable vibration damper being tuned to at least one tested fluid end vibration resonant frequency. And the tunable vibration damper may comprise a tunable check valve assembly, each said a tunable check valve assembly comprising a valve body having a central viscoelastic element coupled to a peripheral groove viscoelastic element via a plurality of radial viscoelastic elements in tension to form a tuned radial array having a resonant vibration frequency equal to one said tested fluid end vibration resonant frequency.
An alternate third embodiment of an adaptive stimulation system comprises a frac pump for creating cyclically-varying down-hole hydraulic pressure in response to a timed pressure signal. A plurality of down-hole hydraulic stimulators is connected in a linear stimulation array, each said down-hole hydraulic stimulator comprising an impulse vibration generator responsive to a timed stimulator transmission signal and a timed stimulator shift signal, each said impulse vibration generator being tuned via an adjustable rebound cycle time and/or an adjustable fluid interface effective elastic modulus (see transverse coil below) to periodically hydraulically transmit, in response to a timed stimulator transmission signal, a vibration burst comprising a plurality of vibration frequencies as part of a directionally propagated array vibration wave front.
A transverse coil is peripheral to and surrounds the fluid interface, the transverse coil generating a step-wise adjustable steady-state longitudinal magnetic field intersecting the fluid interface, and the fluid interface being magnetostrictively responsive to the longitudinal magnetic field for altering its effective elastic modulus.
A programmable controller periodically transmits one said timed pressure signal, a plurality of said timed stimulator transmission signals, and a plurality of said timed stimulator shift signals as a signal group, each said signal group including one said timed stimulator transmission signal and one said timed stimulator shift signal for each said down-hole hydraulic stimulator, each said timed pressure signal being in-phase with one said timed stimulator transmission signal. Note that each said vibration burst comprises a plurality of vibration frequencies and has an adjustable power spectral density that is responsive to one said adjustable rebound cycle time. Note further that said timed stimulator transmission signals within each said signal group are sequential signals, and that said directionally propagated array vibration wave front is responsive to said sequential signals. And note additionally that each said down-hole hydraulic stimulator comprises at least one accelerometer for sensing vibration and transmitting an accelerometer feedback signal derived therefrom, and that each said timed stimulator shift signal is responsive to one said accelerometer feedback signal. And note finally that each said adjustable rebound cycle time is responsive to one said timed stimulator shift signal.
Further, the frac pump of alternate embodiments of adaptive stimulation systems may comprise a tunable valve, each tunable valve comprising a valve body and a valve seat. The valve body comprises a peripheral valve seat interface having a convex curvature which undergoes a substantially elastic concave flexure with slight circular rotation as the valve body seats against the valve seat. The valve seat, in turn, has a concave mating surface with correspondingly less curvature than the peripheral valve seat interface. So the peripheral valve seat interface achieves a circular rolling contact seal with the concave mating surface of the valve seat. As described elsewhere herein, a circular rolling contact seal increases longitudinal compliance of a tunable valve, constituting tuning of the valve to absorb and convert (e.g., via hysteresis loss) a portion of valve closure impact (i.e., kinetic) energy to heat energy. Dissipation of valve closure impact energy as heat rather than excitation of destructive pump vibration resonance(s) tends to improve the reliability of a second alternate array as a whole.
As noted above, part of the vibration sensed at the fluid interface typically includes time-delayed backscatter vibration. It also may contain temperature data related to the degree of rock fracturing and/or fragmentation, including the size of rock fragments. Fracturing-related temperature changes may be induced in part by mechanical inefficiencies secondary to vibration earlier transmitted from the fluid interface. (See U.S. Pat. No. 8,535,250 B2, incorporated by reference). Hence, temperature-related well-stimulation data can be used to augment control of fracturing resulting from transmitted stimulation vibration.
One determinant of imposed stimulation is the hammer element's striking face, which has a predetermined modulus of elasticity that may be relatively high (approximately that of mild steel, for example) if a relatively broad spectrum of stimulation vibration is desired. Conversely, a lower modulus of elasticity may be chosen to reduce the highest frequency components of stimulation vibration spectra.
The spectra of stimulation vibration desired for a particular application will generally be chosen to encompass one or more of the (estimated) resonant frequencies of the geologic structures being stimulated (including resonant frequencies before, during, and after stimulation). For example, it has been reported that vibration frequencies in the ultrasound range (i.e., >20 kHz) can improve the permeability of certain porous media surrounding a well. On the other hand, vibration frequencies <20 kHz may propagate with less loss, while still significantly increasing well flow rates. (See, e.g., U.S. patent publication number 2014/0027110 A1, incorporated by reference). Optimization of the stimulation process may be facilitated using estimates obtained via (1) one or more programmable microprocessors in the tunable down-hole stimulator and/or (2) one or more programmable microprocessors in the tunable down-hole stimulation system programmable controller. Such estimates may be based in part, e.g., on the portion(s) of the backscatter vibration energy from stimulated porous media.
Note that a tunable down-hole stimulator is intended for down-hole use within a fluid environment maintained in the wellbore via (1) fluids collected through explosively-formed perforations or preformed slots in the wellbore casing from the surrounding geologic formations and/or via (2) addition of fluid at the wellhead to equal or exceed the filtration rate (sometimes termed the leakoff rate). (See U.S. Pat. No. 8,540,024 B2, incorporated by reference). Since the tunable down-hole stimulator (i.e., a tunable hydraulic stimulator) can be completely sealed from internal contact with surrounding fluid, its use is not subject to dielectric strength and conductivity limitations (e.g., “compensation dielectric liquid” as required in U.S. patent publication number 2014/0027110 A1 cited above) that are common in pulsed power apparatus. (See also U.S. Pat. No. 8,616,302 B2, incorporated by reference).
Note also that tunable resilient circumferential seals are electively provided to isolate predetermined explosively-formed perforations or preformed slots in portions of the wellbore casing (analogous in part to swell packers). (See, e.g., U.S. patent application number 2014/0051612 A1, incorporated by reference). The circumferential seal comprises a circular tubular area which may contain at least one shear-thickening fluid to assist tuning to a preferred frequency range. And the fluid may further comprise nanoparticles which, in conjunction with the shear-thickening fluid, also facilitate tuning of the seal as well as heat scavenging.
Frequency domain down-shifting (e.g., by increasing longitudinal compliance) and damping (e.g., via viscoelastic and/or shear-thickening materials) both assist vibration control by converting valve-closure energy to heat and dissipating it in each tunable component present in a tunable fluid end embodiment. That is, down-shifting effectively attenuates and/or limits the bandwidth(s) of valve-generated vibration. Subsequent (coordinated) damping assists in converting a portion of this band-limited vibration to heat.
Both down-shifting and damping are dependent in part on constraints causing shear-stress alteration (that is, “tuning”) imposed on one or more viscoelastic and/or shear-thickening materials in each tunable component. Additionally, hysteresis or internal friction (see Harris, p. 5.7) associated with mechanical compliance of certain structures (e.g., valve bodies or springs) may aid damping by converting vibration energy to heat (i.e., hysteresis loss). (See Harris, p. 2.18).
Mechanical compliance is manifest, for example, in elastic valve body flexures secondary to repetitive longitudinal compressive forces (i.e., plunger pressure strokes). Each such flexure is followed by a hysteresis-limited elastic rebound, the duration of the entire flexure-rebound interval being termed herein rebound cycle time. As noted above, the inverse of rebound cycle time is termed herein “characteristic rebound frequency.” Cumulative rebound cycle energy loss in the form of heat (e.g., hysteresis loss plus friction loss) is continuously transported for redistribution within the valve body and eventual rejection to the valve body surroundings (including, e.g., the pumped fluid). This heat loss represents a reduction in the available energy content (and thus the damage-causing potential) of the valve-closure energy impulse.
Note that lengthening rebound cycle time to beneficially narrow the valve-generated vibration spectrum is substantially influenced by a tunable valve assembly's increased longitudinal compliance associated with rolling seal contact (i.e., comprising valve body flexure and rebound) described herein between the valve body's peripheral valve seat interface and the tunable valve seat's mating surface.
Briefly summarizing, as each tunable component present in a tunable fluid end embodiment absorbs, converts and redistributes (i.e., dissipates) a portion of valve closing impulse shock energy, only a fraction of the original closing impulse energy remains at critical frequencies capable of exciting destructive resonant frequencies in the fluid end. Following vibration down-shifting, a significant portion of valve-closure energy has been shifted to lower frequency vibration through structural compliance as described above. This attenuated vibration is then selectively damped (i.e., dissipated as heat) at shifted frequencies via one or more of the tunable components. While tunable components may be relatively sharply tuned (e.g., to act as tuned mass dampers for specific frequencies), they may alternately be more broadly tuned to account for a range of vibration frequencies encountered in certain pump operations.
Note that vibration absorption at specific frequencies (e.g., via dynamic or tuned absorbers) may have limited utility in frac pumps because of the varying speeds at which the pumps operate and the relatively broad bandwidths associated with valve-closing impulse shocks. In contrast, the process of down-shifting followed by damping is more easily adapted to changes inherent in the pumps' operational environment. Damping may nevertheless be added to a dynamic absorber to increase its effective frequency range for certain applications. (See, e.g., tuned vibration absorber and tuned mass damper in ch. 6 of Harris ).
Selective damping of vibration frequencies near the resonant frequencies of fluid ends is desirable for the same reason that soldiers break step when they march over a bridge—because even relatively small amounts of vibration energy applied at the bridge's resonant frequency can cause catastrophic failure. Various combinations of the tunable components described herein are particularly beneficial because they focus the functions of vibration-limiting resources on minimization of vibration energy present in a fluid end near its housing's critical frequencies.
Note that a variety of optimization strategies for vibration attenuation and damping may be employed in specific cases, depending on parameters such as the Q (or quality) factor attributable to each fluid end resonance. The fluid end response to excitation of a resonance may be represented graphically as, for example, a plot of amplitude vs. frequency. Such a Q response plot typically exhibits a single amplitude maximum at the local fluid end resonance frequency, with decreasing amplitude values at frequencies above and below the resonance. At an amplitude value about 0.707 times the maximum value (i.e., the half-power point), the amplitude plot corresponds not to a single frequency but to a bandwidth between upper and lower frequency values on either side of the local fluid end resonance. The quality factor Q is then estimated as the ratio of the resonance frequency to the bandwidth. (See, e.g., pp. 2-18, 2-19 of Harris ). (See also U.S. Pat. No. 7,113,876 B2, incorporated by reference).
Lower Q connotes the presence of more damping and a wider bandwidth (i.e., a relatively broader band of near-resonant frequencies). And higher Q connotes less damping and a narrower bandwidth (ideally, zero damping and a single resonant frequency). Since ideal fluid end resonances are not encountered in practice, optimization strategies typically include choice of the peak resonant frequency and Q of the tunable component in light of the peak resonant frequency and Q of the fluid end resonance of interest. Tunable component resonant frequencies identified herein as “similar” to fluid end or pump housing resonances are thus understood to lie generally in the frequency range indicated by the upper and lower frequency values of the relevant Q response half-power bandwidth.
Note that the peak (or representative) frequency of a tunable component or a fluid end resonance may not be unambiguously obtainable. Thus, optimization of tunable component vibration damping may be an iterative empirical process and may not be characterized by a single-valued solution. Note also that tunable component resonant frequencies may be intentionally “detuned” (i.e., adjusted to slightly different values from nominal resonant or peak frequencies) in pursuit of an overall optimization strategy. The critical frequencies proximate to a fluid end suction bore may differ, for example, from the critical frequencies proximate to the same fluid end's plunger bore due to the different constraints imposed by structures proximate the respective bores.
What follows are descriptions of the structure and function of each tunable component that may be present in a tunable fluid end embodiment comprising a housing with appropriate bores. Within each housing's bores are a suction valve, a discharge valve, and a plunger or piston. When a tunable fluid end comprises multiple subassemblies, each subassembly has at least one tunable component.
One tunable component described herein is a tunable check valve assembly (one being found in each tunable check valve). Installed in a fluid end for high pressure pumping, a tunable check valve assembly comprises at least one vibration damper or, in certain embodiments, a plurality of (radially-spaced) vibration dampers disposed in a valve body. Each vibration damper constitutes at least one tunable structural feature. Since the fluid end has at least a first fluid end resonance frequency, at least one vibration damper has (i.e., is tuned to) at least a first predetermined assembly resonant frequency similar to the first fluid end resonance (i.e., resonant frequency). If, for example, the fluid end has a second fluid end resonance frequency (a common occurrence), a single vibration damper and/or at least one of a plurality of vibration dampers may have (i.e., be tuned to) at least a second predetermined assembly resonant frequency similar to the second fluid end resonance frequency. In general, the specific manner of damping either one or a plurality of fluid end resonance frequencies with either one or a plurality (but not necessarily the same number) of vibration dampers is determined during the optimization process noted above.
Each of the sample embodiments of tunable check valve assemblies schematically illustrated herein comprises a check valve body having guide means (to maintain valve body alignment during longitudinal movement) and a peripheral valve seat interface. A peripheral groove spaced radially apart from a central reservoir is present in certain embodiments, and a viscoelastic structure may be present in the peripheral groove (i.e., the groove damping element). In one such embodiment, the assembly's vibration dampers comprise a plurality of radially-spaced viscoelastic body structures disposed in the groove and reservoir, the viscoelastic groove element comprising a groove circular tubular area. In alternative embodiments, the viscoelastic reservoir (or central) damping element may be replaced by a central spring-mass damper. A viscoelastic central damper may be tuned, for example, via a flange centrally coupled to the valve body. A spring-mass central damper may be tuned, for example, by adjusting spring constant(s) and/or mass(es), and may also or additionally be tuned via the presence of a viscous or shear-thickening liquid in contact with one or more damper elements.
A reservoir (or central) damping element tuning frequency may be, as noted above, a first predetermined assembly resonant frequency similar to a first fluid end resonance. Analogously, the groove circular tubular area may comprise at least one shear thickening material providing the means to tune the groove damping element to at least a second predetermined assembly resonant frequency similar, for example, to either a first or second fluid end resonant frequency. The choice of tuning frequencies for the reservoir and groove damping elements is not fixed, but is based on a chosen optimization strategy for vibration damping in each fluid end.
Note that phase shifts inherent in the (nonlinear) operation of certain vibration dampers described herein create the potential for a plurality of resonant frequencies in a single vibration damper.
Note also that the longitudinal compliance of a tunable check valve assembly affects its rebound cycle time and thus influences vibration attenuation (i.e., downshifting or spectrum narrowing), which constitutes a form of tuning. Further, vibration dampers in alternative tunable check valve assembly embodiments may comprise spring-mass combinations having discrete mechanical components in addition to, or in place of, viscoelastic and/or shear-thickening components. An example of such a spring-mass combination within a valve body central reservoir is schematically illustrated herein.
Another tunable component described herein is a tunable valve seat, certain embodiments of which may be employed with a conventional valve body or, alternatively, may be combined with a tunable check valve assembly to form a tunable check valve. A tunable valve seat in a fluid end for high pressure pumping comprises a concave mating surface and/or a lateral support assembly longitudinally spaced apart from a mating surface. A lateral support assembly, when present, is adjustably secured (e.g., on a lateral support mounting surface) or otherwise coupled to the mating surface. A lateral support assembly is a tunable structural feature for resiliently coupling the tunable valve seat to a fluid end housing (and thus damping vibrations therein). That is, a lateral support assembly (and thus a tunable valve seat of which it is a part) has at least one tunable valve seat resonant frequency similar to at least one fluid end resonant frequency. Further, a lateral support assembly may be combined with a concave mating surface to provide two tunable structural features in a single tunable valve seat. Tunability of the concave mating surface inheres in its influence on rebound cycle time through the predetermined orientation and degree of curvature of the concave mating surface. Since it constitutes a tunable structural feature, a concave mating surface may be present in a tunable valve seat without a lateral support assembly. In the latter case, the concave mating surface will be longitudinally spaced apart from a pump housing interface surface, rather than a lateral support mounting surface (examples of these two surfaces are schematically illustrated herein). In light of a tunable valve seat's potential for embodying either one or two tunable structural features, a plurality of tunable valve seat resonant frequencies may characterize a single tunable valve seat, with the respective frequencies being chosen in light of the fluid end resonance(s) and the valve closure impulse vibration spectrum.
A support assembly's one or more suitably-secured circular viscoelastic support elements resiliently couple the tunable valve seat to a fluid end housing (thus damping vibrations therein). At least one such viscoelastic support element comprises a support circular tubular area. And each support circular tubular area, in turn, comprises at least one shear thickening material having (i.e., being tuned to a resonance frequency similar to) at least one seat resonant frequency that may be chosen to be similar to at least one fluid end resonant frequency.
Still another tunable component described herein is a tunable radial array disposed in a valve body. In a schematically illustrated embodiment, the valve body comprises guide means, a peripheral valve seat interface, and a fenestrated peripheral groove spaced radially apart from a central reservoir. A viscoelastic body element disposed in the groove (the groove element) is coupled to a viscoelastic body element disposed in the reservoir (the reservoir element) by a plurality of viscoelastic radial tension members passing through a plurality of fenestrations in the peripheral groove. Each radial tension member comprises at least one polymer composite and functions to couple the groove element with the reservoir element, a baseline level of radial tension typically arising due to shrinkage of the viscoelastic elements during curing. The tensioned radial members, as schematically illustrated herein, assist anchoring of the coupled groove element firmly within the peripheral seal-retention groove without the use of adhesives and/or serrations as have been commonly used in anchoring conventional valve seals. Radial tension members also create a damped resilient linkage of groove element to reservoir element (analogous in function to a spring-mass damper linkage). This damped linkage can be “tuned” to approximate (i.e., have a resonance similar to) one or more critical frequencies via choice of the viscoelastic and/or composite materials in the damped linkage. Note that radial tension members also furnish a transverse preload force on the valve body, thereby altering longitudinal compliance, rebound cycle time (and thus characteristic rebound frequency), and vibration attenuation.
And another tunable component described herein is a tunable plunger seal comprising at least one lateral support assembly (analogous to that of a tunable valve seat) securably and sealingly positionable along a plunger. Typically, a lateral support assembly will be installed in a packing box (sometimes termed a stuffing box) or analogous structure. The tunable plunger seal's lateral support assembly is analogous in structure and function to that of a tunable valve seat, as are the tuning procedures described above.
Note that the lateral support assembly of either a tunable valve seat or a tunable plunger seal resiliently links the respective valve seat or plunger with adjacent portions of a fluid end housing, effectively creating a spring-mass damper coupled to the housing. This damped linkage can be “tuned” to approximate one or more critical frequencies via, e.g., shear-thickening materials in the respective circular tubular areas as described herein.
Analogous damped linkages between the housing and one or more auxiliary masses may be incorporated in tunable fluid end embodiments for supplemental vibration damping at one or more fluid end resonant frequencies (e.g., auxiliary tuned vibration absorbers and/or tuned-mass dampers). Additionally or alternatively, one or more damping surface layers (applied, e.g., as metallic, ceramic and/or metallic/ceramic coatings) may be employed for dissipating vibration and/or for modifying one or more fluid end resonant frequencies in pursuit of an overall optimization plan for fluid end vibration control. Such damping surface layers may be applied to fluid ends by various methods known to those skilled in the art. These methods may include, for example, cathodic arc, pulsed electron beam physical vapor deposition (EB-PVD), slurry deposition, electrolytic deposition, sol-gel deposition, spinning, thermal spray deposition such as high velocity oxy-fuel (HVOF), vacuum plasma spray (VPS) and air plasma spray (APS). The surface layers may be applied to the desired fluid end surfaces in their entirety or applied only to specified areas. Each surface layer may comprise a plurality of sublayers, at least one of which may comprise, for example, titanium, nickel, cobalt, iron, chromium, silicon, germanium, platinum, palladium and/or ruthenium. An additional sublayer may comprise, for example, aluminum, titanium, nickel, chromium, iron, platinum, palladium and/or ruthenium. One or more sublayers may also comprise, for example, metal oxide (e.g., zirconium oxide and/or aluminum oxide) and/or a nickel-based, cobalt-based or iron-based superalloy. (See e.g., U.S. Pat. No. 8,591,196 B2, incorporated by reference).
In addition to composite viscoelastic element inclusions, control mechanisms for alteration of tunable component resonant frequencies further include the number, size and spacing of peripheral groove fenestrations. When fenestrations are present, they increase valve assembly responsiveness to longitudinal compressive force while stabilizing viscoelastic and/or composite peripheral groove elements. Such responsiveness includes, but is not limited to, variations in the width of the peripheral groove which facilitate “tuning” of the groove together with its viscoelastic element(s).
Note that when a tunable check valve body distorts substantially elastically under the influence of a closing energy impulse, its associated viscoelastic element(s) simultaneously experience(s) shear stress in accommodating the distortion. The resulting viscoelastic shear strain, however, is at least partially time-delayed. And the time delay introduces a phase-shift useful in damping valve-generated vibration (i.e., reducing its amplitude). Analogous time-delay phase shift occurs in a mass-spring damper comprising discrete mechanical elements. Similarly, each instance of compliance takes place over a finite time interval. For example, the duration of a closing energy impulse is effectively increased (and the vibration spectrum correspondingly narrowed) as a function of compliance.
Compliance may be associated with distortions of both groove and reservoir viscoelastic body elements, resulting in viscoelastic stress and its associated time-dependent strain. But the mechanisms differ in the underlying distortions. In a peripheral groove, for example, proximal and distal groove walls respond differently to longitudinal compressive force on the tunable check valve assembly. They generally move out-of-phase longitudinally, thereby imposing time-varying compressive loads on the groove viscoelastic element. Thus the shape of the groove (and the overall compliance of the groove and its viscoelastic element) changes with time, making the groove as a whole responsive to longitudinal force on the assembly.
Peripheral groove fenestrations increase groove responsiveness to longitudinal force. As schematically illustrated herein, fenestrations increase groove responsiveness by changing the coupling of the proximal groove wall to the remainder of the valve body (see Detailed Description herein).
In the reservoir, in contrast, responsiveness to longitudinal force may be modulated by an adjustable preload flange centrally coupled to the valve body. The flange imposes a shear preload on the viscoelastic reservoir element (i.e., shear in addition to that imposed by the reservoir itself and/or by the closing energy impulse acting on the viscoelastic element via the pumped fluid). The amount of shear preload varies with the (adjustable) radial and longitudinal positions of the flange within the reservoir. The overall compliance and resonances of the reservoir and its viscoelastic element may be predictably altered by such a shear preload, which is imposed by the flange's partial constraint of the viscoelastic reservoir element. Note that when reservoir and groove viscoelastic body elements are coupled by a plurality of radial tension members, as in a tunable radial array, the radial tension members lying in groove wall fenestrations allow transmission of shear stress between the groove and reservoir viscoelastic elements.
As noted above, alterations in compliance (with its associated hysteresis loss) contribute to predetermined vibration spectrum narrowing. Such compliance changes (i.e., changes in displacement as a function of force) may be achieved through adjustment of constraint. Constraint, in turn, may be achieved, e.g., via compression applied substantially longitudinally by the adjustable preload flange to a constrained area of the viscoelastic reservoir element. In embodiments comprising a central longitudinal guide stem, the constrained area may be annular. And adjacent to such an annular constrained area may be another annular area of the viscoelastic reservoir element which is not in contact with the adjustable preload flange (i.e., an annular unconstrained area). This annular unconstrained area is typically open to pumped fluid pressure.
Preload flange adjustment may change the longitudinal compliance of the tunable check valve assembly by changing the effective flange radius and/or the longitudinal position of the flange as it constrains the viscoelastic reservoir element. Effective flange radius will generally exceed actual flange radius due to slowing of (viscous) viscoelastic flow near the flange edge. This allows tuning of the check valve assembly to a first predetermined assembly resonant frequency for maximizing hysteresis loss. Stated another way, by constraining a vibrating structure (e.g., an area of the viscoelastic reservoir element), it is possible to force the vibrational energy into different modes and/or frequencies. See, e.g., U.S. Pat. No. 4,181,027, incorporated by reference.
The invention thus includes means for constraining one or more separate viscoelastic elements of a valve assembly, as well as means for constraining a plurality of areas of a single viscoelastic element. And such constraint may be substantially constant or time-varying, with correspondingly different effects on resonant frequencies. Peripherally, time-varying viscoelastic element constraint may be provided by out-of-phase longitudinal movement of peripheral groove walls. In contrast, time-varying viscoelastic element constraint may be applied centrally by a flange coupled to the valve body.
Note that in certain embodiments, the preload flange may comprise a substantially cylindrical periphery associated with substantially longitudinal shear. Other embodiments may comprise a non-cylindrical periphery for facilitating annular shear preload having both longitudinal and transverse components associated with viscoelastic flow past the flange. Such an invention embodiment provides for damping of transverse as well as longitudinal vibration. Transverse vibration may originate, for example, when slight valve body misalignment with a valve seat causes abrupt lateral valve body movement during valve closing.
Note also that one or more flanges may or may not be longitudinally fixed to the guide stem for achieving one or more predetermined assembly resonant frequencies.
Note further that when a nonlinear system is driven by a periodic function, such as can occur with harmonic excitation, chaotic dynamic behavior is possible. Depending on the nature of the nonlinear system, as well as the frequency and amplitude of the driving force, the chaotic behavior may comprise periodic oscillations, almost periodic oscillations, and/or coexisting (multistable) periodic oscillations and nonperiodic-nonstable trajectories (see Harris, p. 4-28).
In addition to a shift in the tunable check valve assembly's vibrating mode, incorporation of at least one circular tubular area containing at least one shear-thickening material within the viscoelastic groove element increases impulse duration by slightly slowing valve closure due to reinforcement of the viscoelastic groove element. Increased impulse duration, in turn, narrows the closing energy impulse vibration spectrum. And shear-thickening material itself is effectively constrained by its circular location within the viscoelastic groove element(s).
The shear-thickening material (sometimes termed dilatant material) is relatively stiff near the time of impact and relatively fluid at other times. Since the viscoelastic groove element strikes a valve seat before the valve body, complete valve closure is slightly delayed by the shear-thickening action. The delay effectively increases the valve-closure energy impulse's duration, which means that vibration which is transmitted from the tunable check valve assembly to its (optionally tunable) valve seat and pump housing has a relatively narrower spectrum and is less likely to excite vibrations that predispose a pump housing to early fatigue failure. The degree of spectrum narrowing can be tuned to minimize excitation of known pump housing resonances by appropriate choice of the shear-thickening material. Such vibration attenuation, and the associated reductions in metal fatigue and corrosion susceptibility, are especially beneficial in cases where the fluid being pumped is corrosive.
The functions of the viscoelastic groove element, with its circular shear-thickening material, are thus seen to include those of a conventional valve seal as well as those of a tunable vibration attenuator and a tunable vibration damper. See, e.g., U.S. Pat. No. 6,026,776, incorporated by reference. Further, the viscoelastic reservoir element, functioning with a predetermined annular shear preload provided via an adjustable preload flange, can dissipate an additional portion of valve-closure impulse energy as heat while also attenuating and damping vibration. And viscoelastic fenestration elements, when present, may contribute further to hysteresis loss as they elastically retain the groove element in the seal-retention groove via coupling to the reservoir element. Overall hysteresis loss in the viscoelastic elements combines with hysteresis loss in the valve body to selectively reduce the bandwidth, amplitude and duration of vibrations that the closing impulse energy would otherwise tend to excite in the valve and/or pump housing.
Examples of mechanisms for such selective vibration reductions are seen in the interactions of the viscoelastic reservoir element with the adjustable preload flange. The interactions contribute to hysteresis loss in a tunable check valve assembly by, for example, creating what has been termed shear damping (see, e.g., U.S. Pat. No. 5,670,006, incorporated by reference). With the preload flange adjustably fixed centrally to the check valve body (e.g., fixed to a central guide stem), valve-closure impact causes both the preload flange and guide stem to temporarily move distally with respect to the (peripheral) valve seat interface (i.e., the valve body experiences a concave-shaped flexure). The impact energy associated with valve closure causes temporary deformation of the check valve body; that is, the valve body periphery (e.g., the valve seat interface) is stopped by contact with a valve seat while the central portion of the valve body continues (under inertial forces and pumped-fluid pressure) to elastically move distally. Thus, the annular constrained area of the viscoelastic reservoir element (shown constrained by the preload flange in the schematic illustrations herein) moves substantially countercurrent (i.e., in shear) relative to the annular unconstrained area (shown radially farther from the guide stem and peripheral to the preload flange). That is, relative distal movement of the preload flange thus tends to extrude the (more peripheral) annular unconstrained area proximally. Energy lost (i.e., dissipated) in connection with the resulting shear strain in the viscoelastic element is subtracted from the total closing impulse energy otherwise available to excite destructive flow-induced vibration resonances in a valve, valve seat and/or pump housing. See, e.g., U.S. Pat. No. 5,158,162, incorporated by reference.
Note that in viscoelastic and shear-thickening materials, the relationship between stress and strain (and thus the effect of material constraint on resonant frequency) is generally time-dependent and non-linear. So a desired degree of non-linearity in “tuning” may be predetermined by appropriate choice of viscoelastic and shear-thickening materials in a tunable check valve assembly or tunable check valve.
Another aspect of the interaction of the viscoelastic reservoir element with an adjustable preload flange contributes to vibration damping and/or absorption in a tunable check valve assembly. As a result of compliance in the viscoelastic element, longitudinal movement of a guide stem and a coupled preload flange results in a phase lag as shear stress develops within the viscoelastic material. This is analogous to the phase lag seen in the outer ring movement in an automotive torsional vibration damper or the antiphase movement of small masses in an automotive pendulum vibration damper. See, e.g., the '776 patent cited above. Adjusting the shear preload flange as described above effectively changes the tunable check valve assembly's compliance and thus the degree of phase lag. One may thus, in one or more limited operational ranges, tune viscoelastic element preload to achieve effective vibration damping plus dynamic vibration absorption at specific frequencies of interest (e.g., pump housing resonant frequencies).
To achieve the desired hysteresis loss associated with attenuation and vibration damping effects described herein, different viscoelastic and/or composite elements may be constructed to have specific elastic and/or viscoelastic properties. Note that the term elastic herein implies substantial characterization by a storage modulus, whereas the term viscoelastic herein implies substantial characterization by a storage modulus and a loss modulus. See, e.g., the '006 patent cited above.
Elastic longitudinal compliance of a tunable check valve assembly results in part from elastic properties of the materials comprising the tunable check valve assembly. Such elastic properties may be achieved through use of composites comprising reinforcement materials as, for example, in an elastic valve body comprising steel, carbon fiber reinforced polymer, carbon nanotube/graphene reinforced polymer, and/or carbon nanotube/graphene reinforced metal matrix. The polymer may comprise a polyaryletherketone (PAEK), for example, polyetheretherketone (PEEK). See, e.g., U.S. Pat. No. 7,847,057 B2, incorporated by reference.
Note that the description herein of valve body flexure as concave-shaped refers to a view from the proximal or high-pressure side of the valve body. Such flexure is substantially elastic and may be associated with slight circular rotation (i.e., a circular rolling contact) of the valve body's valve seat interface with the valve seat itself. When the degree of rolling contact is sufficient to justify conversion of the valve seat interface from a conventional frusto-conical shape to a convex curved shape (which may include, e.g., circular, elliptic and/or parabolic portions), a curved concave tunable valve seat mating surface may be used. In such cases, the valve seat interface has correspondingly greater curvature than the concave tunable valve seat mating surface (see Detailed Description herein). Such rolling contact, when present, augments elastic formation of the concave valve body flexure on the pump pressure stroke, reversing the process on the suction stroke.
The circular rolling contact described herein may be visualized by considering the behavior of the convex valve seat interface as the valve body experiences concave flexure (i.e., the transformation from a relatively flat shape to a concave shape). During such flexure the periphery of the valve seat interface rotates slightly inwardly and translates slightly proximally (relative to the valve body's center of gravity) to become the proximal rim of the concave-shaped flexure.
While substantially elastic, each such valve body flexure is associated with energy loss from the closing energy impulse due to hysteresis in the valve body. Frictional heat loss (and any wear secondary to friction) associated with any circular rolling contact of the convex valve seat interface with the concave tunable valve seat mating surface is intentionally relatively low. Thus, the rolling action, when present, minimizes wear that might otherwise be associated with substantially sliding contact of these surfaces. Further, when rolling contact between valve body and tunable valve seat is present during both longitudinal valve body flexure and the elastic rebound which follows, trapping of particulate matter from the pumped fluid between the rolling surfaces tends to be minimized.
Summarizing, an example invention embodiment includes a tunable check valve assembly in a fluid end for high pressure pumping, the fluid end having at least one fluid end resonant frequency. The tunable check valve assembly comprises a plurality of radially-spaced vibration dampers disposed in a valve body, wherein at least one vibration damper has at least a first predetermined assembly resonant frequency similar to at least one fluid end resonant frequency. Further, the valve body comprises a peripheral valve seat interface having a convex curvature. The valve seat interface undergoes a substantially elastic concave flexure with slight circular rotation as the valve body seats against a valve seat having a concave mating surface with correspondingly less curvature than the peripheral valve seat interface and achieves a circular rolling contact with the mating surface of the valve seat.
An alternative invention embodiment includes a tunable valve seat in a fluid end for high pressure pumping, the fluid end having at least one fluid end resonant frequency. The tunable valve seat comprises a lateral support assembly longitudinally-spaced from a mating surface, the lateral support assembly for resiliently coupling the valve seat to a fluid end housing. The tunable valve seat has at least one seat resonant frequency similar to at least one fluid end resonant frequency; and the mating surface has a concave curvature that forms a circular rolling contact seal with a valve body as the valve body seats against the mating surface. The valve body has a convex peripheral valve seat interface of a correspondingly greater curvature than the mating surface; and the curvature of the mating surface causes the valve seat interface to undergo a substantially elastic concave flexure with slight circular rotation to form the circular rolling contact seal.
Since rolling contact takes place over a finite time interval, it also assists in smoothly redirecting pumped fluid momentum laterally and proximally. Forces due to oppositely directed radial components of the resultant fluid flow tend to cancel, and energy lost in pumped fluid turbulence is subtracted (as heat) from that of the valve-closure energy impulse, thus decreasing both its amplitude and the amplitude of associated vibration.
In addition to the above described energy dissipation (associated with hysteresis secondary to valve body flexure), hysteresis loss will also occur during pressure-induced movements of the viscoelastic groove element (in association with the valve seal function). Note that pumped fluid pressure acting on a valve comprising an embodiment of the invention's tunable check valve assembly may hydraulically pressurize substantially all of the viscoelastic elements in a tunable check valve assembly. Although polymers suitable for use in the viscoelastic elements generally are relatively stiff at room ambient pressures and temperatures, the higher pressures and temperatures experienced during pump pressure strokes tend to cause even relatively stiff polymers to behave like fluids which can transmit pressure hydraulically. Thus, a viscoelastic element in a peripheral seal-retention groove is periodically hydraulically pressurized, thereby increasing its sealing function during the high-pressure portion of the pump cycle. Hydraulic pressurization of the same viscoelastic element is reduced during the low-pressure portion of the pump cycle when the sealing function is not needed.
Because of the above-described energy loss and the time required for valve body longitudinal deformation to take place, with the associated dissipation of closing impulse energy described above, a valve-closure energy impulse applied to a tunable check valve assembly or tunable radial array is relatively lower in amplitude and longer in duration (e.g., secondary to having a longer rise time) than an analogous valve-closure energy impulse applied to a conventionally stiff valve body which closes on a conventional frusto-conical valve seat. The combination of lower amplitude and increased duration of the valve-closure energy impulse results in a narrowed characteristic vibration bandwidth having reduced potential for induction of damaging resonances in the valve, valve seat, and adjacent portions of the pump housing. See, e.g., the above-cited '242 patent.
Note that in describing the fluid-like behavior of certain polymers herein under elevated heat and pressure, the term “polymer” includes relatively homogenous materials (e.g., a single-species fluid polymer) as well as composites and combination materials containing one or more of such relatively homogenous materials plus finely divided particulate matter (e.g., nanoparticles) and/or other dispersed species (e.g., species in colloidal suspension, graphene) to improve heat scavenging and/or other properties. See, e.g., U.S. Pat. No. 6,432,320 B1, incorporated by reference.
In addition to heat scavenging, damping is a function of the viscoelastic elements in various embodiments of the invention. Optimal damping is associated with relatively high storage modulus and loss tangent values, and is obtained over various temperature ranges in multicomponent systems described as having macroscopically phase-separated morphology, microheterogeneous morphology, and/or at least one interpenetrating polymer network. See, e.g., the above-cited '006 patent and U.S. Pat. Nos. 5,091,455; 5,238,744; 6,331,578 B1; and 7,429,220 B2, all incorporated by reference.
Summarizing salient points of the above description, recall that vibration attenuation and damping in a tunable check valve assembly, tunable valve seat, tunable plunger seal, or tunable radial array of the invention operate via four interacting mechanisms. First, impulse amplitude is reduced by converting a portion of total closing impulse energy to heat (e.g., via hysteresis and fluid turbulence), which is then ultimately rejected to the check valve body surroundings (e.g., the pumped fluid). Each such reduction of impulse amplitude means lower amplitudes in the characteristic vibration spectrum transmitted to the pump housing.
Second, the closing energy impulse as sensed at the valve seat is reshaped in part by lengthening the rebound cycle time (estimated as the total time associated with peripheral valve seal compression, concave valve body flexure and elastic rebound). Such reshaping may in general be accomplished using mechanical/hydraulic/pneumatic analogs of electronic wave-shaping techniques. In particular, lengthened rebound cycle time is substantially influenced by the valve body's increased longitudinal compliance associated with the rolling contact/seal and concave valve body flexure described herein between valve body and valve seat. The units of lengthened cycle times are seconds, so their inverse functions have dimensions of per second (or 1/sec), the same dimensions as frequency. Thus, as noted above, the inverse function is termed herein characteristic rebound frequency.
Lowered characteristic rebound frequency (i.e., increased rebound cycle time) corresponds to slower rebound, with a corresponding reduction of the impulse's characteristic bandwidth due to loss of higher frequency content. This condition is created during impulse hammer testing by adding to hammer head inertia and by use of softer impact tips (e.g., plastic tips instead of the metal tips used when higher frequency excitation is desired). In contrast, tunable check valve assemblies and tunable radial arrays achieve bandwidth narrowing (and thus reduction of the damage potential of induced higher-frequency vibrations) at least in part through increased longitudinal compliance. In other words, bandwidth narrowing is achieved in embodiments of the invention through an increase of the effective impulse duration (as by, e.g., slowing the impulse's rise time and/or fall time as the valve assembly's components flex and relax over a finite time interval).
Third, induced vibration resonances of the tunable check valve assembly, tunable valve seat, and/or other tunable components are effectively damped by interactions generating structural hysteresis loss. Associated fluid turbulence further assists in dissipating heat energy via the pumped fluid.
And fourth, the potential for excitation of damaging resonances in pump vibration induced by a closing energy impulse is further reduced through narrowing of the impulse's characteristic vibration bandwidth by increasing the check valve body's effective inertia without increasing its actual mass. Such an increase of effective inertia is possible because a portion of pumped fluid moves with the valve body as it flexes and/or longitudinally compresses. The mass of this portion of pumped fluid is effectively added to the valve body's mass during the period of flexure/rebound, thereby increasing the valve body's effective inertia to create a low-pass filter effect (i.e., tending to block higher frequencies in the manner of an engine mount).
To increase understanding of the invention, certain aspects of tunable components (e.g., alternate embodiments and multiple functions of structural features) are considered in greater detail. Alternate embodiments are available, for example, in guide means known to those skilled in the art for maintaining valve body alignment within a (suction or discharge) bore. Guide means thus include, e.g., a central guide stem and/or a full-open or wing-guided design (i.e., having a distal crow-foot guide).
Similarly, alteration of a viscoelastic element's vibration pattern(s) in a tunable fluid end is addressed (i.e., tuned) via adjustable and/or time-varying constraints. Magnitude and timing of the constraints are determined in part by closing-impulse-related distortions and/or the associated vibration. For example, a viscoelastic reservoir (or central) element is at least partially constrained as it is disposed in the central annular reservoir, an unconstrained area optionally being open to pumped fluid pressure. That is, the viscoelastic reservoir element is at least partially constrained by relative movement of the interior surface(s) of the (optionally annular) reservoir, and further constrained by one or more structures (e.g., flanges) coupled to such surface(s). Analogously, a viscoelastic groove (or peripheral) element is at least partially constrained by relative movement of the groove walls, and further constrained by shear-thickening material within one or more circular tubular areas of the element (any of which may comprise a plurality of lumens).
Since the magnitude and timing of closing-impulse-related distortions are directly related to each closing energy impulse, the tunable fluid end's overall response is adaptive to changing pump operating pressures and speeds on a stroke-by-stroke basis. So for each set of operating parameters (e.g. cycle time and peak pressure for each pressure/suction stroke cycle), one or more of the constrained viscoelastic elements has at least a first predetermined assembly resonant frequency substantially similar to an instantaneous pump resonant frequency (e.g., a resonant frequency measured or estimated proximate the suction valve seat deck). And for optimal damping, one or more of the constrained viscoelastic elements may have, for example, at least a second predetermined assembly resonant frequency similar to the first predetermined assembly resonant frequency.
Note that the adaptive behavior of viscoelastic elements is beneficially designed to complement both the time-varying behavior of valves generating vibration with each punp pressure stroke, and the time-varying response of the fluid end as a whole to that vibration.
Note also that a tunable check valve assembly and/or tunable valve seat analogous to those designed for use in a tunable suction check valve may be incorporated in a tunable discharge check valve as well. Either a tunable suction check valve or a tunable discharge check valve or both may be installed in a pump fluid end housing. Additionally, one or more other tunable components may be combined with tunable suction and/or discharge check valves. A pump housing resonant frequency may be chosen as substantially equal to a first predetermined resonant frequency of each of the tunable components installed, or of any combination of the installed tunable components. Or the predetermined component resonant frequencies may be tuned to approximate different pump housing resonant frequencies as determined for optimal vibration damping.
For increased flexibility in accomplishing the above tuning, fenestrations may be present in the groove wall to accommodate radial tension members. At least a portion of each fenestration may have a transverse area which increases with decreasing radial distance to said longitudinal axis. That is, each fenestration flares to greater transverse areas in portions closer to the longitudinal axis, relative to the transverse areas of portions of the fenestration which are more distant from the longitudinal axis. Thus, a flared fenestration is partly analogous to a conventionally flared tube, with possible differences arising from the facts that (1) fenestrations are not limited to circular cross-sections, and (2) the degree of flare may differ in different portions of a fenestration. Such flares assist in stabilizing a viscoelastic groove element via a plurality of radial tension members.
Note that in addition to the example alternate embodiments described herein, still other alternative invention embodiments exist, including valves, pump housings and pumps comprising one or more of the example embodiments or equivalents thereof. Additionally, use of a variety of fabrication techniques known to those skilled in the art may lead to embodiments differing in detail from those schematically illustrated herein. For example, internal valve body spaces may be formed during fabrication by welding (e.g., inertial welding or laser welding) valve body portions together as in the above-cited '837 patent, or by separately machining such spaces with separate coverings. Valve body fabrication may also be by rapid-prototyping (i.e., layer-wise) techniques. See, e.g., the above-cited '057 patent. Viscoelastic elements may be cast and cured separately or in place in a valve body as described herein. See, e.g., U.S. Pat. No. 7,513,483 B1, incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic 3-dimensional view of a partially sectioned tunable check valve assembly/tunable radial array embodiment showing how an adjustable preload flange constrains an area of the viscoelastic reservoir element as described herein.
FIG. 2 includes a schematic 3-dimensional exploded view of the tunable check valve assembly/tunable radial array embodiment of FIG. 1 showing viscoelastic body elements, the valve body, and the adjustable preload flange.
FIG. 3 is a schematic 3-dimensional partially-sectioned view of viscoelastic reservoir, groove and fenestration elements (i.e., viscoelastic body elements) of FIGS. 1 and 2 showing the constrained area of the reservoir element where it contacts an adjustable preload flange, as well as an adjacent unconstrained area.
FIG. 4 is a schematic 3-dimensional partially-sectioned view of two check valve bodies with an adjustable preload flange located at different longitudinal positions on a central guide stem.
FIG. 5 is a schematic 3-dimensional instantaneous partially-sectioned view of shear-thickening material which would, e.g., substantially fill a circular tubular area in a viscoelastic groove element, a support circular tubular area of a tunable valve seat, a tunable plunger seal, or a tunable resilient circumferential seal.
FIG. 6 is a schematic illustration of an exploded partially-sectioned 2-dimensional view of major components of a pump fluid end subassembly. Brief explanatory comments on component functions are found in the detailed description. The schematically-illustrated subassembly comprises a pumping chamber within a subassembly pump housing, the pumping chamber being in fluid communication with a suction bore, a discharge bore, and a piston/plunger bore. Schematic representations of a suction check valve, a discharge check valve, and a piston/plunger are shown in their respective bores.
FIG. 7 is a schematic illustration of two views of an exploded partially-sectioned 3-dimensional view of a valve body and tunable valve seat embodiment. Curved longitudinal section edges of the valve body's convex valve seat interface and corresponding concave mating portions of the tunable valve seat are shown schematically in a detail breakout view to aid description herein of a rolling valve seal along a circular line. A tunable (suction or discharge) check valve embodiment of the invention may comprise a combination of a tunable check valve assembly/tunable radial array (see, e.g., FIGS. 1 and 2 ) and a tunable valve seat (see, e.g., FIGS. 7 and 8 ).
FIG. 8 is a schematic 3-dimensional exploded and partially-sectioned view of a tunable valve seat embodiment showing a concave mating surface longitudinally spaced apart from a lateral support mounting surface, and an adjustable lateral support assembly comprising first and second securable end spacers in combination with a plurality of circular viscoelastic support elements, each support element comprising a support circular tubular area.
FIG. 9 is a schematic 3-dimensional exploded view of a partially sectioned tunable check valve assembly embodiment. A dilatant (i.e., shear-thickening) liquid is schematically shown being added to a check valve body's internal cavity, the cavity being shown as enclosing a tuned vibration damper comprising discrete mechanical elements (e.g., a mass and three springs).
FIG. 10 is a schematic 3-dimensional exploded view of a tunable check valve embodiment comprising the tunable check valve assembly of FIG. 9 together with a tunable valve seat, the tunable check valve embodiment including structures to facilitate a rolling seal along a circular line between the valve body's valve seat interface and the tunable valve seat's mating surface. Note that the (convex) valve seat interface has correspondingly greater curvature than the (concave) mating surface, and the mating surface has correspondingly less curvature than the valve seat interface.
FIG. 11 is a schematic 3-dimensional exploded view of an alternate tunable check valve embodiment comprising the tunable check valve assembly of FIG. 9 together with a tunable valve seat, the tunable check valve embodiment including structures to facilitate a rolling seal along a circular line between the check valve body's peripheral valve seat interface and the tunable valve seat's mating surface. An adjustable lateral support assembly is shown with the tunable valve seat, the assembly comprising first and second securable end spacers in combination with a plurality of circular viscoelastic support elements, each support element shown in a detail breakout view as comprising a support circular tubular area.
FIG. 12 illustrates longitudinal sections of two schematic 3-dimensional views of an alternate tunable check valve assembly embodiment comprising a plurality of radially-spaced vibration dampers disposed in a valve body having a peripheral seal. Each vibration damper comprises a circular tubular area, and at least one vibration damper is tunable via a fluid tuning medium in a tubular area. A central fluid tuning medium is shown schematically being added to the central circular tubular area. A fluid tuning medium may comprise, e.g., one or more shear-thickening materials.
FIG. 13 includes more-detailed longitudinal sections of a schematic 3-dimensional exploded view analogous-in-part to that of the alternate tunable check valve assembly embodiment of FIG. 12 . Detail breakout views include the peripheral seal's medial flange and the medial flange's corresponding flange channel. An instantaneous schematic view of a peripheral fluid tuning medium in the peripheral seal's circular tubular area is shown separately, and a central fluid tuning medium is shown schematically being added to the central circular tubular area. Note that a portion of the peripheral circular tubular area (with its fluid tuning medium) extends into (i.e., is partially surrounded by) the peripheral seal's medial flange. The central and peripheral circular tubular areas, with their respective fluid tuning media, constitute a plurality of tunable vibration dampers in the form of a tunable radial array.
FIG. 14A illustrates longitudinal sections of a partial schematic 3-dimensional view of an alternate tunable check valve embodiment comprising the tunable valve body shown as part of the exploded assembly in FIG. 13 , together with a tunable valve seat 450 . Note that tapered mounting surface 452 interfaces with a fluid end housing in which tunable valve seat 450 may be mounted. A detail breakout view shows that peripheral valve seat interface 434 is convex, having correspondingly greater curvature than tunable valve seat concave mating surface 454 . The concave mating surface has correspondingly less curvature than the peripheral valve seat interface to facilitate a circular rolling contact seal providing decreased contact area substantially along a circular line between the valve body's peripheral valve seat interface and the tunable valve seat's concave mating surface.
FIG. 14B illustrates longitudinal sections of a partial schematic 3-dimensional view of an alternate tunable check valve embodiment comprising the tunable check valve assembly embodiment of FIG. 13 (having a first plurality of tunable vibration dampers), together with a tunable valve seat (having a second plurality of tunable vibration dampers). The tunable valve seat of FIG. 14B comprises a plurality of tunable vibration-damping structural features comprising a concave mating surface and an adjustable lateral support assembly. The lateral support assembly interfaces with a fluid end housing in which tunable valve seat 450 ′ may be mounted, creating tunable coupling to the fluid end housing which differs from the coupling provided via tapered mounting surface 452 (see FIG. 14A ).
FIG. 15 illustrates a partial schematic 3-dimensional view of a tunable hydraulic stimulator embodiment comprising a hammer element longitudinally movable within a hollow cylindrical housing having a longitudinal axis, one end of the housing being closed by a fluid interface, and the other end being closed by a driver element. The fluid interface is shown with a MEMS accelerometer for detecting vibration of the interface.
FIG. 16A illustrates a partial schematic 3-dimensional exploded view of the tunable hydraulic stimulator embodiment of FIG. 15 , a first electrical cable being shown to schematically indicate a feedback path (for an accelerometer signal) from the accelerometer to the driver element. A second electrical cable is shown to schematically indicate an interconnection path for, e.g., communication with one or more additional stimulators and/or associated equipment such as a programmable controller.
FIG. 16B illustrates a schematic 3-dimensional exploded view of an adaptive stimulator embodiment that differs from the embodiment of FIGS. 15 and 16A in part because it comprises a fluid interface comprising three disc-shaped thin members. Electrical leads signify that each disc-shaped thin member can function as a vibration detector, and electrical leads also draw attention to an electromagnetic hammer driver and a peripheral transverse coil for creating a stepwise adjustable steady-state longitudinal magnetic field.
FIG. 17 schematically illustrates a 2-dimensional view of major components, subsystems, and interconnections of an adaptive down-hole stimulation system embodiment, together with brief explanatory comments on component and subsystem functions. As aids to orientation, a schematic wellbore is shown, as are control link pathways for communication among pumps, tunable down-hole stimulator(s) and a tunable down-hole stimulation system controller. Schematic pathways are shown for stimulation vibration energy directed toward down-hole geologic material adjacent to the wellbore, and for backscatter vibration energy emanating from the stimulated geologic material.
FIG. 18 schematically illustrates an embodiment of an adaptive down-hole stimulation system embodiment analogous in part to that of FIG. 17 . Portions of the illustration of FIG. 18 resemble analogous portions of FIG. 17 . But structural and functional differences between the systems of FIGS. 17 and 18 include replacement of a single tunable down-hole stimulator (in FIG. 17 ) with a linear array of three tunable down-hole stimulators (in FIG. 18 ). Further, power spectral densities (PSD's) of impulse-generated vibration from each stimulator of FIG. 18 may be adjusted for stimulation comprising resonance excitation, fracturing and/or analysis of geologic materials. A frac pump producing cyclically-varying down-hole pressure provides for such stimulation at varying distances from a wellbore. And appropriate timing of stimulation vibration bursts from each stimulator facilitates directional propagation of combined vibration wave fronts. Further, relative shifts (i.e., discrete time intervals and/or phase relationships) among timed stimulator transmission signals, timed stimulator shift signals and/or timed pressure signals may be controlled via a programmable controller.
DETAILED DESCRIPTION
Tunable equipment associated with high-pressure well-stimulation comprises tunable down-hole stimulators (plus associated controllers, power supplies, etc.). Frac and/or proppant pumps optionally comprise tunable fluid ends (which include but are not limited to, e.g., tunable valve assemblies and/or vibration dampers) which facilitate selective attenuation of valve-generated vibration at or near its source to reduce fluid end fatigue failures. Tunable down-hole stimulation systems includes system controllers plus single or multiple tunable hydraulic stimulators, with optional inclusion of tunable fluid ends. FIGS. 1-16 relate to components and subsystems, while FIGS. 17 and 18 schematically illustrate various embodiments of down-hole stimulation systems.
FIGS. 1-14B schematically illustrate how adding multifunction rings, tunable valve seats, tunable radial arrays and/or plunger seals to tunable check valve assemblies in a fluid end further facilitates optimal damping and/or selective attenuation of vibration at one or more predetermined (and frequently-localized) fluid end resonant frequencies.
A tunable (suction or discharge) check valve of the invention may comprise, for example, a combination of a tunable check valve assembly/tunable radial array 99 (see, e.g., FIG. 1 ) and a tunable valve seat 20 or a tunable valve seat 389 (see, e.g., FIGS. 7 and 11 ). Details of the structure and functions of each component are provided herein both separately and as combined with other components to obtain synergistic benefits contributing to longer pump service life.
FIGS. 1 and 2 schematically illustrate an invention embodiment of a tunable check valve assembly/tunable radial array 99 substantially symmetrical about a longitudinal axis. Illustrated components include a valve body 10 , an adjustable preload flange 30 , and a plurality of viscoelastic body elements 50 . Check valve body 10 , in turn, comprises a peripheral groove 12 (see FIG. 2 ) spaced apart by an annular (central) reservoir 16 from a longitudinal guide stem 14 , groove 12 being responsive to longitudinal compressive force. A plurality of viscoelastic body elements 50 comprises an annular (central) reservoir element 52 coupled to a (peripheral) groove element 54 by a plurality of (optional) radial fenestration elements 56 (in fenestrations 18 ) to form a tunable radial array. Groove element 54 functions as a vibration damper and valve seal, comprising at least one circular tubular area 58 .
Responsiveness of groove 12 to longitudinal compressive force is characterized in part by damping of groove wall 11 / 13 / 15 vibrations. Such damping is due in part to out-of-phase vibrations in proximal groove wall 13 and distal groove wall 11 which are induced by longitudinal compressive force. Such out-of-phase vibrations will cause various groove-related dimensions to vary with longitudinal compressive force, thereby indicating the responsiveness of groove 12 to such force (see, for example, the dimension labeled A in FIG. 2 ). Each phase shift, in turn, is associated with differences in the coupling of proximal groove wall 13 to guide stem 14 (indirectly via longitudinal groove wall 15 and radial reservoir floor 19 ) and the coupling of distal groove wall 11 to guide stem 14 (directly via radial reservoir floor 19 ). Note that longitudinal groove wall 15 may comprise fenestrations 18 , thereby increasing the responsiveness of groove 12 to longitudinal compressive force on tunable check valve assembly 99 .
Referring to FIGS. 1-3 , adjustable preload flange 30 extends radially from guide stem 14 (toward peripheral reservoir wall 17 ) over, for example, about 20% to about 80% of viscoelastic reservoir element 52 (see FIG. 3 ). Adjustable preload flange 30 thus imposes an adjustable annular shear preload over an annular constrained area 62 of viscoelastic reservoir element 52 to achieve at least a first predetermined assembly resonant frequency substantially replicating a (similar) measured or estimated resonant frequency (e.g., a pump housing resonant frequency). Note that an adjacent annular unconstrained area 60 of viscoelastic reservoir element 52 remains open to pumped fluid pressure. Note also that adjustable preload flange 30 may be adjusted in effective radial extent and/or longitudinal position.
Note further that annular constrained area 62 and annular unconstrained area 60 are substantially concentric and adjacent. Thus, for a tunable suction valve subject to longitudinal (i.e., distally-directed) compressive constraint applied via preload flange 30 to annular constrained area 62 , annular unconstrained area 60 will tend to move (i.e., extrude) proximally relative to area 62 . The oppositely-directed (i.e., countercurrent) movements of constrained and unconstrained annular areas of viscoelastic reservoir element 52 create a substantially annular area of shear stress.
Finally, each circular tubular area 58 is substantially filled with at least one shear-thickening material 80 (see FIG. 5 ) chosen to achieve at least a second predetermined assembly resonant frequency similar, for example, to the first predetermined assembly resonant frequency). Note that FIG. 5 schematically represents a partially-sectioned view of an instantaneous configuration of the shear-thickening material 80 within circular tubular area 58 .
Referring to FIGS. 1 and 2 in greater detail, a tunable check valve assembly/tunable radial array embodiment 99 comprises viscoelastic body elements 50 which comprise, in turn, reservoir (central) element 52 coupled to groove (peripheral) element 54 via radial fenestration (tension) elements 56 . Elements 52 , 54 and 56 are disposed in (i.e., integrated with and/or lie substantially in) reservoir 16 , groove 12 and fenestrations 18 respectively to provide a tuned radial array having at least a third predetermined resonant frequency. An adjustable preload flange 30 is coupled to guide stem 14 and contacts viscoelastic reservoir element 52 in reservoir 16 to impose an adjustable annular constraint on viscoelastic reservoir element 52 for achieving at least a first predetermined assembly resonant frequency substantially similar to, for example, a measured resonant frequency (e.g., a pump housing resonant frequency). Such adjustable annular constraint imposes an adjustable shear preload between constrained annular area 62 and unconstrained annular area 60 . Tunable check valve assembly 99 may additionally comprise at least one circular tubular area 58 in groove element 54 residing in groove 12 , each tubular area 58 being substantially filled with at least one shear-thickening material 80 chosen to achieve at least a second predetermined assembly resonant frequency similar, for example, to the first predetermined assembly resonant frequency).
The above embodiment may be installed in a pump housing having a measured housing resonant frequency; the measured housing resonant frequency may then be substantially replicated in the (similar) first predetermined resonant frequency of the tunable check valve assembly. Such a combination would be an application of an alternate embodiment. An analogous tuning procedure may be followed if the tunable check valve assembly of the second embodiment is installed in a pump having a (similar or different) resonant frequency substantially equal to the second predetermined resonant frequency. This synergistic combination would broaden the scope of the valve assembly's beneficial effects, being yet another application of the invention's alternate embodiment.
Note that preload flange 30 may have a non-cylindrical periphery 32 for imposing on viscoelastic reservoir element 52 an adjustable annular shear preload having both longitudinal and transverse components.
Note further that the periphery of adjustable preload flange 30 , if cylindrical, predisposes a tunable check valve assembly to substantially longitudinal shear damping with each longitudinal distortion of check valve body 10 associated with valve closure. The character of such shear damping depends, in part, on the longitudinal position of the preload flange. Examples of different longitudinal positions are seen in FIG. 4 , which schematically illustrates the flange 30 ′ longitudinally displaced from flange 30 ″. Further, as shown in FIG. 4 , the convex periphery of a longitudinally adjusted preload flange 30 ′ or 30 ″ may introduce shear damping of variable magnitude and having both longitudinal and transverse components. Such damping may be beneficial in cases where significant transverse valve-generated vibration occurs.
To clarify the placement of viscoelastic body elements 50 , labels indicating the portions are placed on a sectional view in FIGS. 2 and 3 . Actual placement of viscoelastic body elements 50 in valve body 10 (see FIG. 1 ) may be by, for example, casting viscoelastic body elements 50 in place, or placing viscoelastic body elements 50 (which have been precast) in place during layer-built or welded fabrication. The tunable check valve assembly embodiment of the invention is intended to represent check valve body 10 and viscoelastic body elements 50 as complementary components at any stage of manufacture leading to functional integration of the two components.
To enhance scavenging of heat due to friction loss and/or hysteresis loss, shear-thickening material 80 and/or viscoelastic body elements 50 may comprise one or more polymers which have been augmented with nanoparticles and/or graphene 82 (see, e.g., FIG. 5 ). Nanoparticles and/or graphene may be invisible to the eye as they are typically dispersed in a colloidal suspension. Hence, they are schematically represented by cross-hatching 82 in FIG. 5 . Nanoparticles may comprise, for example, carbon forms (e.g., graphene) and/or metallic materials such as copper, beryllium, titanium, nickel, iron, alloys or blends thereof. The term nanoparticle may conveniently be defined as including particles having an average size of up to about 2000 nm. See, e.g., the '320 patent.
FIG. 6 is a schematic illustration of an exploded partially-sectioned 2-dimensional view of major components of a pump fluid end subassembly 88 , together with graphical aids and brief explanatory comments on component functions. The schematically-illustrated subassembly 88 comprises a pumping chamber 74 within a subassembly (pump) housing 78 , the pumping chamber 74 being in fluid communication with a suction bore 76 , a discharge bore 72 , and a piston/plunger bore 70 . Note that piston/plunger bore 70 comprises at least one recess (analogous to that labeled “packing box” in FIG. 6 ) in which at least one lateral support assembly 130 (see FIG. 8 ) may be sealingly positionable along the plunger as part of a tunable plunger seal embodiment. Schematic representations of a tunable suction valve 95 (illustrated for simplicity as a hinged check valve), a tunable discharge valve 97 (also illustrated for simplicity as a hinged check valve), and a piston/plunger 93 (illustrated for simplicity as a plunger) are shown in their respective bores. Note that longitudinally-moving valve bodies in check valve embodiments schematically illustrated herein (e.g., valve body 10 ) are associated with certain operational phenomena analogous to phenomena seen in hinged check valves (including, e.g., structural compliance secondary to closing energy impulses).
Regarding the graphical aids of FIG. 6 , the double-ended arrows that signify fluid communication between the bores (suction, discharge and piston/plunger) and the pumping chamber are double-ended to represent the fluid flow reversals that occur in each bore during each transition between pressure stroke and suction stroke of the piston/plunger. The large single-ended arrow within the pumping chamber is intended to represent the periodic and relatively large, substantially unidirectional fluid flow from suction bore through discharge bore during pump operation.
Further regarding the graphical aids of FIG. 6 , tunable suction (check) valve 95 and tunable discharge (check) valve 97 are shown schematically as hinged check valves in FIG. 6 because of the relative complexity of check valve embodiments having longitudinally-moving valve bodies. More detailed schematics of several check valve assemblies and elements are shown in FIGS. 1-11 , certain tunable check valve embodiments comprising a tunable check valve assembly and a tunable valve seat. In general, the tunable check valve assemblies/tunable radial arrays of tunable suction and discharge valves will typically be tuned to different assembly resonant frequencies because of their different positions in a subassembly housing 78 (and thus in a pump housing as described herein). Pump housing resonant frequencies that are measured proximate the tunable suction and discharge valves will differ in general, depending on the overall pump housing design. In each case they serve to guide the choices of the respective assembly resonant frequencies for the valves.
Note that the combination of major components labeled in FIG. 6 as a pump fluid end subassembly 88 is so labeled (i.e., is labeled as a subassembly) because typical fluid end configurations comprise a plurality of such subassemblies combined in a single machined block. Thus, in such typical (multi-subassembly) pump fluid end designs, as well as in less-common single-subassembly pump fluid end configurations, the housing is simply termed a “pump housing” rather than the “subassembly housing 78 ” terminology of FIG. 6 .
Further as schematically-illustrated and described herein for clarity, each pump fluid end subassembly 88 comprises only major components: a pumping chamber 74 , with its associated tunable suction valve 95 , tunable discharge valve 97 , and piston/plunger 93 in their respective bores 76 , 72 and 70 of subassembly housing 78 . For greater clarity of description, common fluid end features well-known to those skilled in the art (such as access bores, plugs, seals, and miscellaneous fixtures) are not shown. Similarly, a common suction manifold through which incoming pumped fluid is distributed to each suction bore 76 , and a common discharge manifold for collecting and combining discharged pumped fluid from each discharge bore 72 , are also well-known to those skilled in the art and thus are not shown.
Note that the desired check-valve function of tunable check valves 95 and 97 schematically-illustrated in FIG. 6 requires interaction of the respective tunable check valve assemblies (see, e.g., FIGS. 1-5 ) with a corresponding (schematically-illustrated) tunable valve seat (see, e.g., FIGS. 7, 8, 10 and 11 ). The schematic illustrations of FIG. 6 are only intended to convey general ideas of relationships and functions of the major components of a pump fluid end subassembly. Structural details of the tunable check valve assemblies that are in turn part of tunable check valves 95 and 97 of the invention (including their respective tunable valve seats) are illustrated in greater detail in other figures as noted above. Such structural details facilitate a plurality of complementary functions that are best understood through reference to FIGS. 1-5 and 7-11 .
The above complementary functions of tunable check valves include, but are not limited to, closing energy conversion to heat via structural compliance, energy redistribution through rejection of heat to the pumped fluid and pump housing, vibration damping and/or selective vibration spectrum narrowing through changes in tunable check valve assembly compliance, vibration frequency down-shifting (via decrease in characteristic rebound frequency) through increase of rebound cycle time, and selective vibration attenuation through energy dissipation (i.e., via redistribution) at predetermined assembly resonant frequencies.
FIG. 7 is a schematic illustration of two views of an exploded partially-sectioned 3-dimensional view including a check valve body 10 and its convex valve seat interface 22 , together with concave mating surface 24 of tunable valve seat 20 . Mating surface 24 is longitudinally spaced apart from a pump housing interface surface 21 . A curved longitudinal section edge 28 of the tunable valve seat's mating surface 24 , together with a correspondingly greater curved longitudinal section edge 26 of the valve body's valve seat interface 22 , are shown schematically in detail view A to aid description herein of a rolling valve seal.
In summary, the valve body comprises a peripheral valve seat interface having a convex curvature. The valve seat interface undergoes a substantially elastic concave flexure with slight circular rotation as the valve body seats against a valve seat having a concave mating surface with correspondingly less curvature than the peripheral valve seat interface. As a result, the peripheral valve seat interface achieves a circular rolling contact with the mating surface of the valve seat.
Alternatively, the valve seat mating has a concave curvature that forms a circular rolling contact seal with a valve body as the valve body seats against the mating surface. The valve body has a convex peripheral valve seat interface with a correspondingly greater curvature than the mating surface. And the curvature of the mating surface causes the valve seat interface to undergo a substantially elastic concave flexure with slight circular rotation to form the circular rolling contact seal.
The correspondingly greater curvature of valve seat interface 22 , as compared to the curvature of mating surface 24 , effectively provides a rolling seal against fluid leakage which reduces wear on the surfaces in contact. The rolling seal also increases longitudinal compliance of a tunable suction or discharge valve of the invention, with the added benefit of increasing the rise and fall times of the closing energy impulse (thus narrowing the associated vibration spectrum). Widening the closing energy impulse increases rebound cycle time and correspondingly decreases characteristic rebound frequency.
Further regarding the terms “correspondingly greater curvature” or “correspondingly less curvature” as used herein, note that the curvatures of the schematically illustrated longitudinal section edges (i.e., 26 and 28 ) and the surfaces of which they are a part (i.e., valve seat interface 22 and mating surface 24 respectively) are chosen so that the degree of longitudinal curvature of valve seat interface 22 (including edge 26 ) exceeds that of (i.e., has correspondingly greater curvature than) mating surface 24 (including edge 28 ) at any point of rolling contact. In other words, mating surface 24 (including edge 28 ) has correspondingly less curvature than valve seat interface 22 (including edge 26 ). Hence, rolling contact (i.e., a rolling valve seal) between valve seat interface 22 and mating surface 24 is along a substantially circular line (i.e., mating surface 24 is a curved mating surface for providing decreased contract area along the circular line). The plane of the circular line is generally transverse to the (substantially coaxial) longitudinal axes of valve body 10 and tunable valve seat 20 . And the decreased contract area along the circular line is so described because it is small relative to the nominal contact area otherwise provided by conventional (frusto-conical) valve seat interfaces and valve seat mating surfaces.
Note that the nominal frusto-conical contact area mentioned above is customarily shown in engineering drawings as broad and smooth. But the actual contact area is subject to unpredictable variation in practice due to uneven distortions (e.g., wrinkling) of the respective closely-aligned frusto-conical surfaces under longitudinal forces that may exceed 250,000 pounds. An advantage of the rolling valve seal along a substantially circular line as described herein is minimization of the unpredictable effects of such uneven distortions of valve seat interfaces and their corresponding mating surfaces.
Note also that although valve seat interface 22 and mating surface 24 (and other valve seat interface/mating surface combinations described herein) are schematically illustrated as curved, either may be frusto-conical (at least in part) in certain tuned component embodiments. Such frusto-conical embodiments may have lower fabrication costs and may exhibit suboptimal distortion, down-shifting performance and/or wear characteristics. They may be employed in relatively lower-pressure applications where other tunable component characteristics provide sufficient operational advantages in vibration control.
The above discussion of rolling contact applies to the alternate tunable valve seat 20 ′ of FIG. 8 , as it does to the tunable valve seat 20 of FIG. 7 . FIG. 8 schematically illustrates a 3-dimensional exploded and partially-sectioned view of a tunable valve seat showing a mating surface (analogous to mating surface 24 of FIG. 7 ) longitudinally spaced apart from a lateral support mounting surface 21 ′. But the lateral support mounting surface 21 ′ in FIG. 8 differs from pump housing interface surface 21 of FIG. 7 in that it facilitates adjustably securing a lateral support assembly 130 to alternate tunable valve seat 20 ′. Lateral support assembly 130 comprises first and second securable end spacers ( 110 and 124 respectively) in combination with a plurality of circular viscoelastic support elements ( 114 , 118 and 122 ), each support element comprising a support circular tubular area (see areas 112 , 116 and 120 respectively). Shear-thickening material in each support circular tubular area 112 , 116 and 120 is chosen so each lateral support assembly 130 has at least one predetermined resonant frequency. Lateral support assemblies thus configured may be part of each tunable valve seat and each tunable plunger seal. When part of a tunable plunger seal, one or more lateral support assemblies 130 reside in at least one recess analogous to the packing box schematically illustrated adjacent to piston/plunger 93 (i.e., as a portion of piston/plunger bore 70 ) in FIG. 6 .
Note also that in general, a tunable (suction or discharge) check valve of the invention may comprise a combination of a tunable check valve assembly 99 (see, e.g., FIG. 1 ) and a tunable valve seat 20 (see, e.g., FIG. 7 ) or a tunable valve seat 20 ′ (see, e.g., FIG. 8 ). Referring more specifically to FIG. 6 , tunable suction check valve 95 is distinguished from tunable discharge check valve 97 by one or more factors, including each measured resonant frequency to which each tunable check valve is tuned so as to optimize the overall effectiveness of valve-generated vibration attenuation in the associated pump housing 78 .
FIGS. 9-11 show schematic exploded views of a nonlinear spring-mass damper 227 / 228 / 229 / 230 , which may be incorporated in a tunable check valve assembly embodiment 210 . FIGS. 9-11 can each be understood as schematically illustrating a tunable check valve assembly with or without a peripheral groove viscoelastic element. That is, each figure may also be understood to additionally comprise a viscoelastic groove element analogous to groove element 54 (see FIG. 2 ) residing in groove 218 ′/ 218 ″ (see FIG. 9 )—this groove element is not shown in exploded FIGS. 9-11 for clarity, but may be considered to comprise at least one circular tubular area analogous to tubular area 58 in groove element 54 (see FIG. 2 ), each tubular area 58 being substantially filled with at least one shear-thickening material 80 chosen to achieve at least one predetermined assembly resonant frequency.
Referring to FIG. 9 , Belleville springs 227 / 228 / 229 are nonlinear, and they couple mass 230 to the valve body base plate 216 and the proximal valve body portion 214 . Additionally, dilatant liquid 242 is optionally added (via sealable ports 222 and/or 220 ) to central internal cavity 224 to immerse nonlinear spring-mass damper 227 / 228 / 229 / 230 . The nonlinear behavior of dilatant liquid 242 in shear (as, e.g., between Belleville springs 227 and 228 ) expands the range of tuning the nonlinear spring-mass damper 227 / 228 / 229 / 230 to a larger plurality of predetermined frequencies to reduce “ringing” of valve body 214 / 216 in response to a closing energy impulse.
To clarify the function of nonlinear spring-mass damper 227 / 228 / 229 / 230 , mass 230 is shown perforated centrally to form a washer shape and thus provide a passage for flow of dilatant liquid 242 during longitudinal movement of mass 230 . This passage is analogous to that provided by each of the Belleville springs 227 / 228 / 229 by reason of their washer-like shape.
FIG. 10 shows an exploded view of an alternate embodiment of a tunable check valve comprising the tunable check valve assembly 210 of FIG. 9 , plus a tunable valve seat 250 . FIGS. 10 and 11 schematically illustrate two views of an exploded partially-sectioned 3-dimensional view including a valve body 214 / 216 and its valve seat interface 234 , together with mating surface 254 of tunable valve seats 250 and 250 ′. Mating surface 254 is longitudinally spaced apart from pump housing interface surface 252 in FIG. 10 , and from lateral support mounting surface 252 ′ in FIG. 11 . In FIG. 10 , a curved longitudinal section edge 256 of the tunable valve seat's mating surface 254 , together with a correspondingly greater curved longitudinal section edge 236 of valve seat interface 234 , are shown schematically to aid description herein of a rolling valve seal along a substantially circular line.
Note that valve body 214 / 216 may be fabricated by several methods, including that schematically illustrated in FIGS. 9-11 . For example, circular boss 215 on proximal valve body portion 214 may be inertia welded or otherwise joined to circular groove 217 on valve body base plate 216 . Such joining results in the creation of peripheral seal-retention groove 218 ′/ 218 ″ having proximal groove wall 218 ′ and distal groove wall 218 ″.
To enhance scavenging of heat due to friction loss and/or hysteresis loss, liquid polymer(s) 242 may be augmented by adding nanoparticles which are generally invisible to the eye as they are typically dispersed in a colloidal suspension. Nanoparticles comprise, for example, carbon and/or metallic materials such as copper, beryllium, titanium, nickel, iron, alloys or blends thereof. The term nanoparticle may conveniently be defined as including particles having an average size of up to about 2000 nm. See, e.g., the '320 patent.
The correspondingly greater curvature of valve seat interface 234 , as compared to the curvature of mating surface 254 , effectively provides a rolling seal against fluid leakage which reduces frictional wear on the surfaces in contact. The rolling seal also increases longitudinal compliance of a tunable suction or discharge valve of the invention, with the added benefit of increasing the rise and fall times of the closing energy impulse (thus narrowing the associated vibration spectrum).
Further regarding the term “correspondingly greater curvature” as used herein, note that the curvatures of the schematically illustrated longitudinal section edges (i.e., 236 and 256 ) and the surfaces of which they are a part (i.e., valve seat interface 234 and mating surface 254 respectively) are chosen so that the degree of longitudinal curvature of valve seat interface 234 (including edge 236 ) exceeds that of (i.e., has correspondingly greater curvature than) mating surface 254 (including edge 256 ) at any point of rolling contact. Hence, rolling contact between valve seat interface 234 and mating surface 254 is always along a substantially circular line that decreases contact area relative to the (potentially variable) contact area of a (potentially distorted) conventional frusto-conical valve body/valve seat interface (see discussion above). The plane of the circular line is generally transverse to the (substantially coaxial) longitudinal axes of valve body 214 / 216 and tunable valve seat 250 . (See notes above re frusto-conical valve seat interface shapes and mating surfaces).
The above discussion of rolling contact applies to the alternate tunable valve seat 250 ′ of FIG. 11 , as it does to the tunable valve seat 250 of FIG. 10 . But the lateral support mounting surface 252 ′ in tunable check valve 399 of FIG. 11 differs from pump housing interface surface 252 of FIG. 10 in that it facilitates adjustably securing a lateral support assembly 330 to alternate tunable valve seat 250 ′ to form tunable valve seat 389 . Lateral support assembly 330 comprises first and second securable end spacers ( 310 and 324 respectively) in combination with a plurality of circular viscoelastic support elements ( 314 , 318 and 322 ), each support element comprising a support circular tubular area ( 312 , 316 and 320 respectively).
Note that in general, a tunable (suction or discharge) check valve of the invention may comprise a combination of a tunable check valve assembly 210 (see, e.g., FIG. 9 ) and a tunable valve seat 250 (see, e.g., FIG. 10 ) or a tunable valve seat 250 ′ (see, e.g., FIG. 11 ). Referring more specifically to FIG. 6 , tunable suction valve 95 is distinguished from tunable discharge check valve 97 by one or more factors, including each measured or estimated resonant frequency to which each tunable check valve is tuned so as to optimize the overall effectiveness of valve-generated vibration attenuation in the associated pump housing 78 .
FIG. 12 illustrates two schematic 3-dimensional longitudinally-sectioned views of an alternate tunable check valve assembly embodiment comprising a plurality of radially-spaced vibration dampers disposed in a valve body 410 having a resilient peripheral seal 470 . Each of two radially-spaced vibration dampers comprises a circular tubular area (i.e., central circular tubular area 462 as seen in FIG. 12 , and peripheral circular tubular area 472 / 474 as seen in FIG. 13 ). Note that peripheral circular tubular area 472 / 474 is so designated because it comprises a lateral circular tubular portion 472 and a medial circular tubular portion 474 (see FIG. 13 ). And further note that at least one of the radially-spaced vibration dampers is tunable via a fluid tuning medium in a tubular area (see, e.g., in FIG. 12 that a central fluid tuning medium 442 is being added to spaces including central circular tubular area 462 ). A fluid tuning medium may comprise, e.g., one or more shear-thickening materials, and the medium may further comprise nanoparticles.
Thus, each vibration damper comprises a circular tubular area ( 462 / 472 ), and at least one vibration damper is tunable to a predetermined frequency (e.g., a resonant frequency of a fluid end in which the assembly is installed). The tuning mechanisms may differ: e.g., via a fluid medium 442 (shown schematically being added in FIG. 12 via a sealable port 422 in valve body 410 ) in a tubular area 462 and/or via a fluid medium 482 (shown as an instantaneous shape 480 ) within tubular area 472 . Control of variable fluid flow resistance and/or fluid stiffness (in the case of shear-thickening fluids) facilitates predetermination of resonant frequency or frequencies in the central and peripheral dampers.
In either case, tuning is function of responsiveness of the respective dampers to vibration secondary to valve closure impact (see above discussion of such impact and vibration). For example, longitudinal force on the closed valve will tend to reduce the distance between opposing fluid flow restrictors 466 / 468 , simultaneously prompting flow of fluid tuning medium 442 from circular tubular area 462 to areas 464 and/or 460 ( 460 acting as a surge chamber). Flow resistance will be a function of fluid flow restrictors 466 / 468 and the fluid viscosity. Note that viscosity may vary with time in a shear-thickening liquid 442 , thereby introducing nonlinearity for predictably altering center frequency and/or Q of the damper. Analogous predetermined viscosity variation in fluid tuning medium 482 is available for predictably altering the center frequency and/or Q (i.e., altering the tuning) of the peripheral damper 470 / 472 / 482 as the seal 470 distorts under the longitudinal load of valve closure.
Note that the peripheral seal vibration damper 470 / 472 / 482 comprises a medial flange 479 sized to closely fit within flange channel 419 of valve body 410 , and medial flange 419 partially surrounds circular tubular area 472 within said seal 470 . Those skilled in the art know that conventional peripheral seals tend to rotate within their retaining groove. The illustrated seal embodiment herein shows that such rotation will tend to be resisted by the combined action of medial flange 479 and flange channel 419 . Further, the portion of circular tubular area 472 partially surrounded by medial flange 419 will tend to stiffen medial flange 479 in a nonlinear manner when circular tubular area 472 contains a shear-thickening fluid tuning medium.
FIG. 13 is a more-detailed schematic 3-dimensional longitudinally-sectioned exploded view analogous-in-part to that of the alternate tunable check valve assembly embodiment of FIG. 12 . Detail breakout views include medial flange 479 of resilient peripheral seal 470 , as well as the medial flange's corresponding flange channel 419 . An instantaneous schematic view of peripheral fluid tuning medium 480 in the peripheral circular tubular area 472 / 474 is shown spaced apart in the exploded view of FIG. 13 . Note that the longitudinally-sectioned (instantaneous shape) schematic illustration of peripheral fluid tuning medium 480 comprises a lateral fluid tuning medium portion 482 corresponding to lateral circular tubular portion 472 . Analogously, a medial fluid tuning medium portion 484 corresponds to medial circular tubular portion 474 . Hence, peripheral fluid tuning medium 480 , which includes both lateral fluid tuning medium portion 482 and medial fluid tuning medium portion 484 , may be referred to herein as peripheral fluid tuning medium 482 / 484 .
A central fluid tuning medium 442 is shown schematically being added (see FIGS. 12 and 13 ) to spaces including central circular tubular area 462 (labeled in FIG. 12 ). Note in FIG. 13 that medial portion 474 of peripheral circular tubular area 472 / 474 (with its medial fluid tuning medium portion 484 ) extends into (i.e., is partially surrounded by) medial flange 479 of resilient peripheral seal 470 . The central and peripheral circular tubular areas ( 462 and 472 / 474 respectively), with their respective central and peripheral fluid tuning media ( 442 and 482 / 484 respectively), constitute a first plurality of tunable vibration dampers in the form of a tunable radial array comprising two radially-spaced vibration dampers.
FIG. 14A illustrates a schematic 3-dimensional longitudinally-sectioned view of an alternate tunable check valve assembly embodiment comprising the valve body 410 (also shown in FIGS. 12, 13 and 14B ), together with a tunable valve seat 450 . Note that tapered mounting surface 452 of tunable valve seat 450 is intended for interfacing with a fluid end housing in which tunable valve seat 450 may be mounted. Detail breakout view A of FIG. 14 A shows that peripheral valve seat interface 434 is convex, having correspondingly greater curvature (as shown more clearly in section edge 436 ) than the concave mating surface 454 (as shown more clearly in section edge 456 ). The concave mating surface 454 has correspondingly less curvature than peripheral valve seat interface 434 to facilitate a circular rolling contact seal providing decreased contact area substantially along a circular line between the valve body's peripheral valve seat interface 434 and the tunable valve seat's concave mating surface 454 . As noted above, the circular rolling contact seal also increases longitudinal compliance of a tunable suction or discharge valve of the invention, with the added benefit of increasing the rise and fall times of the closing energy impulse (thus widening the closing energy impulse and narrowing the associated vibration spectrum). Widening the closing energy impulse in the time domain is reflected in an increased rebound cycle time, with a corresponding decrease in characteristic rebound frequency. Rebound cycle time and characteristic rebound frequency may thus be tuned for optimal damping.
FIG. 14B illustrates a schematic 3-dimensional longitudinally-sectioned view of an alternate tunable check valve embodiment comprising the tunable check valve assembly embodiment of FIG. 13 (having the above-described first plurality of tunable vibration dampers), together with a tunable valve seat (the tunable valve seat having a second plurality of tunable vibration dampers). The tunable valve seat of FIG. 14B comprises a plurality of tunable vibration-damping structural features including, for example, tunable valve seat 450 ′ with a concave mating surface 454 (surface 454 also being present in tunable valve seat 450 ). Tunable valve seat 450 ′ has the prime designation due to the inclusion of an adjustable lateral support assembly 724 / 722 / 720 / 718 / 716 / 714 / 712 / 710 , the lateral support assembly not being present in tunable valve seat 450 . The lateral support assembly interfaces with a fluid end housing in which tunable valve seat 450 ′ may be mounted, creating tunable coupling to the fluid end housing which differs from the coupling provided via tapered mounting surface 452 (see FIG. 14A ).
Considering the first plurality of tunable vibration dampers in greater detail, alternate tunable check valve assembly embodiment 442 / 410 / 470 / 480 (see, e.g., FIG. 13 ) is symmetrical about a longitudinal axis and comprises a plurality of radially-spaced vibration dampers (i.e., a tunable radial array of vibration dampers). A first vibration damper (i.e., a peripheral damper) is in the resilient peripheral seal 470 with its peripheral circular tubular area 472 / 474 and enclosed peripheral fluid tuning medium 482 / 484 . Peripheral circular tubular area 472 / 474 is responsive to cyclical longitudinal compression of the assembly (as, for example, due to increased proximal fluid pressure due to a pump pressure stroke).
Responsiveness to cyclical longitudinal compression is in-part secondary, e.g., to compression of resilient peripheral seal 470 against a tunable valve seat 450 or 450 ′ (see, e.g., FIGS. 14A and 14B ). Responsiveness to cyclical longitudinal compression is also in-part secondary, e.g., to alteration of the shape of peripheral seal groove 418 (see FIG. 13 ). The shape of peripheral seal groove 418 is imposed on resilient peripheral seal 470 due to relative movement of proximal and distal groove walls 418 ′ and 418 ″ (see FIG. 13 ) during longitudinal compression of the assembly against a tunable valve seat 450 or 450 ′ (see, e.g., FIGS. 14A and 14B respectively). Note, as above herein, that the proximal and distal designations assume a suction valve (as opposed to a discharge valve) configuration.
Note also that the valve body 410 comprises peripheral valve seat interface 434 having a convex curvature (see section edge 436 in FIG. 14A ). Peripheral valve seat interface 434 undergoes a substantially elastic concave flexure with slight circular rotation as the valve body 410 seats against a tunable valve seat such as 450 or 450 ′ (see FIGS. 14A and 14B respectively), each tunable valve seat embodiment having a concave mating surface 454 with correspondingly less curvature (see, e.g., section edge 456 in FIG. 14A ) than the peripheral valve seat interface (see e.g., section edge 436 in FIG. 14A ). As a result, peripheral valve seat interface 434 achieves a circular rolling contact seal with concave mating surface 454 of either tunable valve seat 450 or tunable valve seat 450 ′. That is, the structures for achieving a circular rolling contact seal with peripheral valve seat interface 434 are identical in tunable valve seats 450 and 450 ′.
Further considering the first plurality of tunable vibration dampers in greater detail, a second damper (i.e., a central vibration damper) is schematically illustrated in valve body 410 (see FIG. 12 ). The second damper comprises surge chamber 460 and receiving area 464 in fluid communication with central circular tubular area 462 via longitudinally-opposing fluid flow restrictors 466 / 468 . In the presence of central fluid tuning medium 442 , central circular tubular area 462 and longitudinally-opposing fluid flow restrictors 466 / 468 are responsive to cyclical longitudinal compression of the assembly, resulting in cyclically reversible reductions of the internal volumes of central circular tubular area 462 and receiving area 464 . Such reversible volume reductions in central circular tubular area 462 and receiving area 464 prompt flow of central fluid tuning medium 442 through the longitudinally-opposing fluid flow restrictors 466 / 468 to surge chamber 460 in association with valve closure shock and/or vibration. Such flow of central fluid tuning medium 442 reverses with each cycle of longitudinal compression.
Thus, each of the radially-spaced (i.e., peripheral and central) vibration dampers of the first plurality of tunable vibration dampers comprises a circular tubular area (e.g., peripheral circular tubular area 472 / 474 and central circular tubular area 462 respectively), and at least one such vibration damper is tunable to a predetermined frequency (e.g., a resonant frequency of a fluid end in which the assembly is installed). The tuning mechanisms may differ: e.g., via central fluid tuning medium 442 in central circular tubular area 462 and/or via peripheral fluid tuning medium 482 / 484 (shown combined as an instantaneous shape of peripheral fluid tuning medium 480 ) within peripheral circular tubular area 472 / 474 . Note that central fluid tuning medium 442 is shown schematically being added in FIG. 12 via a sealable port 422 (see FIG. 13 ) through guide 412 in valve body 410 . Control of variable fluid flow resistance and/or fluid stiffness (e.g., in the case of fluid tuning media comprising one or more shear-thickening fluids) facilitates predetermination of resonant frequency or frequencies in the central and peripheral vibration dampers.
Note also that central fluid tuning medium 442 might also or alternatively be added via sealable port 420 in (distal) base plate 416 . And further note that proximal valve body portion 414 in FIG. 13 is separately identified to call attention to the possibility of fabricating base plate 416 and proximal valve body portion 414 separately and then welding them together to form valve body 410 . The terms proximal and distal in this paragraph assume a suction valve configuration; in a discharge valve configuration the positions of the terms would be reversed.
In either case, tuning is a function of responsiveness of the respective vibration dampers to vibration generated by valve closure impact (see above discussion of the vibration spectrum of an impulse). For example, longitudinal force on the closed (suction) valve will tend to reduce the distance between longitudinally-opposing fluid flow restrictors 466 / 468 , simultaneously prompting flow of central fluid tuning medium 442 from central circular tubular area 462 into receiving area 464 and, with sufficient longitudinal force, into surge chamber 460 . When central fluid tuning medium 442 comprises one or more shear-thickening materials, vibration damping will be a nonlinear function of (the longitudinal-force-dependent) fluid flow resistance associated with longitudinally-opposing fluid flow restrictors 466 / 468 .
Note that the viscosity of the central fluid tuning medium 442 may vary with time when shear-thickening material(s) are present in the central fluid tuning medium 442 , thereby introducing nonlinearity for predictably altering the center frequency and/or the Q of the central vibration damper. Analogous predetermined viscosity variation associated with changes of instantaneous shape of peripheral fluid tuning medium 480 is available for predictably altering the center frequency and/or the Q (i.e., altering the tuning) of the peripheral seal vibration damper 470 / 472 / 474 / 480 as the resilient peripheral seal 470 distorts under the cyclical longitudinal compressive load of valve closure.
Note also that the peripheral seal vibration damper 470 / 472 / 474 / 480 comprises a medial flange 479 sized to fit within flange channel 419 of valve body 410 . See detail breakout view A of FIG. 13 showing flange channel 419 and a peripheral valve seat interface 434 for sealing against concave mating surface 454 (see FIG. 14A ). See also detail breakout view B of FIG. 13 showing medial flange 479 of resilient peripheral seal 470 , medial flange 479 partially surrounding medial portion 474 of peripheral circular tubular area 472 / 474 within resilient peripheral seal 470 . Those skilled in the art know that conventional peripheral valve body seals (analogous-in-part to resilient peripheral seal 470 ) tend to rotate within their retaining groove as a conventional valve body mates with a conventional valve seat. Considered as a whole, the peripheral seal vibration damper illustrated herein that comprises peripheral seal vibration damper 470 / 472 / 474 / 480 shows that such rotation will be resisted by the combined action of medial flange 479 within flange channel 419 , together with rotation resistance inherent in the wedge-shape (seen in longitudinal cross-section as in FIG. 13 ) of peripheral circular tubular area 472 / 474 with its peripheral fluid tuning medium 480 .
Facilitating such combined action, the medial portion 474 of peripheral circular tubular area 472 / 474 (portion 474 being partially surrounded by flange channel 419 ) will tend to stiffen medial flange 479 in a nonlinear manner. The stiffening of medial flange 479 is due in part to the presence of shear-thickening material in peripheral fluid tuning medium 480 (and particularly the medial fluid tuning medium portion 484 thereof) in peripheral circular tubular area 472 / 474 . Thus, a schematically illustrated example (see FIG. 13 ) of peripheral circular tubular area 472 / 474 is shown as containing peripheral fluid tuning medium 480 (peripheral fluid tuning medium portions 482 / 484 being shown as having the instantaneous shape schematically illustrated in FIGS. 13 and 14B ).
Combined action resisting rotation of peripheral seal vibration damper 470 / 472 / 474 / 480 is also facilitated by the wedge-shape (as shown schematically in longitudinal cross-section in FIG. 13 ) of the instantaneous representation of peripheral fluid tuning medium 480 within peripheral circular tubular area 472 / 474 . The wedge-shape has a relatively thicker portion adjacent to lateral boundary 481 and a relatively thinner portion adjacent to medial boundary 483 . As shown in FIG. 13 , the wedge-shape of the instantaneous representation of peripheral fluid tuning medium 480 tapers monotonically in thickness from the relatively thicker portion adjacent to lateral boundary 481 to the relatively thinner portion adjacent to medial boundary 483 .
Rotation of a peripheral seal vibration damper 470 / 472 / 474 / 480 as a whole would then necessarily require rotation of the instantaneous shape of peripheral fluid tuning medium 480 , with the thicker lateral portion translating proximally and medially (relative to more central portions of the valve body and seal assembly) during closure of a suction valve and compression of resilient peripheral seal 470 . Relative proximal translation of the more peripheral portion of resilient peripheral seal 470 occurs during valve closure for two reasons. The first reason (1) is: because the seal strikes the tunable valve seat first, causing the more peripheral seal portion to be distorted by the tunable valve seat contact, the peripheral seal portion being relatively free to move in relation to more central portions of the valve body and seal assembly due to the resilient character of the seal itself. The second reason (2) is: because of the elastic valve body concave flexure, with slight circular rotation, that accompanies valve closure (as described herein).
Note that slight circular rotation includes slight translation proximally and medially of the thicker lateral portion of the peripheral fluid tuning medium 480 . And medially directed force exerted on the peripheral seal by the tunable valve seat adds to the tendency of the thicker portion of the wedge-shaped peripheral fluid tuning medium 480 to rotate medially. But this medial movement would require compression of the relatively thicker lateral portion of instantaneous shape of peripheral fluid tuning medium 480 . Such thicker-portion compression of the peripheral fluid tuning medium 480 would be resisted nonlinearly, and relatively strongly, with consequent energy dissipation as heat in the shear-thickening material(s) within the fluid tuning medium. Thus, rotation resistance in peripheral seal vibration damper 470 / 472 / 474 / 480 as a whole contributes to dissipation of closing impulse energy. And such energy dissipation, in turn, contributes to vibration damping.
Further vibration damping in the illustrated alternate tunable check valve embodiment takes place in the second plurality of tunable vibration dampers. To support description of the damping in greater detail, alternate tunable check valve assembly embodiment 442 / 410 / 470 / 480 is shown in FIG. 14B combined with tunable valve seat lateral support assembly 450 ′/ 724 / 722 / 720 / 718 / 716 / 714 / 712 / 710 . The combination is analogous-in-part to that schematically illustrated in FIG. 11 . Formation of a circular rolling contact seal between the tunable valve seat's concave mating surface 454 and the correspondingly greater curvature of peripheral valve seat interface 434 is described above. The lateral support assembly comprises first and second adjustable end spacers ( 710 and 724 respectively) in combination with a plurality of tunable circular viscoelastic support elements ( 714 , 718 and 722 ). Each support element comprises a support circular tubular area ( 712 , 716 and 720 respectively). At least one such tubular area being substantially filled with at least one shear-thickening material analogous to material 80 (see, e.g., FIG. 5 ). Each shear-thickening material is chosen to achieve at least one predetermined assembly resonant damping frequency.
FIGS. 15 and 16A illustrate partial schematic 3-dimensional views of a tunable hydraulic stimulator embodiment 599 , FIG. 16A being an exploded view of stimulator embodiment 599 . FIG. 16B , in contrast, is an exploded view of a stimulator embodiment 699 , which is similar to embodiment 599 in some respects but different in its inclusion of several structures (e.g., a peripheral transverse coil 682 within coil form 680 and powered by cable 684 ). An additional difference between stimulators 599 and 699 is the multi-layer form of fluid interface 621 / 622 / 623 in stimulator 699 , compared to the single-layer form of fluid interface 520 in stimulator 599 .
In stimulator 599 , a hollow cylindrical housing 590 has a longitudinal axis, a first end 594 , and a second end 592 . First end 594 is closed by fluid interface 520 for transmitting and receiving vibration. Fluid interface 520 comprises at least one accelerometer 518 for producing an accelerometer electrical signal (i.e., an accelerometer-generated feedback signal) representing vibration transmitted and received via fluid interface 520 . In stimulator 699 , a hollow cylindrical housing 690 has a longitudinal axis, a first end 694 , and a second end 692 . Second end 692 is closed by fluid interface 621 / 622 / 623 for transmitting and receiving vibration. Fluid interface 621 / 622 / 623 comprises at least one accelerometer (e.g., a MEMS accelerometer represented by its cable connection 601 , 602 and/or 603 ) for producing at least one accelerometer electrical signal (i.e., an accelerometer-generated feedback signal) representing vibration transmitted and received via fluid interface 621 / 622 / 623 . Advantages of the more complex structure of stimulator 699 , compared to stimulator 599 , are explained in the following discussion.
Referring to stimulator 599 ( FIGS. 15 and 16A ), driver element 560 (comprising a field emission structure which itself comprises electromagnet/controller 564 / 562 ) reversibly seals second end 592 , and hammer (or movable mass) element 540 is longitudinally movable within housing 590 between driver element 560 and fluid interface 520 . In some embodiments, hammer element 540 may itself be a field emission structure consisting of a permanent magnet (or consisting of a plurality of permanent magnets). Polarity of any such permanent magnets is not specified because it would be assigned in light of the electromagnet/controller 564 / 562 . Alternatively, hammer element 540 may be analogous in part to the armature of a linear electric motor, as in a railgun. (See, e.g., the '205 and '877 patents noted above). Note that the above accelerometer-generated feedback electrical signal may be augmented by, or replaced by, sensorless control means (e.g., controlling operating parameters of electromagnet 564 such as magnetic field strength and polarity) in free piston embodiments of the tunable hydraulic stimulator. (See, e.g., U.S. Pat. No. 6,883,333 B2, incorporated by reference). The above description applies analogously to stimulator 699 , comprising driver element 660 and hammer 640 interacting with fluid interface 621 / 622 / 623 within housing 690 .
Thus, in stimulator 599 , hammer element 540 is responsive to the magnetic field emitted by driver element 560 for striking, and rebounding from, fluid interface 520 . In stimulator 699 , hammer element 640 is responsive to the magnetic field emitted by driver element 660 for striking, and rebounding from, fluid interface 621 / 622 / 623 . The duration of each such striking and rebounding cycle (termed herein the “rebound cycle time”) has the dimension of seconds. And the inverse of this duration has the dimension of frequency. Hence, the term herein “characteristic rebound frequency” is the inverse of a rebound cycle time, and the rebound cycle time itself is inversely proportional to the bandwidth of transmitted vibration spectra resulting from each hammer strike and rebound from fluid interface 520 or fluid interface 621 / 622 / 623 .
Fluid interface 520 or fluid interface 621 / 622 / 623 transmits vibration spectra generated by hammer impacts on the respective fluid interface, as well as receiving backscatter vibration from geologic formations excited by the transmitted vibration. Either fluid interface configuration comprises, for example, one or more MEMS accelerometers for producing an accelerometer signal representing vibration transmitted and received by the fluid interface. (See MicroElectro-Mechanical Systems in Harris, pp. 10-26, 10-27).
Hammer element 540 comprises a striking face 542 (see FIG. 16A ) which has a predetermined modulus of elasticity (e.g., that of mild steel, about 29,000,000 psi) which can interact with the modulus of elasticity of fluid interface 520 (again, e.g., that of mild steel). In an illustrative example, interaction of the two suggested moduli of elasticity predetermines a relatively short rebound cycle time for hammer element 540 , which is associated with a corresponding relatively broad-spectrum of vibration to be transmitted by fluid interface 520 . In other words, striking face 542 strikes fluid interface 520 and rebounds to produce a relatively short-duration, high-amplitude mechanical shock. (See, e.g., Harris p. 10.31).
In contrast, fluid interfaces of stimulators of class 699 (see FIG. 16B ) each comprise one or more disc-shaped thin members which are analogous-in-part to disc-shaped thin member 621 , disc-shaped thin member 622 and/or disc-shaped thin member 623 . The illustrated fluid interface embodiment 621 / 622 / 623 comprises the three illustrated disc-shaped thin members in a compact (e.g., laminated) subassembly for purposes of description only, but alternate fluid interface embodiments of the invention may contain more or fewer disc-shaped thin members. At least one disc-shaped thin member within fluid interface 621 / 622 / 623 comprises ferromagnetic amorphous alloy, the effective elastic modulus of which is magnetostrictively-responsive to a step-wise adjustable steady-state longitudinal magnetic field created by electrical current in peripheral transverse coil 682 which is schematically shown as enclosed in coil form 680 . The longitudinal magnetic field influences the effective hardness of, and thus the resonant frequencies of: (1) at least one disc-shaped thin member 621 , 622 and/or 623 and (2) the fluid interface 621 / 622 / 623 as a whole. Further, at least one disc-shaped thin member within fluid interface 621 / 622 / 623 comprises a vibration detector for generating a vibration electrical signals representing both vibration transmitted and characteristic backscatter vibration received via fluid interface 621 / 622 / 623 .
Note that neither vibration transmitted nor backscatter vibration received (as claimed in the present invention) are corrupted by electromagnetically-induced vibration of the fluid interface 621 / 622 / 623 . While electromagnetically-induced vibration of the fluid interface may occur during changes in the longitudinal magnetic field (e.g., during changes in an adjustable, alternating or time-varying magnetic field), such corruption of either vibration transmitted or characteristic backscatter vibration received is prevented in the present invention by limiting transmitted and received vibration measurements to periods when the step-wise adjustable longitudinal magnetic field is unchanging (i.e., when the field is in a steady-state).
Both FIGS. 15 and 16A schematically illustrate a tunable resilient circumferential seal 580 for sealing housing 590 within a wellbore, thus partially isolating vibration transmitted by fluid interface 520 within the wellbore. Seal 580 comprises at least one circular tubular area 582 which may contain at least one shear-thickening fluid 80 (see FIG. 5 ) which is useful in part for tuning purposes. And fluid 80 may comprise nanoparticles 82 for, e.g., facilitating heat scavenging.
FIG. 16A also schematically illustrates a first electrical cable 516 for carrying accelerometer feedback electrical signals (schematically representing vibration data transmitted by and/or received by fluid interface 520 ) from accelerometer 518 to driver element 560 . A second electrical cable 514 also connects to driver element 560 of each tunable hydraulic stimulator to schematically represent interconnection of two or more such stimulators (to form a tunable hydraulic stimulator array) and/or for connecting one or more down-hole tunable hydraulic stimulators to related equipment (e.g., programmable controller 650 as shown in FIGS. 17 and 18 ) proximal in a wellbore and/or adjacent to the wellhead. Accelerometer electrical signals provide feedback on transmitted vibration and also on received backscatter vibration to driver element 560 . Analogous cabling 696 is illustrated in FIG. 16B for connecting programmable controller 650 with accelerometer(s) 601 , 602 and/or 603 , with driver element 660 , including driver electronics 662 (via cable 614 ), and with peripheral transverse coil 682 (via cable 684 ).
While accelerometer-mediated feedback may be desired for tailoring stimulation to specific geologic formations and/or to progress in producing desired degrees for fracture within a geologic formation, predetermined stimulation protocols may be used instead to simplify operations and/or lower costs.
In certain embodiments, frac diagnostic software and data to implement sensorless control via operating parameters (e.g., magnetic field strength and polarity) of electromagnet 564 , or to implement feedback control incorporating accelerometer 518 , are conveniently stored and executed in a microprocessor (located, e.g., in controller 562 ). (See, e.g., U.S. Pat. No. 8,386,040 B2, incorporated by reference). See FIGS. 5 and 6 of the '040 patent reference, for example, with their accompanying specification.
Note, however, that while certain of the electrodynamic control characteristics of a tunable hydraulic stimulator may be represented in earlier devices, the tunable hydraulic stimulator's reliance on mechanical shock (e.g., generated by hammer strike and rebound) to generate tuned vibration (i.e., vibration characterized by approximately predetermined magnitude and/or frequency and/or PSD) imposes unique requirements indicated by the dynamic responsiveness of certain mechanical structures (e.g., hammers and fluid interfaces) to electromagnetic effects of field-emitting components (e.g., electromagnets and electret materials) as described herein. Variability of stimulation vibration is further responsive to one or more programmable controllers via, e.g., the power/data cable 514 , and/or an analogous communication medium or control link (see FIGS. 16A and 17 ). Such responsiveness may extend to other hydraulic stimulators and/or to wellhead or other auxiliary equipment (see, e.g., FIG. 17 ) that may 1) power the hydraulic stimulator, 2) receive and transmit stimulation-related data, 3) coordinate stimulator operation (e.g. vibration phase, frequency, amplitude and/or PSD) with related equipment, and/or 4) modify driver-related frac diagnostic software programs affecting tunable hydraulic stimulator operations.
Note also that in addition to individual applications of a tunable hydraulic stimulator, two or more such stimulators may operate in a combined tunable hydraulic stimulator array during a given stage of fracking (e.g., in a temporarily isolated section or stage of horizontal wellbore). Section isolation in a wellbore may be accomplished with swell packers, which may function interchangeably in part as the tunable resilient circumferential seals described herein. A single tunable hydraulic stimulator or an interconnected tunable hydraulic stimulator array may be programmed in near-real time to alter stimulation parameters in response to changing conditions in geologic materials adjacent to a wellbore. A record of such changes, together with results, guides future changes to increase stimulation efficiency.
In summary, the responsiveness of certain elements of a tunable hydraulic stimulator to other elements and/or to parameter relationships facilitates operational advantages in various alternative stimulator embodiments. Examples involving such responsiveness and/or parameter relationships include, but are not limited to: 1) driver element 560 comprises a field emission structure comprising an electromagnet/electronics 564 / 562 having cyclical magnetic polarity reversal characterized by a variable polarity reversal frequency; 2) longitudinal movement of hammer (or movable mass) element 540 is responsive to the driver cyclical magnetic polarity reversal; 3) longitudinal movement of hammer element 540 striking, and rebounding from, fluid interface 520 may be substantially in-phase with the polarity reversal frequency to generate vibration transmitted by fluid interface 520 ; 4) the driver element polarity reversal frequency may be responsive to accelerometer 518 's electrical signal (and thus responsive to vibration sensed by accelerometer 518 ; 5) longitudinal movement of hammer element 540 may be substantially in-phase with the polarity reversal frequency; 6) longitudinal movement of hammer element 540 striking, and rebounding from, fluid interface 520 has a characteristic rebound frequency which, as noted above, is the inverse of the rebound cycle time; 7) the hammer may rebound in-phase with polarity reversal and; 8) the rebound cycle time is a function of i) the cyclical magnetic polarity of driver element 560 and/or; ii) the moduli of elasticity of hammer element 540 and fluid interface 520 .
FIG. 17 schematically illustrates a 2-dimensional view of major components and interconnections of a tunable down-hole stimulation system 698 ′, together with brief explanatory labels and comments on component functions. As aids to orientation, a schematic wellbore is shown, including surface pipe connections with pumps. Hydraulic pathways are illustrated for transmitting broad-spectrum vibration to, and receiving band-limited backscatter vibration from, down-hole geologic material adjacent to the wellbore. The hydraulic pathways are shown passing to and from geologic material via, e.g., a preformed casing slot or an explosively-formed casing perforation.
The tunable down-hole stimulation system 698 ′ schematically illustrated in FIG. 17 is relatively sophisticated, employing several structures, functions and interactions that may appear in different invention embodiments (but that need not appear in all invention embodiments) and are described in greater detail below. To improve clarity, certain structures and functions inherent in the system of FIG. 17 are schematically represented in FIGS. 15-16 . For example, references to specific elements (e.g., hammer element 540 or fluid interface 520 ) should be understood with reference to FIGS. 15-16 . Further, the illustration of tunable down-hole stimulator 648 in FIG. 17 should be understood as including a tunable hydraulic vibration generator (labeled as such) which is analogous to the illustrated tunable hydraulic stimulator 599 in FIGS. 15-16 . So while a portion of tunable down-hole stimulator 648 should be understood as schematically analogous to tunable hydraulic stimulator 599 , it should also be recognized that stimulator 648 represents a different (expanded in part) subset of structures and functions not represented in stimulator 599 .
A first example of a tunable down-hole stimulation system is one of the embodiments schematically illustrated in portions of FIGS. 15-17 . The embodiment comprises at least one frac pump 688 for creating down-hole hydraulic pressure, together with at least one tunable down-hole stimulator 648 . Each stimulator 648 comprises a tunable hydraulic vibration generator (labeled in FIG. 17 ) for transmitting vibration hydraulically, as well as a programmable controller 650 for creating a plurality of control signals and transmitting at least one control signal to each said frac pump 688 and each said tunable down-hole stimulator 648 . Additionally, each tunable down-hole stimulator 648 comprises at least one accelerometer 518 for sensing vibration and for transmitting an electrical signal derived therefrom. And the programmable controller 650 is responsive to accelerometer 518 via the electrical signal derived therefrom.
A second example of a tunable down-hole stimulation system is one of the embodiments schematically illustrated in portions of FIGS. 15-17 . The embodiment comprises at least one frac pump 688 for creating down-hole hydraulic pressure, together with at least one proppant pump 618 connected in parallel with at least one frac pump 688 for adding exogenous proppant. The system further comprises at least one tunable down-hole stimulator 648 , each stimulator 648 comprising a tunable hydraulic vibration generator (labeled in FIG. 17 ) having a characteristic rebound frequency. A programmable controller 650 is included for creating a plurality of control signals and transmitting at least one control signal to each frac pump 688 , each proppant pump 618 , and each tunable down-hole stimulator 648 . Each tunable down-hole stimulator 648 comprises at least one accelerometer 518 for detecting vibration and for transmitting an electrical signal derived therefrom, and each accelerometer 518 is responsive to the characteristic rebound frequency. Finally, the programmable controller 650 is responsive to accelerometer 518 via the electrical signal.
A third example of a tunable down-hole stimulation system is one of the embodiments schematically illustrated in portions of FIGS. 15-17 . The embodiment comprises a wellbore comprising a vertical wellbore, a kickoff point, a heel, and a toe (all portions labeled in FIG. 17 ). At least one frac pump 688 creates down-hole hydraulic pressure in the wellbore, and at least one tunable down-hole stimulator 648 is located within the wellbore (and between the heel and toe as labeled in FIG. 17 ). Each stimulator comprises a tunable hydraulic vibration generator (labeled in FIG. 17 ), and a programmable controller 650 creates a plurality of control signals and transmits at least one control signal to each frac pump 688 and each tunable down-hole stimulator 648 . Each tunable down-hole stimulator 648 comprises at least one accelerometer 518 for sensing vibration and for transmitting an electrical signal derived therefrom, and the programmable controller 650 is responsive to accelerometer 518 via the electrical signal.
An alternative embodiment included in the tunable down-hole stimulation system 698 ′ of FIG. 17 , for example, comprises at least one frac pump 688 for creating down-hole hydraulic pressure. System 698 ′ further comprises at least one down-hole tunable hydraulic stimulator 648 for generation and transmission of broad-spectrum vibration, and for detection of backscatter vibration, stimulator 648 being hydraulically pressurized by frac pump 688 . A programmable controller 650 is linked to at least one frac pump 688 and at least one tunable hydraulic stimulator 648 for controlling down-hole hydraulic pressure and vibration generation as functions of backscatter vibration sensed by one or more detectors on at least one tunable hydraulic stimulator 648 . Each tunable hydraulic stimulator 648 comprises a movable mass or hammer element 540 (see FIGS. 15-16 ) which is movable via a field emission structure in the form of an electromagnet/controller 562 / 564 to strike, and rebound from, a fluid interface 520 (see FIGS. 15-16 ) for generating broad-spectrum vibration (see FIG. 17 ). At least one tunable hydraulic stimulator 648 detects the backscatter vibration via an accelerometer 518 coupled to fluid interface 520 (see FIGS. 15-16 ). An electric signal derived from accelerometer 518 is carried via link 516 , link 514 and at least one additional link 654 (labeled in FIG. 17 ) to programmable controller 650 . The broad-spectrum vibration indicated in FIG. 17 is characterized by a vibration spectrum having a predetermined PSD, and programmable controller 650 (see FIG. 17 ) alters the predetermined PSD during the course of stimulation as a function of the backscatter vibration.
The alternative embodiment of the tunable stimulation system 698 ′ described above may be further described as follows: tunable down-hole hydraulic stimulator 648 comprises a hollow cylindrical housing 590 having a longitudinal axis, a first end 594 , and a second end 592 , first end 594 being closed by fluid interface 520 for transmitting and receiving vibration, and fluid interface 520 comprising at least one accelerometer 518 for producing an accelerometer signal representing vibration transmitted and received by fluid interface 520 . A driver element 560 reversibly seals second end 592 , and driver element 560 comprises a field emission structure comprising an electromagnet/controller 562 / 564 having cyclical magnetic polarity reversal characterized by a variable polarity reversal frequency.
The alternative embodiment of the tunable stimulation system 698 ′ may additionally comprise at least one temperature sensor (labeled in FIG. 17 ). Down-hole hydraulic pressure may be sensed (as labeled in FIG. 17 ) and transmitted as a pressure signal derived therefrom. Programmable controller 650 (through change in one or more of the control signals it produces) is responsive to the pressure signal when present. Pressure may analogously be controlled as a function-in-part of both temperature and backscatter vibration sensed at tunable down-hole stimulator 648 . And predetermined PSD may similarly be altered as a function-in-part of both temperature and backscatter vibration sensed at tunable down-hole stimulator 648 .
In the above embodiments, a field emission structure may be responsive to at least one control signal (e.g., timed stimulator transmission signals and/or timed stimulator shift signals). Such responsiveness to at least one control signal is achieved, e.g., by emitting one or more electric and/or magnetic fields which are functions of at least one control signal as sensed by the field emission structure through change in one or more field emission structure electrical parameters. Thus, vibration transmitted by a down-hole hydraulic vibration generator may have a predetermined PSD which is a function of its rebound cycle time. The rebound cycle time, in turn, being dependent-in-part on one or more field emission structures that are themselves responsive to at least one control signal (e.g., a stimulator shift signal). A timed stimulator shift signal, in turn, may be responsive to one accelerometer feedback signal (e.g., via cable 516 in FIG. 16 ).
FIG. 18 schematically illustrates an embodiment 698 of an adaptive stimulation system which differs from embodiment 698 ′ of a tunable down-hole stimulation system in FIG. 17 . A portion of the 2-dimensional stimulation system view of FIG. 17 is reproduced in FIG. 18 , but differences between FIGS. 17 and 18 include replacement of a single tunable down-hole stimulator (in FIG. 17 ) with linear array 648 comprising three analogous tunable down-hole stimulators ( 638 ′, 638 ″ and 638 ′″) in FIG. 18 . Descriptions of functional features of stimulators in FIG. 18 resemble (in-part) analogous descriptions of the stimulator in FIG. 17 , but adaptive stimulation system 698 combines impulse-generated swept-frequency stimulation vibration with cyclically-varying hydraulic pressure to provide adaptive down-hole stimulation. Swept-frequency stimulation vibration arises from cyclical up-shifts and down-shifts of the PSD of impulse-generated stimulation vibration. The cyclical PSD shifts, in turn, are achieved via closed-loop control of the impulse-generated vibration produced by linear array 648 . PSD's may be adjusted for resonance excitation, fracturing and/or analysis of geologic materials at varying distances from a wellbore when combined with cyclically-varying down-hole hydraulic pressure.
Thus, a distinct functional feature of adaptive stimulation system 698 is creation of cyclically-varying down-hole hydraulic pressure by frac pump 688 in response to a timed pressure signal from programmable controller 650 . Further, descriptions of structural features of stimulators in FIGS. 17 and 18 resemble (in-part) analogous descriptions associated with FIGS. 15 and 16 . Thus, detailed labeling and/or annotating of stimulators in FIG. 18 are minimized to improve readability.
Stimulation linear array 648 may behave in-part in a manner analogous to that of a phased array antenna. For example, elective discrete time delays among sequential transmission times for vibration bursts from each stimulator in array 648 are controlled via timed stimulator transmission signals from programmable controller 650 so as to exert control over the propagation direction of the combined stimulation vibration (i.e., control over the directionally propagated array vibration wave front). Timed stimulator transmission signals, in turn, may have a phase relation (e.g., in-phase) with timed pressure signals sent to frac pump 688 .
And other timing issues affect vibration from each hydraulic stimulator in linear array 648 . For example, differences in individual rebound cycle times among the stimulators affect their individual PSD's. Adjustable rebound cycle times, in turn, may reflect changes in electrical parameters (e.g., magnetic field polarity, magnetic field strength, and/or the phase relationship of stimulator driver polarity reversal to hammer strike). Variability in adjustable rebound cycle times (e.g., non-uniform rebound cycle times) may also be responsive to timed stimulator shift signals from programmable controller 650 . Such variability may result in vibration interference among stimulators in a spatial array. Both constructive interference (i.e., increase in amplitude) at one or more frequencies and destructive interference (i.e., decrease in amplitude) at other frequencies are likely, providing higher stimulation vibration energy levels at a plurality of discrete frequencies within a vibration burst.
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Adaptive stimulation systems combine impulse-generated swept-frequency stimulation vibration with cyclically-varying hydraulic pressure to provide adaptive down-hole stimulation. Swept-frequency stimulation vibration arises from cyclical shifts of the power spectral density (PSD) of each stimulator's fluid interface vibration (via closed-loop control of the rebound cycle time and/or the fluid interface's effective elastic modulus). PSD's are adjusted for resonance excitation and fracturing of geologic materials at varying distances from a wellbore, closed-loop control incorporating backscatter vibration from stimulated geologic material. One or more stimulators generate vibration in bursts comprising a plurality of vibration frequencies. Timed signals from a programmable controller affect directional propagation of combined vibration wave fronts from a stimulator array. As fracturing proceeds to smaller (e.g., proppant-sized) fragments having higher resonant frequencies, PSD's are up-shifted, increasing relative stimulation vibration power in higher frequencies. Progressive stimulation is thereby optimized, facilitating plain-water (or liquefied propane) fracs with self-generated proppant.
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BACKGROUND OF THE INVENTION
In recent years joist girder floor and roof systems have become increasingly more popular as a structural system. Joist girders are a manufactured product and serve as a replacement for steel beams. In general, economic benefits will result in the substitution of joist girders for rolled beams in floor and roof systems. Conventional engineering practice is to design the joist girders as simply supported members, i.e. the ends of the joist girders are free to rotate. The design procedure follows design procedures established by the Steel Joist Institute in Standard Specifications for Joist girders adopted by Steel Joist Institute May 15, 1978, Steel Joist Institute, Richmond, Va. Steel joists which support flooring material or roof deck typically rest on the joist girders. The joist girders in turn are typically supported on steel or concrete columns. Typically, no attempt is made to achieve beam continuity by connecting the ends of the joist girders where they meet at a column.
The invention described herein relates to the use of end ties for connecting the adjoining ends of joist girders together, thereby providing continuity between joist girders at the supporting column. The purpose of using end ties is to create a horizontal end force through the ties to significantly reduce the axial forces in the upper and lower chords so that lighter weight chords can be employed to thus reduce the cost and weight of the joist girders required to accommodate the design load.
Continuity between adjoining structural elements and beams has been used for many years. For instance, steel beams are often positioned over the tops of supporting columns in a continuous manner, i.e. joined end-to-end. The use of continuous steel beams as opposed to simple span beams results in the use of smaller sized beams, thus reducing weight and cost. During the late 1950's plastic steel design concepts were developed in order to achieve an even greater economic benefit in continuous beam systems. This design concept is predicated on a material property characteristic of most structural steels. Specifically, the ability of steel to reach a given stress level (yield strength) and then to flow plastically without an increase or decrease in the stress level. The plastic design procedure makes use of this property by recognizing that once a beam reaches yield levels at highly stressed points the steel will "flow" and a redistribution of internal stresses will occur. This redistribution allows the designer to select beams of less weight, which again reduces cost. In addition to the required steel behavior, the steel beam must possess certain geometrical cross-sectional properties in order to permit the mentioned redistribution to occur without premature beam flange of beam web buckling. Should flange or web buckling occur prematurely, then the beam will not reach its full predicted load capacity and an inadequate factor of safety would exist. Most steel beams manufactured in the United States and foreign steel mills have the required geometrical cross-sectional properties to permit plastic design procedure.
Plastic design concepts permit the selection of a beam cross section to be based on an ultimate design moment of (1/16)wL 2 ; where w is the factored load per foot (safety factor times design load), and L is the beam span length. This moment is the optimum moment that can be used in design for a uniformly loaded structural member.
This optimum moment can also be achieved by using cantilever construction systems ("drop in systems"). These procedures have also been used for many years with steel beams and also in some cases with steel girders. Unlike plastic design procedures, this method does not rely upon yielding of the member or the reliance upon redistribution of stresses in the member in order to achieve the optimum moment condition of (1/16)wL 2 , but rather by judiciously selecting the length of a cantilever from the support. Currently both the plastic design technique and the cantilever construction method are in common use for steel beams. The Fish U.S. Pat. No. 2,588,225 illustrates the cantilever construction.
Joist girders have not been designed using plastic design procedures because of very special design precautions which must be followed. In 1973, Croucher and I proposed a construction in which plastic design concepts could be used for steel trusses; Croucher and Fisher, AISC Engineering Journal, First Quarter, 1973, Vol. 10, No. 2, l pages 20-32. This concept required fixity of the ends of the trusses to supporting columns, with the yieldable mechanism being the end portions of the upper chord. This was made possible by redesign of the conventional truss diagonal layout. However, since the required geometrical layout and the connection requirements are "non-standard" for fabricated trusses and for steel joist girder fabricators, the procedure is not readily used. Cantilever construction techniques are occasionally used with joist girders and trusses; however, they have not met with wide acceptance due to connection costs and because they do not fit withing standard product lines for joist girder manufacturers.
By means of the present invention, standard joist girder geometrical layouts can be used, with reduced chord sizes as compared to simple spans or fully continuous spans. Load (stress) redistribution can be accomplished as in plastic design of beams without cost penalty for connections or non-standard layout. The tie connection angles or plates can be designed to yield at a predetermined moment so that a maximum moment of (1/16)wL 2 is created. The end result is a significant weight savings in the joist girders without the penalty of high cost field connections or changing existing standard geometrical layouts.
Tie plate connections that yield have been used by designers of multi-story steel frames to connect beams to columns. This concept of "semi-rigid connections" or "wind connections" has been used to provide a given moment capacity at a beam to column joint. The connections are designed to provide a given (determined) moment resistance from the beam to the column. The present invention is not used to transfer moment from a beam to column, but rather to achieve a load transfer across the top of the column, i.e. to transfer moment (force) from joist girder to joist girder.
Other prior art of interest is U.S. Pat. No. 3,793,790. In this patent the object is to reduce the size of the column by using a deflection pad to reduce the column moment caused by deflection of the lower chord of a joist girder under load.
SUMMARY OF THE INVENTION
The primary objective of this invention is to reduce the required size of joist girders to support the design loads. This is accomplished by connecting the adjacent ends of the top chords of two joist girders together by steel ties. The ties are of a predetermined size and can be in the form of plates or angles and are attached to the adjacent ends of the top chords of the joist girder by welding, bolting or other suitable means. The ties have non-welded or unattached zones intermediate the welded ends to obtain the benefit of plastic elongation of the ties. Plastic elongation will allow the ties to reach and maintain a constant stress level and minimize premature fracture of the tie connection. It is also necessary that the joist girder seat not be tightly connected to the column or any structure which would restrain the lateral movement of the top of the joist girder at the support location, which would minimize the benefits of plastic elongation.
In addition, to obtain the maximum benefit of the invention, adjacent ends of the bottom chords of the joist girders must be connected together so that forces may be transferred from one bottom chord to the other without significant elastic or inelastic shortening. The ties of the invention thus allow the joist girder to rotate or pivot about the bottom chord at the support location, restrained only by the ties connecting the top chords. Based on a given steel yield strength, the ties are mathematically sized to yield when a given load is placed on the joist girder. Having reached the yielded condition, a constant force is maintained in the connection tie. With the application of additional vertical loads, the joist girders will continue to deflect and carry the additional load as would a simple and conventionally supported joist girder.
Further objects, advantages and features of the invention will be apparent from the disclosure.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary side elevational view of a joist girder and column connection with the top chord ties of the invention.
FIG. 2 is a plan view of the system shown in FIG. 1.
FIG. 3 is a plan view of a modified embodiment of a tie.
FIGS. 4A, B, C and D are force diagrams for different conditions between the upper chords of joist girders, with FIGS. 4A and 4D representing prior art conditions and FIGS. 4B and 4C illustrating connections within the purview of the invention.
FIG. 5 is a fragmentary enlarged view of the tie connection illustrated in FIGS. 1 and 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structure. While the best known embodiment has been described, the details may be changed without departing from the invention which is defined by the claims.
FIG. 1 shows two joist girders 6 and 8 and an intermediate supporting element of column 10 along a single framing line in a structure. Most structures which employ joist girders would include two or more of such frame lines. Joist girder seat 12 is attached by bolts 13 to the column cap 4. The bolts 13 secure the joist girders to the column against wind uplift and facilitate assembly. The bolts desirably extend through slots 15 in the flange 9 of the girder seat or the column cap 4 which enable plastic elongation of connecting ties as hereinafter described.
Also shown in FIGS. 1 and 5 is a steel joist seat 55 resting on top of the joist girder. The steel joist seat 55 is attached by bolts 56 to the joist girder top chord. The bolts desirably extend through slots 57 in the top chords 20, 22, which also enable plastic elongation of connecting ties as hereinafter described.
Each of the joist girders 6 and 8 include bottom chords 16, 18, top chords 20, 22, vertical members 23 and diagonal members 24. The bottom chords 16, 18 are bolted or welded to a plate or angle seat 30 which is fixed to the column 10. The plate 30 can extend through the column 10. Alternatively, the column 10 itself can provide the connection between the lower chords 16 to two adjacent joist girders.
In accordance with the invention, tie means are employed to connect the adjacent ends of the top chords 20 and 22. In the disclosed construction, the means illustrated in FIGS. 1, 2 and 5 comprises short lengths of angle stock 36, 38. The angle ties 36, 38 are welded to opposite sides of the top chords 20, 22 along weld zones 40, 42 along the top legs 47 of the ties and the top edge 49 of the upper chords 20, 22. The weld zones 40, 42 are separated by a non-weld or plastic stretch zone 44 (FIG. 5). In FIGS. 1 and 2, the vertical legs of the angle ties 36, 38 are spaced from the vertical legs of the top chords to provide a space for the bolts 56. In FIG. 5, the vertical legs are spaced from the top chords to accommodate the bolts securing the steel joists and to provide clearance for wide diagonals 24. In FIG. 5, the mouth formed by the legs of the angle ties is facing the chords rather than facing outwardly as in FIG. 1.
In the modified embodiment illustrated in FIG. 3, the tie means is in the form of a plate 48 with weld zones 50, 52 connecting the plate 48 to the top edges 49 of the upper chords 20 and a non-weld or plastic stretch zone 54. In the FIG. 3 embodiment, the upper chords are supported on seat angles 63 connected to the vertical sides of the column 10 rather than on the top of the column as illustrated in FIG. 1. The steel joist seat 58 is bolted at 61 or welded to the column cap 59. Thus slotted holes in the top chord of the joist girder are not required for plastic elongation to occur in the ties. Slots are required in the joist girder seat in FIGS. 1 and 5. The plastic stretch zone 54 is desirably equal to 1.2W. For the angle stock, W is equal to the sum of the adjoining leg lengths and for the plate 48, W equals the width of the plate 48. The 1.2W parameter is recommended in the design of semi-rigid connections for steel beams.
The function of the ties can be explained using the force diagrams 4A, 4B, 4C, 4D. The FIGS. 4A and 4D illustrate the forces in prior art joist girder assemblies. FIG. 4C is also illustrative of the truss design mentioned in Croucher and Fisher, AISC Engineering Journal, First Quarter, 1973, Vol. 10, No. 2, pages 29-32. FIGS. 4B and 4C illustrate joist girder assemblies using the tie means of the invention and a non-fixed connect-on of the joist girders to the supporting column, such as with bolts and slots as illustrated in the drawings. FIG. 4B has lighter weight ties than FIG. 4C and hence provides less horizontal force than generated in the 4C condition. However, the 4B condition is an improvement over the prior art and within the purview of the invention.
The chord force in the joist girder is equal to the moment divided by the centroidal distance d (the distance between the center of gravity of the upper and lower chords of the joist girder). A "simply" supported joist girder without any tie plates or end restraint which can rotate freely at its ends will have a force diagram as shown in FIG. 4A when subjected to a uniformly distributed load or gravity load. The maximum moment due to this loading will occur at mid-span and will equal M 1 =1/8wL 2 , where w is the load per foot of length and L is the span length. The chord force at the center of the joist girder will be M 1 divided by d. The size of the chord selected depends upon the chord force. A joist girder which is fully restrained at its ends, i.e. welded or bolted rigidly to a column or to an adjacent joist girder, will have a force diagram as shown in FIG. 4D. The maximum moment will be M 2 =(1/12)wL 2 . The size of the chords for this situation will be approximately fifty percent lighter than for the "simply" supported joist girder illustrated in FIG. 4A. This type of system is occasionally used; however, the cost of fully welded or bolted end connections may affect the cost benefits of the chord weight savings.
By properly sizing the tie angles or tie plates of this invention, the chord force can be varied between the simple span case FIG. 4A and the fully rigid case FIG. 4D. As material is added to the connecting ties, the shape of the force diagram will change progressively, as shown in FIGS. 4B and 4C. The optimum or balanced condition illustrated in 4C can be achieved when the end moment equals the interior moment M=(1/16)wL 2 or the force transferred through the ties equals the maximum chord force within the joist girders. This will result in minimum chord forces and thus a minimum weight design for the joist girder. In FIG. 4C, plastic elongation of the ties provides the desirable optimum moment of M=(1/16)wL 2 . In a tie connection where there is no plastic stretch zone, such as zone 44, because of continuous welding of the ties to the top chords plastic flow cannot occur. Thus redistribution of forces cannot occur. Without redistribution, designs must be predicated on the larger force F 2 (FIG. 4D) occurring in the tie connection and in the joist girder chords. This requires more steel in the chords as compared to F (FIG. 4C). Hence the steel savings is not as great as with the 4C case.
In FIG. 4B, some horizontal forces are present as compared with the "simply" supported joist girder condition illustrated in FIG. 4A. However, in FIG. 4B the chords would have to be sized larger than with the FIG. 4C tie condition.
Selection of the proper size of connecting tie angles or plate to achieve optimum conditions is accomplished as follows:
(1) The optimum end moment is first determined:
M=(1/16)wL.sup.2
(2) Based on a selected depth of joist girder, the force in the connecting ties is F=M/d.
(3) The area of connecting ties must equal the force divided by the steel yield strength.
(4) The connecting ties must then be attached to each joist girder top chord in a manner sufficient to transfer the force from the top chords through the connection ties and provide a plastic zone calculated to be equal to 1.2W.
With the appropriate chord ties, significant weight and cost savings result because optimum moments are used, thus reducing the size of the chords and hence the weight of and cost of the joist girders. In addition, standard joist girder geometrical layouts are used which is advantageous to the manufacturer and also the ties are less costly to use as compared to full continuity connections.
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A joist girder construction includes connecting ties which connect adjacent ends of joist girders at a point where they are supported. The ties include a non-welded zone to afford plastic elongation of the tie. The ties create an axial connection force between the top chords to reduce the force a load causes within the joist girder to thus reduce the size of the upper and lower joist chords to minimize overall weight and expense.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to U.S. patent application Ser. No. 12/469,563, filed concurrently herewith, the specification of which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The embodiments disclosed herein relate generally to the field of semiconductor selection devices and, more particularly, to access devices for semiconductor memory devices.
BACKGROUND OF THE INVENTION
[0003] A non-volatile memory device is capable of retaining stored information even when power to the memory device is turned off. Traditionally, non-volatile memory devices occupied large amounts of space and consumed large quantities of power. As a result, non-volatile memory devices have been widely used in systems where limited power drain is tolerable and battery-life is not an issue. However, as systems requiring non-volatile memories have continued to shrink in size, improvements in non-volatile memory devices have been sought in order to make these devices more suitable for use in portable electronics or as substitutes for frequently-accessed volatile memory devices. Desired improvements include decreasing the size and power consumption of these memories and improving the memory access devices.
[0004] Improved non-volatile memory devices under research include resistive memory cells where resistance states can be programmably changed. Resistive memory cells store data by structurally or chemically changing a physical property of the memory cells in response to applied programming voltages, which in turn changes cell resistance. Examples of variable resistance memory devices being investigated include memories using variable resistance polymers, perovskite materials, doped amorphous silicon, phase-changing glasses, and doped chalcogenide glass, among others. Phase change memory (“PCM”) cells have varying resistances as a result of changes in the crystal phase of the cell material. Spin-tunneling random access memory (“STRAM”) cells have varying resistances as a result of changes in current induced magnetization of the cell material.
[0005] For many resistive memory cells, changing the cell resistance is accomplished by passing an electrical current of sufficient strength through the resistive memory cell. For phase change memory cells and spin-tunneling memory cells, for example, programming and reset currents of 50 to 100 μA are not uncommon. However, these high currents result in extremely high current densities as the size of the memory cells continues to shrink. For example, for a 20×20 nm 2 memory cell, the resulting current density is of the order of 1×10 7 A/cm 2 or greater. For such high current densities, improved memory access devices are desired to provide high currents and low “off” state leakage.
[0006] Improved access devices such as those desired for use with resistive memory cells could also be used to provide high currents to any type of memory or semiconductor circuit that requires a high current.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates a vertically-oriented semiconductor transistor device.
[0008] FIGS. 2A and 2B illustrate a memory cell and a memory access device, according to one or more embodiments of the disclosure.
[0009] FIGS. 3A , 3 B and 3 C illustrate an array of memory cells and memory access devices, according to one or more embodiments of the disclosure.
[0010] FIG. 4 illustrates a processing system utilizing a memory array, according to one or more embodiments of the disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0011] Traditional memory access devices are planar in nature, meaning that the access devices are formed layer by layer within the plane of the underlying structure. The underlying structure includes a substrate that is a base material and layers formed on the surface of the substrate. The substrate and overlaying layers on top of the substrate are flat or planar. The access devices are formed within these layers so that the resulting devices are also laid out in a planar arrangement. As a specific example, a planar field-effect transistor (“FET”) is a FET with a conductive channel that is within the layers of the underlying structure. Planar access devices have a relatively large footprint since area is required for source and drain contacts as well as isolation between the contacts.
[0012] Non-planar access devices are alternatives to planar devices. Non-planar access devices are access devices that are not flat or planar and can be oriented in a vertical direction from a substrate. These devices can include raised portions that extend above the planar surface of the underlying structure. An example of a non-planar access device is a fin-FET. A fin-FET is a FET that includes thin vertical “fins” of the underlying substrate material that act as the transistor body. The source and drain of the fin-FET are located at the ends of the fin, while one or more gates are located on a surface of the fin. Upon activation, current flows through the fin. The thin vertical structure results in significant space savings over traditional planar access devices.
[0013] FIG. 1 illustrates a vertical FET 100 . The vertical FET 100 includes a thin vertical fin or mesa 120 through which current flows vertically between a source 130 and a drain 140 . The mesa 120 extends above a substrate 555 . In the example vertical FET 100 , the substrate 555 and the mesa 120 are formed of silicon. The source 130 and drain 140 regions are both either n-doped or p-doped, while a vertical current channel 125 is either p-doped or n-doped, accordingly. A gate 150 is formed along a sidewall of the mesa 120 . Additional gates 150 may be formed. In the example of FIG. 1 , two gates 150 are formed on opposite sidewalls of the mesa 120 , although vertical FET 100 may also be formed with only a single gate 150 . Gates 150 are separated from the sidewalls of the mesa 120 by thin gate insulators 155 such as a gate oxide layer. The thin gate insulators 155 are L-shaped in order to insulate the gates 150 from contact with the mesas 120 and the substrate 555 or any conductor on the substrate 555 . The gates 150 may be formed of polysilicon. When an appropriate bias is applied to one or more of the gates 150 , current flows vertically through the channel 125 from the source 130 to the drain 140 .
[0014] In a disclosed embodiment, the vertical FET 100 may be used as a selection device such as a memory access device 200 for one or more electrical devices, as illustrated in the structure of FIG. 2A and the schematic diagram of FIG. 2B . In FIG. 2A , a memory cell 220 is electrically coupled to the vertical FET device 200 . The memory cell 220 includes a top electrode 222 and a bottom electrode 224 . The bottom electrode 224 is coupled to a contact 240 for the drain 140 . The source 130 is coupled to a contact 230 . Upon appropriate biasing of the source contact 230 , the gate 150 and the top electrode 222 , the vertical FET 100 is turned “on” and current flows through the channel 125 and memory cell 220 . With appropriate biasing, the current flowing through the memory cell 220 is strong enough to be used as a programming or reset current for the memory cell 220 .
[0015] The memory access device 200 and the memory cells 220 are generally formed in an array of access devices 200 and memory cells 220 . Thus, the source contact 230 may extend a relatively long distance from the source 130 of memory access device 200 to the nearest voltage source. Additionally, source contacts 230 may be shared by multiple access devices. In order to facilitate the shared contacts 230 and to minimize the effect of parasitic resistance, the contacts 230 are formed of metal silicide 250 . In other words, the substrate 555 surface near the bottom of the mesa 120 is silicided with metal such as Ni, Co or Ti. The metal silicide 250 (also known as a salicide) near the bottom of the mesa 120 (or the source metal silicide layer 252 ) acts to reduce the series resistance that results from using a common current source contact for each individual access device 200 in an array. The source contacts 230 may also be formed of heavily doped silicon as long as the resistance of the doped silicon is low enough to carry the required current.
[0016] Additionally, the drain contact 240 is also formed of a metal silicide 250 which helps to reduce contact resistance between the access device 200 and the bottom electrode 224 of the memory cell 220 . The metal silicide 250 formed on the upper portion of the access device 200 is the drain metal silicide layer 251 .
[0017] In a disclosed embodiment, the access devices 200 and the memory cells 220 are arranged in an array 300 as illustrated in FIG. 3A . In FIG. 3A , a silicon substrate 555 is shown. Rising from the silicon substrate 555 are four silicon mesas 120 . Other substrate and mesa material, such as Ge, SiC, GaN, GaAs, InP, carbon nanotube and graphene, for example, may be used instead of silicon. Additionally, the array 300 generally includes many more than just four mesas. The illustration of the array 300 is simplified in order to aid explanation.
[0018] The mesas 120 each include source 130 , drain 140 and gate 350 regions. The gate 350 regions are formed on one or more sidewalls of the silicon mesas 120 and are commonly shared between mesas 120 . In the example of FIG. 3A , gates 350 are formed on two opposite sides of each mesa 120 , thus forming double-gated vertical FETs. Single-gated vertical FETs (i.e., only one gate 350 on a mesa 120 ) or surround-gated vertical FETs (i.e., the gate 350 surrounds mesa 120 ) may also be formed. The sidewall gates 350 extend along the column of mesas 120 so that each column of mesas 120 includes at least one common sidewall gate 350 . The sidewall gates 350 may also be silicided. The source 130 regions of each mesa 120 are electrically coupled with the source metal silicide layer 252 which covers the surface of the silicon substrate 555 . In this way, source 130 regions for multiple mesas 120 are electrically coupled together to form shared sources 130 . Source 130 regions may also merge into a single common source 130 . The drain 140 regions are electrically coupled to the drain metal silicide layer 251 which covers the top portion of the mesas 120 . The gates 350 are insulated from the silicide layers 251 , 252 by the thin gate insulator 155 . In order to further insulate gates 350 from the silicide layers 251 , gate 350 need not extend all the way to the top edge of the mesas 120 .
[0019] The memory cells 220 are electrically coupled via a bottom electrode 224 to the drain metal silicide layer 251 located on the upper surfaces of the mesas 120 . The top electrode 222 of each memory cell 220 is electrically coupled to a conductor 322 . In one embodiment, conductor 322 may extend horizontally in a direction perpendicular to the direction that the sidewall gates 350 extend. Other array layouts are contemplated where conductor 322 may extend in a direction other than perpendicular to sidewall gates 350 .
[0020] A simplified top view of the array 300 is illustrated in FIG. 3B . From the top view, it is apparent that all access devices 200 and memory cells 220 share a common source metal silicide layer 252 that surrounds the base of each mesa 120 . Access devices 200 in the same column share a common gate 350 . Additionally, gates 350 may be formed on all sides of each access device 200 , resulting in a surround-gated vertical FET, as illustrated in FIG. 3C . Memory cells 220 in the same row share a common conductor 322 . The common conductor 322 may be made of metal, but may also be made of other conductive materials such as polysilicon, for example. Memory cells 220 are coupled to the upper portion of each mesa 120 via a drain metal silicide layer 251 .
[0021] Individual memory cells 220 are activated (meaning that a desired current flows through the memory cell 220 ) by the appropriate biasing of the source 130 , the respective gate 350 and the respective conductor 322 . While biasing the source 130 or any one of the gates 350 or conductors 322 may affect multiple memory cells 220 , activation of a specific memory cell 220 is only accomplished through the appropriate biasing of that cell's gate 350 and conductor 322 .
[0022] By using a common source 130 and by surrounding the base of each mesa 120 with a metal silicide 250 (the source metal silicide layer 252 ), the parasitic resistance in the source is reduced. The source metal silicide layer 252 provides additional current paths, resulting in higher current flow. In this example, because every mesa 120 shares a common source 130 , a dedicated contact is not required for any specific strip of source metal silicide layer 252 . Thus, efficiency of current flow through the source metal silicide layer 252 to a specific mesa 120 may be improved. Additionally, by using a drain metal silicide layer 251 on the top surface of each mesa 120 , the contact resistance between the access device 200 and the bottom electrode 224 of each memory cell 220 is reduced.
[0023] The memory access devices of array 300 are able to provide large amounts of current through any selected memory cell 220 . In array 300 , access devices share common sources 130 because of the source metal silicide layers 252 . Mesas 120 in the array 300 share a common source 130 . Thus, the source metal silicide layer 252 helps to facilitate a larger source current.
[0024] It should be appreciated that the array 300 may be fabricated as part of an integrated circuit. The corresponding integrated circuits may be utilized in a processor system. For example, FIG. 4 illustrates a simplified processor system 700 , which includes a memory device 702 that includes array 300 in accordance with any of the above described embodiments. A processor system, such as a computer system, generally comprises a central processing unit (CPU) 710 , such as a microprocessor, a digital signal processor, or other programmable digital logic devices, which communicates with an input/output (I/O) device 720 over a bus 790 . The memory device 702 communicates with the CPU 710 over bus 790 typically through a memory controller.
[0025] In the case of a computer system, the processor system 700 may include peripheral devices such as removable media devices 750 (e.g., CD-ROM drive or DVD drive) which communicate with CPU 710 over the bus 790 . Memory device 702 can be constructed as an integrated circuit, which includes one or more phase change memory devices. If desired, the memory device 702 may be combined with the processor, for example CPU 710 , as a single integrated circuit.
[0026] The above description and drawings should only be considered illustrative of exemplary embodiments that achieve the features and advantages described herein. Modification and substitutions to specific process conditions and structures can be made. Accordingly, the claimed invention is not to be considered as being limited by the foregoing description and drawings, but is only limited by the scope of the appended claims.
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A vertical semiconductor material mesa upstanding from a semiconductor base that forms a conductive channel between first and second doped regions. The first doped region is electrically coupled to one or more first silicide layers on the surface of the base. The second doped region is electrically coupled to a second silicide layer on the upper surface of the mesa. A gate conductor is provided on one or more sidewalls of the mesa.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED-RESEARCH OR DEVELOPMENT
[0002] Not Applicable
TECHNICAL FIELD
[0003] This invention is related to a method and apparatus for dynamically determining the optimal page size to use for an application running in a computer system.
BACKGROUND OF THE INVENTION
[0004] Referring to FIG. 1 , there is shown a typical data processing system 10 comprising a central processing unit (CPU) 12 which occasionally requires accesses to data elements stored in the physical memory 14 . The CPU 12 specifies particular elements using virtual addresses which are mapped to real addresses by the Dynamic Address Translation (DAT) unit 16 . To minimize the overhead for maintaining a description of the current mapping, contiguous blocks of virtual memory are mapped to contiguous blocks of real memory. The size of the block is called a “page”. A page typically contains one or more records and, for many computers, comprises 4096 bytes, where a byte is the number of bits required to represent a single character (usually 8 bits). However, in the description of the present invention, the term “page” may be any arbitrary block of data. To improve performance, mapping information for recently translated pages is maintained in the DAT unit with a Translation Look-aside Buffer (TLB) 18 . While, for illustrative purposes, the CPU 12 is depicted as being separate from the dynamic address translation mechanism, both these items may be on the same chip.
[0005] With the advent of multiple page size support in most modem operating systems, applications can significantly benefit by selecting an appropriate page size to use to attain the best performance. On a system that supports two page sizes, for example 4 KB and 64 KB, applications which access small dispersed chunks of memory (from a program address' perspective) are better off using the smaller page size of 4 KB. The trade-off in page size selection is typically increased memory fragmentation and longer page-in and page-out delays for larger page sizes versus increased TLB (Translation Look-aside Buffer) misses with decreased fragmentation and shorter page-in and page-out delays for smaller page sizes.
[0006] A Translation Look-aside Buffer (TLB) is a hardware apparatus with which a processor can efficiently translate the virtual/effective addresses used by the applications to the real/physical addresses used by the memory controller/coherence controller, etc. The TLB is organized as a list of entries, where each entry maps a contiguous range of virtual addresses (e.g. one page) to a contiguous range of physical addresses of the same size. The size of a TLB (number of entries) is limited by the amount of time it takes to associatively search the TLB entries.
[0007] Whenever there is a TLB miss (i.e. a TLB entry cannot be found for the given virtual address), the processor looks up the virtual-to-real address translation in the page table. Page table lookup is a much more time consuming operation than a TLB lookup. So, from the application performance's point of view, and also from the overall system throughput's point of view, it is best to have as few TLB misses as possible.
[0008] Since increasing the page size of each TLB entry amounts to increasing the amount of memory covered by the TLB at any point in time (“TLB reach”), one might think that one way of reducing the number of TLB misses is to increase the size of the address range (page size) referred to by each TLB entry. However, increasing page size may not necessarily result in reduction in the number of TLE misses, which can vary for each application depending on the memory access behavior of that application. For example, if an application's memory access patterns are highly dispersed, then increasing the page size would not result in any reduction in TLB misses; moreover, increasing page size may cause memory fragmentation, thereby resulting in lower memory utilization for the OS.
[0009] Currently, the application programmer or the system administrator has to know the memory access patterns of the application and instruct the operating system to use the best page size for each application. This becomes even more complex because users often want to run their applications on different platforms, but different platforms support different page sizes. Hence, an application programmer has to know which platforms the application is going to run on, which page sizes are supported on those platforms, and what is the best page size to use on each of those platforms. On a given platform, requiring the system administrator to select the right page size for each application introduces an even bigger problem of the sysadmin having to know each application's characteristics. It also involves much manual work, and hence increases the probably of errors.
[0010] One attempt to relieve the programmer of the burden of having to adjust page size is a method known as “preemptive reservation”, where the Virtual Memory Manager (VMM) reserves large page sizes, but “takes back” the unused reserved memory if there is a demand for real memory. While “preemptive reservation” is effective against fragmentation, it is not effective against TLB misses. “Preemptive reservation” is described in the following paper: Juan Navarro, Rice University and Universidad Catolica de Chile; Sitaram Iyer, Peter Druschel, and Alan Cox, Rice University; Practical, Transparent Operating System Support for Superpages ; Fifth Symposium on Operating Systems Design and Implementation, December 2002.
[0011] There is therefore a need for automatic and dynamic changing to an optimum page size determined as a result of running an application.
OBJECTS OF THE INVENTION
[0012] It is, therefore, an object of this invention to autonomically determine and dynamically set the page size of an application to an optimal value by tracking the number of virtual to real address translation mechanism misses (for example, TLB (Translation Look-aside Buffer misses) for each page size per unit of time incurred during the execution of that application on a given platform (i.e. hardware and operating system combination).
[0013] It is another object of this invention to eliminate the need for the system administrator to manually specify the optimal page size for an application.
[0014] It is another object of this invention to eliminate the need for the application programmer and/or system administrator to know the correct page size to use for an application's memory accesses, and the need to know the different page sizes available on a given platform.
SUMMARY OF THE INVENTION
[0015] This invention uses a mechanism to keep track of the number of virtual to real address translation caching mechanism misses, such as TLB misses, on a per-process basis, associates an application with a set of processes, determines the optimum page size for the application based on the miss counts for the application's processes, and optionally, dynamically sets the optimal page-size for the running application. This invention can also be used to discover different optimal page sizes for different memory regions in the process.
[0016] This invention provides a mechanism to determine the optimal page size for an application by monitoring the TLB misses for different page sizes.
[0017] This invention provides a mechanism to maintain the list of frequently used applications whose TLB misses are worth tracking, to identify the list of processes of each application, to enable/disableTLB-miss-tracking for each of the processes, to maintain the TLB misses on a per-process basis, and to consolidate the per-process TLB misses into per-application TLB misses, and finally to determine whether the page size of each application should be changed based on its TLB misses.
[0018] With this invention, the application programmer and/or system administrator is relieved of the need to know the correct page size to use for the application's memory accesses, and the need to know of the different page sizes available on a given platform. This invention also eliminates the need for the system administrator to manually specify the optimal page size for the applications.
[0019] Most computer platforms already have a mechanism to accumulate the TLB miss counts. This invention uses such a mechanism to keep track of the number of TLB misses on a per-process basis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features and also the advantages of the invention will be apparent from the following detailed description taken in conjunction with the accompanying drawings.
[0021] FIG. 1 shows a portion typical data processing system with a processor, Dynamic Address Translation Table (DAT), Translation Look-aside Buffer (TLB), and memory for implementing one embodiment of the present invention.
[0022] FIG. 2 is a flow diagram graphically illustrating a method of maintaining the Application State Table that is used for implementing one embodiment of the present invention.
[0023] FIG. 3 is a flow diagram graphically illustrating a method of maintaining the Application Page Size Data Table that is used for implementing one embodiment of the present invention.
[0024] FIG. 4 graphically illustrates the Application Page Size Data Table that is used for implementing one embodiment of the present invention.
[0025] FIG. 5 graphically illustrates the Application State Table that is used for implementing one embodiment of the present invention.
[0026] FIG. 6 graphically illustrates the Application Processor List that is used for implementing one embodiment of the present invention.
[0027] FIG. 7 graphically illustrates how the Translation Look Aside Buffer (TLB) miss counter is maintained for one embodiment of the present invention.
[0028] FIG. 8 is a high level block diagram showing an information processing system useful for implementing one embodiment of the present invention
DETAILED DESCRIPTION OF THE INVENTION
[0029] This invention provides a mechanism to determine the optimal page size for an application by monitoring the TLB misses for different page sizes. This detailed description describes:
[0030] 1. A mechanism to maintain the list of frequently used applications whose TLB misses are worth tracking.
[0031] 2. A mechanism to identify the list of processes of each application, and to enable/disable TLB-miss-tracking for each process.
[0032] 3. A mechanism to maintain the TLB misses on a per-process basis.
[0033] 4. A mechanism to consolidate the per-process TLB misses into per-application TLB misses, and to determine whether the page size of each application should be changed.
[0034] Although it is assumed for the purposes of illustration that one single page size is used for all of the application's data, the methods described in this invention can be used even when different address regions of the application use different page sizes. The hardware could provide a mechanism to obtain the TLB miss data for each region while the OS provides mechanisms to get and set the page size value for each address region.
[0035] The current invention is not limited to TLB-based systems; it is also applicable to any virtual-to-real address translation caching mechanisms.
[0036] 1. A mechanism to maintain the list of frequently used applications whose TLB misses are worth tracking. See FIGS. 2, 4 , and 6 .
[0037] Referring to FIG. 2 , the first step is to identify applications whose TLB misses are worth tracking. The idea is that the server operating systems typically run a small number of frequently used applications which utilize operating system (OS) resources heavily and run many other infrequently used applications which utilize OS resources sparingly. Since tracking TLB misses adds overhead, one should track the TLB misses for only those applications that can provide significant benefits from using a higher page size. To identify these applications, a user mode daemon periodically polls the OS for the list of applications and processes that are currently running as shown in 201 of FIG. 2 . Then, a list of processes belonging to each application is identified 202 and maintained in a Application Process List 600 of FIG. 6 . Then, in step 203 of FIG. 2 , each application in the List 600 is selected, and examined as described in steps 204 to 210 to maintain the Application State Table 400 of FIG. 4 . In step 204 of FIG. 2 , it is determined if an application is listed in the Application State Table 400 . If the application is listed then the state of the application is checked. If the application is in the “Evaluate” state ( 205 ), then in step 206 , the application's run frequency counter is incremented. If the counter exceeds a threshold ( 207 ), then the application state is set to “Track” ( 208 ). On the other hand, if the frequency counter is below the threshold ( 207 ), the application is removed ( 209 ) from the Application Process List. However, if the listed application was originally found to be in the “Do Not Track” state 210 , then the application is removed from list 600 . If in step 204 , the application was not found in the Application State Table 400 , then the application is added to the Table 400 as shown in step 211 of FIG. 2 . This added application is initialized to the “Evaluate” state, and its frequency counter is initialized to 0. Then, in step 206 , the added application's frequency counter is incremented to determine its final state. If there are any additional applications in the List 600 to be examined, then the state of the application is updated by starting at step 203 . If there are no more applications to be examined ( 212 ), then the Application Page Size Table is maintained as shown in FIG. 3 .
[0038] An alternative mechanism to identify the frequently used applications that are worth tracking is to use the Operating system provided accounting tools. Operating systems typically come with software tools that enable system administrators to keep track of which applications are running on the system, which users are logged on to the system and for how long, etc. These tools are referred to as “accounting tools” since they are used to track the usage of the system and charge the customers based on the usage.
[0039] Referring now to FIG. 3 , the Application Page Size Table is maintained by first setting a pgszTrace flag (See below.) for each process of each application ( 301 ) in the Application Process List 600 . Then, in step 302 , the user daemon reads all the TLB miss counters and corresponding CPU times for all the processes by invoking a system call get_tlb_misses as described below.
get_tlb_misses ( pidTlbMisses_t *buf, int *n_entries).
This system call reads all the per-process data structures in the kernel and stores the TLBmisses and clockTics values into the buf provided.
[0040] The type pidTlbMisses_t is defined as follows:
typedef struct { pid_t pid; /* Process identification number */ long nTLBmisses; /* TLB miss counter */ time_t clockTics; /* CPU time used by the process */ } pidTlbMisses_t;
[0041] In step 303 the TLB miss counters and corresponding CPU times for each application are calculated by adding all the TLB miss counters of all the processes belonging to each application. Note, that instead of simply adding TLB miss counter values, one could also add weighted TLB miss counter values. In step 304 , the Application Page Size Table 500 of FIG. 5 is updated with the calculated TLB miss counter values inserted in column 503 and corresponding CPU times inserted in column 504 . In step 305 each application in the Application Page Size Table 500 is examined as described below. In step 306 the CPU time is checked to determine if more tracking is needed by comparing the CPU time with a minimum running time threshold value. If the running time is below the threshold, then the next unexamined application ( That is, the application was not checked for a sufficient CPU time period or to determine if all page sizes were tried as described in steps 306 - 307 of FIG. 3 ) in the Table 500 is selected. If, on the other hand, the running time is above the threshold, then ( 307 ) the Application Page Size Table 500 is checked to see if there are any more page sizes to try for the current application being processed. If there are no more page sizes to examine, then as indicated in 308 , the Application Page Size Table 500 is examined to determine which page sized yielded the minimum TLB misses per unit time as indicated in the TLB miss counters. In addition, in step 308 the Application State Table 400 of FIG. 4 is updated to put the current application in the “Do Not Track” state; so that it will no longer be tracked for TLB misses. On the other hand, in step 307 , if it is found that there are some page sizes that still need to be tried, then the application page size is set to the next untried page size as indicated in step 309 . After steps 308 and 309 , the Application Page Size Table is checked to see if there are any more applications that need to be examined as shown in 310 . If there are any remaining applications to be examined, then next unexamined application in the Application Page Size Data Table 500 is selected in step 305 and examined in steps 306 to 309 . If, however, all the applications in the Table 500 have been examined, then the user mode daemon sleeps for a period of time ( 311 ) and proceeds to step 201 of FIG. 2 after waking up.
[0042] Tables 400 , 500 , and List 600 are described below.
[0043] Shown in FIG. 4 is an appState table (Application State Table) 400 that is used to keep track of the run frequency counters for each application listed therein. The first column 401 lists the applications in the table, and the corresponding state of each application is listed in column 402 . Columns 403 and 404 include the frequency counter values and the time stamps respectively. The states are described immediately below.
[0044] TRACK→the application is already marked for TLB miss tracking;
[0045] EVALUATE→the application is being evaluated to determine whether its TLB misses should be traced;
[0046] DO_NOT_TRACK→the application should not be tracked for TLB misses.
[0047] FIG. 4 , for example, shows two applications (See 402 .), where the first application (APP 1 ) is in the TRACK state and the second application (APP 2 ) is in the EVALUATE state with the frequency counter at 1200 (See 403 .). The frequency counter 403 measures the number of times the application is found to be running since the time stamp 404 . The time stamp 404 is an indication of when the application was found to be running for the first time, which is measured by the number of seconds that elapsed since the system was booted.
[0048] Once an application is identified as a candidate whose TLB miss rate should be tracked, it will be added to an appPgSzData table as shown in FIG. 5 . This table ( 500 ) will be used to maintain information about the TLB misses for different page sizes for an application (See 501 .). For example, in FIG. 5 , there are four entries, each indicating the number of TLB misses (See 503 .) and the corresponding number of clock ticks ( 504 ) for a specific page size ( 502 ) for a specific application (See 501 .).
[0049] FIG. 6 shows how the Application Process List 600 is maintained. Each application 601 has a link to the list of all the processes 602 that belong to it. This list is dynamically expanded and shrunk as new applications and processes are created in the operating system (OS), and old ones are terminated.
[0050] FIG. 7 shows how the TLB miss counter values are maintained inside the OS kernel with the help of the processor and its register. For each process, a value, nTLBmisses ( 701 ), is maintained in the kernel's per-process data structure 700 to keep track of the number of TLB misses. This field will be updated by all the threads belonging to the process. Whenever there is a context switch on a CPU 704 (i.e. change of thread—from old thread to new thread—running on a CPU), the dispatcher takes the following actions:
a) If the old thread's process has the pgszTraceflag ( 702 ) set (see below), read the CPU register ( 703 ) that maintains the number of TLB misses, and atomically add the value to the nTLBmisses field of the old process. b) If the new thread's process has the pgszTrace flag ( 702 ) set, reset the CPU register ( 703 ) that maintains the number of TLB misses.
[0053] Since maintaining the TLB misses for every process adds overhead to the system, we want to track the TLB misses for only those applications which can significantly benefit themselves and other users of the OS by changing their page size. So, we will also maintain a flag in the kernel, pgsztrace, ( 702 ) in each process' kernel data structure to indicate that this process' TLB misses should be tracked. The following syscall provides the interface to set/reset this flag for each process.
int trace_tlb_misses(pid_t pid, int flag) /* where flag can have value of TRACE_ON or TRACE_OFF */
[0054] FIG. 8 is a high level block diagram showing an information processing system useful for implementing one embodiment of the present invention. The computer system includes one or more processors, such as processor 12 . The processor 12 is connected to a communication infrastructure 802 (e.g., a communications bus, cross-over bar, or network). Various software embodiments are described in terms of this exemplary computer system. After reading this description, it will become apparent to a person of ordinary skill in the relevant art(s) how to implement the invention using other computer systems and/or computer architectures.
[0055] The computer system can include a display interface 708 that forwards graphics, text, and other data from the communication infrastructure 802 (or from a frame buffer not shown) for display on the display unit 710 . The computer system also includes a main memory 14 , preferably random access memory (RAM), and may also include a secondary memory 712 . The secondary memory 712 may include, for example, a hard disk drive 714 and/or a removable storage drive 716 , representing a floppy disk drive, a magnetic tape drive, an optical disk drive, etc. The removable storage drive 716 reads from and/or writes to a removable storage unit 718 in a manner well known to those having ordinary skill in the art. Removable storage unit 718 , represents a floppy disk, a compact disc, magnetic tape, optical disk, etc. which is read by and written to by removable storage drive 716 . As will be appreciated, the removable storage unit 718 includes a computer readable medium having stored therein computer software and/or data.
[0056] In alternative embodiments, the secondary memory 712 may include other similar means for allowing computer programs or other instructions to be loaded into the computer system. Such means may include, for example, a removable storage unit 722 and an interface 720 . Examples of such may include a program cartridge and cartridge interface (such as that found in video game devices), a removable memory chip (such as an EPROM, or PROM) and associated socket, and other removable storage units 722 and interfaces 720 which allow software and data to be transferred from the removable storage unit 722 to the computer system.
[0057] The computer system may also include a communications interface 724 . Communications interface 724 allows software and data to be transferred between the computer system and external devices. Examples of communications interface 724 may include a modem, a network interface (such as an Ethernet card), a communications port, a PCMCIA slot and card, etc. Software and data transferred via communications interface 724 are in the form of signals which may be, for example, electronic, electromagnetic, optical, or other signals capable of being received by communications interface 724 . These signals are provided to communications interface 724 via a communications path (i.e., channel) 726 . This channel 726 carries signals and may be implemented using wire or cable, fiber optics, a phone line, a cellular phone link, an RF link, and/or other communications channels.
[0058] In this document, the terms “computer program medium,” “computer usable medium,” and “computer readable medium” are used to generally refer to media such as main memory 14 and secondary memory 712 , removable storage drive 716 , a hard disk installed in hard disk drive 714 , and signals. These computer program products are means for providing software to the computer system. The computer readable medium allows the computer system to read data, instructions, messages or message packets, and other computer readable information from the computer readable medium. The computer readable medium, for example, may include non-volatile memory, such as a floppy disk, ROM, flash memory, disk drive memory, a CD-ROM, and other permanent storage. It is useful, for example, for transporting information, such as data and computer instructions, between computer systems. Furthermore, the computer readable medium may comprise computer readable information in a transitory state medium such as a network link and/or a network interface, including a wired network or a wireless network, that allow a computer to read such computer readable information.
[0059] Computer programs (also called computer control logic) are stored in main memory 14 and/or secondary memory 712 . Computer programs may also be received via communications interface 724 . Such computer programs, when executed, enable the computer system to perform the features of the present invention as discussed herein. In particular, the computer programs, when executed, enable the processor 12 to perform the features of the computer system. Accordingly, such computer programs represent controllers of the computer system.
[0060] Although specific embodiments of the invention have been disclosed, those having ordinary skill in the art will understand that changes can be made to the specific embodiments without departing from the spirit and scope of the invention. The scope of the invention is not to be restricted, therefore, to the specific embodiments. Furthermore, it is intended that the appended claims cover any and all such applications, modifications, and embodiments within the scope of the present invention.
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A method of determining and using the optimal page size in the execution of an application wherein the number of virtual to real address caching mechanism misses per unit time is calculated for available page sizes and wherein the optimal page size is determined based on the determined number of mechanism misses. In a more specific aspect of this invention, mechanism misses per unit time are calculated for only those applications which are more likely to consume computer system resources. In yet another more specific aspect of this invention, the mechanism misses for a selected application are determined for each of a number of memory address regions.
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CROSS-REFERENCE TO RELATED APPLICATION(S)
This application claims the benefit of U.S. Provisional Patent Application No. 61/311,917 filed Mar. 9, 2010, the entirety of which is incorporated herein by reference.
GOVERNMENT RIGHTS
The research leading to the present invention was supported in part by a grant from the National Institute of Justice discretionary grant program (Grant No. 990595). Accordingly, the United States Government may have certain rights in the invention.
FIELD OF THE INVENTION
The present invention relates to firearms, and more specifically, to firearm firing inhibition devices and methods.
BACKGROUND OF THE INVENTION
In order for a firearm to have maximum utility and effectiveness, the firearm should be accessible and ready to fire when needed. However, in the interests of safety, it is not always desirable to keep a firearm ready to use at a moment's notice and within arm's reach. For example, firearms used for home defense typically must be kept in a secure location, such as a gun safe, away from small children, and/or secured with trigger locks, which typically must be used on unloaded guns. Keeping a firearm secured in such a manner is a large obstacle to being prepared for example in the event of a home invasion. Precious seconds are lost while the firearm is retrieved from the secure location, trigger locks are removed and the gun is loaded.
Moreover, there are times when firearms fall into the hands of one other than the owner. For example, it is not uncommon for firearms to be stolen and later used in connection with violent crimes. Another example is that during an altercation between law enforcement and criminals, the criminals may successfully take possession of the law enforcement personnel's firearm. In such instances it would be desirable for the firearm to be unusable to anyone but the owner.
Therefore there is a need for a firearm device that prevents the firearm from firing by anyone except an authorized user.
SUMMARY OF THE INVENTION
Accordingly, firearm firing inhibition technology is described herein which has been developed to stop events such as accidental shootings and unauthorized users discharging firearms. In the civilian sphere, this would allow the gun owner, but no one else, to fire the gun, thereby preventing accidental shootings in the home or elsewhere. The applications for law enforcement and military applications are similar. Employing the technology described herein, unauthorized discharge of firearms is prevented.
Firing mechanisms in a firearm are primarily based on percussion of the firing pin onto the primer of the cartridge. In personalized weapons technology, for example, biometric user recognition leads to a “go” or “no-go” signal. The latter is then realized as firing inhibition. A solenoid actuation system may be employed for firing inhibition. Although other electromechanical actuators (voice coil, piezoelectric, etc.) can be used, solenoid actuation system has the advantages of being low cost, compact, and fast.
The presently disclosed subject matter relates in one aspect to dynamic grip recognition and weapon discharge inhibition. The presently disclosed subject matter further relates to both a conformal sensor array and signal processor as well as weapon discharge inhibition mechanisms that may work in concert with one another. The subject matter is based in part on the concept that everyone holds a weapon in a different fashion, and that the unique pressure signature with which one holds a weapon acts as the necessary input to said weapon that allows it to fire. If the pressure signature is different than the pressure signature of the individual for whom the weapon is programmed the weapon will not discharge.
In accordance with one embodiment, a firing inhibition system for a firearm is disclosed which includes an electromechanical actuator electrically connected to a dynamic grip recognition module having at least one sensor and a microcontroller, wherein the at least one sensor is located in a portion of a firearm operable to receive grip pressure from a user and wherein the at least one sensor is operable to transmit a signal to the microcontroller, wherein the microcontroller is operable to receive programming comprising grip pressure of an authorized user and is operable to interpret whether the grip pressure of the user matches the grip pressure of the authorized user, and to send a signal to the electromechanical actuator to actuate or to not actuate.
In one embodiment the electromechanical actuator is a solenoid. The solenoid may be positioned in the firearm to inhibit motion of a trigger bar of the firearm. At least one block fixed on a surface of the trigger bar may be employed to operate as a stop against which a plunger of the solenoid may contact, preventing movement of the trigger bar.
In another embodiment a solenoid may be positioned in the firearm in the location of a firing pin, replacing the firing pin. The solenoid may be operable to reduce impact force from a hammer of the firearm to prevent primer detonation. Alternatively, the solenoid may operate to generate a force complementary to a permanent reductive impact force of a hammer of the firearm which is achieved by changing the restoring rate of a metal spring that drives the hammer, wherein when a signal is issued from the dynamic grip recognition module, the solenoid is actuated to generate a force complementary to the hammer force so the totality of two forces is adequate to detonate the primer. A solenoid which actuates with a speed sufficient to detonate primer of a cartridge may be employed. A solenoid with an actuation speed of at least 203.2 mm/sec may be employed.
In another embodiment a firing inhibition system is disclosed wherein the dynamic grip recognition module comprises a plurality of sensors disposed on at least one printed circuit board dimensioned to be located in the grip of a firearm. The sensors may be operable to obtain a temporal signature of user grip pressure before an act of firing is commenced and transmit signature information to the microcontroller. At least one of the sensors may be a tactile pressure sensor.
The arrangement of components necessary to actuate the electromechanical actuator may vary. In one embodiment, at least one printed circuit board is included and may include the microcontroller and a power and input/output connector. The printed circuit board may include a power management module and a pre-amplifier and optionally a battery.
In another embodiment, a firing inhibition system is disclosed in which the dynamic grip recognition module includes a first and second printed circuit board, wherein the first printed circuit board is associated with a left side of a firearm grip and the second printed circuit board is associated with a right side of the firearm grip, and the first and second printed circuit boards are electrically connected, wherein one of the printed circuit boards includes the microcontroller and the other printed circuit board includes at least a plurality of sensors. One of the printed circuit boards may further include a power and input/output connector. One of the printed circuit boards may include a power management module and a pre-amplifier and optionally a battery; and/or one of the printed circuit boards further comprises a clock, converter, switch, amplifier, and/or AND gate operably linked to the microcontroller.
In accordance with another embodiment, a firearm is disclosed having an electromechanical actuator electrically connected to a dynamic grip recognition module comprising at least one sensor and a microcontroller, wherein the at least one sensor is located in a portion of the firearm operable to receive grip pressure from a user and wherein the at least one sensor is operable to transmit a signal to the microcontroller, wherein the microcontroller is operable to receive programming comprising grip pressure of an authorized user and is operable to interpret whether the grip pressure of the user matches the grip pressure of the authorized user, and to send a signal to the electromechanical actuator to actuate or to not actuate.
In a further embodiment, methods are disclosed for inhibiting the firing of a firearm by providing a firearm with an electromechanical actuator and a dynamic grip recognition module, electrically connecting the actuator to the dynamic grip recognition module, the dynamic grip recognition module including at least one sensor and a microcontroller, positioning the sensor in a portion of the firearm operable to receive grip pressure from a user, wherein the at least one sensor is operable to transmit a signal to the microcontroller, programming the microcontroller with data relating to grip pressure of an authorized user, and programming the microcontroller to interpret whether the grip pressure of the user matches the grip pressure of the authorized user, and to send a signal to the electromechanical actuator to actuate or to not actuate.
BRIEF DESCRIPTION OF THE DRAWINGS
To assist those of ordinary skill in the relevant art in making and using the subject matter hereof, reference is made to the appended drawings, wherein:
FIG. 1 is a side perspective view of a firearm including a firing inhibition system in accordance with one embodiment of the present disclosure;
FIG. 2 is a side perspective view of a firearm including a firing inhibition system in accordance with one embodiment of the present disclosure;
FIG. 3 is a cross-sectional, schematic view of a solenoid-based firing/blocking system in accordance with one embodiment of the present disclosure;
FIG. 4A is a photographic side view of a solenoid-based firing/blocking system installed in a firearm in accordance with one embodiment of the present disclosure;
FIG. 4B is a photographic top view of a solenoid-based firing/blocking system installed in a firearm in accordance with one embodiment of the present disclosure;
FIG. 5 is a schematic diagram of a solenoid dynamic test in accordance with one embodiment of the present disclosure;
FIG. 6 is a graphical depiction of a drive voltage curve of a solenoid dynamic test in accordance with one embodiment of the present disclosure;
FIG. 7 is a graphical depiction of a displacement curve of a solenoid dynamic test in accordance with one embodiment of the present disclosure;
FIG. 8 is a graphical depiction of a velocity curve of a solenoid dynamic test in accordance with one embodiment of the present disclosure;
FIG. 9 is a schematic diagram of an electrical design of a solenoid firing inhibition system in accordance with one embodiment of the present disclosure;
FIG. 10 is a side perspective view of a firearm including a solenoid percussion system in accordance with one embodiment of the present disclosure;
FIG. 11 is a photographic bottom side view of a slide of a pistol and a solenoid for installation in a firearm in accordance with one embodiment of the present disclosure;
FIG. 12 is a schematic diagram of an electrical design of a solenoid percussion system in accordance with one embodiment of the present disclosure;
FIGS. 13A-13C are schematic diagrams depicting front ( FIG. 13A ), rear ( FIG. 13B ) and side ( FIG. 13C ) views of a left side hand grip of a firearm including elements of a dynamic grip recognition module in accordance with one embodiment of the present disclosure; and
FIGS. 14A-14C are schematic diagrams depicting front ( FIG. 14A ), rear ( FIG. 14B ) and side ( FIG. 14C ) views of a right side hand grip of a firearm including elements of a dynamic grip recognition module in accordance with one embodiment of the present disclosure.
It should be noted that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be construed as limiting of its scope, for the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION OF THE INVENTION
The following is a detailed description of the invention provided to aid those skilled in the art in practicing the present invention. Those of ordinary skill in the art may make modifications and variations in the embodiments described herein without departing from the spirit or scope of the present invention. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. All publications, patent applications, patents, figures and other references mentioned herein are expressly incorporated by reference in their entirety.
Now referring to FIG. 1 , in general a firearm 2 is equipped with a firing inhibition system including electromechanical actuator 20 electrically connected to dynamic grip recognition module 50 shown in phantom.
Firearm 2 may be any firearm that can be equipped with an electromechanical actuator and dynamic grip recognition module 50 . For purposes of illustration the firearm 2 depicted herein is an automatic pistol as is well known in the art. Those skilled in the art will recognize the presently disclosed subject matter is easily incorporated into any automatic pistol such as a Beretta® automatic pistol and the like, as well as any automatic firearm having a grip including rifles and shotguns, etc.
Electromechanical actuator 20 may comprise a solenoid, voice coil, piezoelectric device or the like. The electromechanical actuator 20 is disposed in the firearm 2 so that it is operable to inhibit firing of the firearm.
Dynamic grip recognition module 50 is described in further detail herein below and in one embodiment essentially includes at least one printed circuit board (PCB) with electronics components including for example, a power management device, sensor amplifiers, and microprocessor(s); pressure sensors such as piezoelectric pressure sensors, piezoresistive pressure sensors, capacitive pressure sensors, etc.; and electrical interconnects and mechanical support. As will be apparent form the following discussion, the pressure sensors must be located on a portion of a firearm that receives a grip of a user. The remaining portions of the dynamic grip recognition module 50 may be located elsewhere on the firearm.
Now referring to FIG. 2 , in accordance with one embodiment, electromechanical actuator 20 is positioned and operable to disable the trigger bar 4 of firearm 2 , which transmits finger trigger action mechanically into releasing the hammer 6 . By blocking/disabling this transmission, the hammer 6 cannot actuate the firing pin (not shown), hence there is no strike on the cartridge primer.
Now further referring to FIG. 3 , in one embodiment, electromechanical actuator 20 is a solenoid operable to block the trigger transmission activity of a standard automatic firearm such as a Beretta pistol. Solenoid 20 includes plunger 22 , spring 24 , core 25 and connections 26 for connection to a power source and the dynamic grip recognition module 50 . Suitable solenoids include low-profile solenoids available commercially from Magnetic Sensor Systems of Van Nuys, Calif. Solenoid 20 may include frame 28 . The solenoid is disposed in the hollow magazine 8 or magazine receiving channel and electrically connected to the dynamic grip recognition module 50 located for example in the grip portion of firearm 2 . As shown, the solenoid 20 is in the “off” position. With the help of stopper blocks 30 mounted on the trigger bar 4 , the plunger 22 limits the travel of the trigger bar 4 when in the “off” position. For an unauthorized user, determined by the dynamic grip recognition module 50 , described in further detail herein below, the de-energized solenoid firing/blocking system stays in the “off” position as shown. The hammer 6 will not fall to strike the firing pin although the pistol 2 has been triggered. For an authorized user, determined by the dynamic grip recognition module 50 , the solenoid 20 drives the plunger 22 retracting back into the solenoid core 25 to release the blocked trigger bar 4 . The shooting activity may then be completed.
The spring 24 connecting the plunger 22 and the core 25 supplies return force to restore the plunger 22 to its default de-energized position, i.e., “off” position, after each shoot activity in accordance with one embodiment. FIGS. 4A and 4B show an example of the solenoid 20 employed as a firing/blocking system assembled in a Beretta® handgun.
For an authorized user, the solenoid plunger 22 must retract totally before it touches the front stopper block 30 on the trigger bar 4 to avoid being stuck. One skilled in the art will recognize the solenoid 20 should actuate fast enough compared to the speed of the dynamic grip recognition module 50 and trigger pulling action. Experiments were conducted to test the dynamics of the solenoid 20 for use in a firing/blocking system in accordance with the present disclosures.
Travel range was set as 0.17 mm for testing in the experiments.
The displacement of the plunger for testing was measured by MTI-1000 Fotonic Sensor and collected by data acquisition card PCI-6024E and program LabVIEW 8.0. The performance characteristics of the solenoid, such as speed and power consumption with various sets of drive voltage and duty cycle were evaluated. Higher driving voltage resulted in greater speed but higher power consumption. Hence it may be desirable to tune the device to a driving voltage suitable to achieve an adequate speed while maximizing battery life. Parameters of an exemplary push-pull solenoid SMT-1913SL available from TSE Technology Co., Ltd. of Zhejiang, China, www.nbtse.com, are listed in Table 1.
TABLE 1
Parameters of push solenoid SMT-1913SL
Plunger weight (g)
4
DC Voltage (volt)
9.5
(Duty cycle less than 10%)
Total weight (g)
20
Resistance at 20° C. (Ω)
89
Number of turns
1230
Ampere turns at 20° C. (At)
537
The schematic diagram for one exemplary embodiment of the solenoid dynamic test is shown in FIG. 5 . The drive voltage, displacement and velocity curves are shown in FIGS. 6 , 7 and 8 , respectively. The drive signal was set to a series of periodical pulses with amplitude 5 volt and duty cycle 10%. Displacement represents the distance between the core and plunger cap of the solenoid. Table 2 lists the relative dynamic data analysis for the embodiment.
TABLE 2
Dynamic Analysis
Ampli- tude U (volt)
Duty cycle (%)
Time t (sec)
Average speed v (m/s)
Maxi- mum Speed vmax (m/s)
Momen- tum M = mvmax (Ns)
Kinetic
energy
E
=
1
2
mv
2
(
J
)
5
10
10 × 10 −3
0.017
0.055
2.2 × 10 −4
5.78 × 10 −7
Now referring to FIG. 9 , an embodiment of a solenoid firing inhibition system 60 in accordance with the presently disclosed subject matter includes a solenoid 20 , a power source 70 , power management module 72 , pre-amplification module 73 , clock 74 , microcontroller 76 , converter 78 , and switch 80 . Microcontroller 76 is initially programmed with pressure signature data from an authorized user. Once the data is programmed in the microcontroller 76 , if the pressure signature which is detected by the microcontroller is different than the pressure signature of the individual for whom the weapon is programmed the weapon will not discharge.
The configuration in this embodiment utilizes two indication signals (Pass/Fail) provided by the microcontroller 76 , in this example a MPC566 32 bit microcontroller available from Freescale Semiconductor at www.freescale.com, through its digital I/O line at the end of a dynamic grip recognition program to determine the firing/blocking operation. The “Pass” signal is implemented to activate the electrical switch, in this example, a MOSFET relay. For an authorized user, the firing system may be enabled by a logic high signal. With further reference to FIG. 3 , the plunger 22 of the solenoid 20 is retracted away from the block on the trigger bar 4 to enable the firing activity. Suitable electrical switch 80 and DC/DC converter 78 are employed to generate fast response of the solenoid firing system 60 compared with the speed of normal trigger transmission system. For an unauthorized user, the electrical switch 80 remains in the “off” mode with a logic low signal, the solenoid 20 is not activated and the plunger 22 remains disposed to block movement of the trigger bar 4 .
It will be apparent to the skilled artisan that any suitable power source (preferably a battery), electrical switch, clock, pre-amplification module, DC/DC converter and/or power management module may be employed in connection with the present subject matter. Applicants have found that in consideration of the requirements of the trigger activity transmission speed, power efficiency, and compact dimension, the components listed in Tables 3 and 4 are good choices for embodiments described herein. However, alternative components may be utilized as well.
TABLE 3
Parameters of electrical switch
Max
Max
turn
turn
on time
off time
(VDD =
(VDD =
20 V
20 V
Max
Switch
IF =
IF =
supply
threshold
Model
5 mA)
5 mA)
voltage
voltage
Dimension
Power
Number
(ms)
(ms)
(V)
(VDC)
(mm)
(W)
Toshiba
3
1
48
1.15
7 × 4.4 ×
2
MOSFET
3.9
relay
TLP3122
TABLE 4
Key parameters of DC/DC converter
Voltage
Voltage
Model
input
output
Dimension
Power
Number
(VDC)
(VDC)
(mm)
(W)
Mounting type
CUI Inc
4.5~9
24 VDC@80 mA
22 × 12 × 9.5
2
Through Hole
VWRBS2D5-S24-
SIP
Now referring to FIG. 10 , a firing pin-based solenoid mechanical percussion apparatus for a firearm 2 includes a solenoid 20 and dynamic grip recognition module 50 , which system is based on replacing the firing pin of a firearm with an axial solenoid. Suitable solenoids include tubular solenoids available commercially for example from Magnetic Sensor Systems of Van Nuys, Calif. Two modes of operation can be employed. In the first, the solenoid 20 reduces the impact force from the hammer sufficiently to prevent primer detonation. The second mode of operation employs a permanent reduction of the hammer impact force by changing the restoring rate of the metal spring that drives the hammer. When a “Go” signal is issued from the dynamic grip recognition module 50 , the solenoid 20 is actuated to generate a force complementary to the hammer force so the totality of two forces is adequate to detonate the primer. In one embodiment, a solenoid 20 is employed which is powerful enough to detonate the primer, thereby eliminating the need for a hammer.
As will be apparent to the skilled artisan, the fit, placement and orientation of the solenoid 20 in the firearm 2 are dependent on the make and model of the firearm and the desired mode of firing inhibition.
The conventional mechanical firing pin may be replaced with a solenoid plunger for multiple exemplary embodiments of the present invention. The diameter of the plunger tip for one such embodiment is similar to that of the conventional firing pin. FIG. 11 shows the slide of a pistol and an exemplary solenoid, SMT-1325S12A available from Jameco Electronics of Belmont, Calif. for one embodiment of the present invention.
Now referring to FIG. 12 , the electrical design of a solenoid percussion system 100 may include a solenoid 20 , a power source 70 , power management module 72 , pre-amplification module 73 , clock 74 , microcontroller 76 , inverter 77 , AND gate 79 and amplifier 81 . The configuration utilizes two indication signals (Pass/Fail) provided by the microcontroller, in this case a MPC566 32 bit microcontroller available from Freescale Semiconductor through its digital I/O line at the end of the dynamic grip recognition program to determine the firing/blocking operation. The “Pass” and the inverted “Fail” signals are ANDed and then amplified. For an authorized user, the firing system is enabled by a logic high signal and disabled by a logic low signal for an unauthorized user.
The electronics of the solenoid percussion systems 60 and 100 described herein above may be included in the dynamic grip recognition module 50 along with sensors as will be described further herein below.
In order to select a proper solenoid to inhibit/disable firing, it is desirable to determine the detonation characteristics of the primer, namely, energy, velocity and momentum that should be delivered by the striking pin. A number of primer detonation tests based on the fixture and primers were conducted. Some parameters and operating conditions play an important role in the detonation while most of the others have very little if any effect. Table 5 lists the results of the primer detonation tests.
TABLE 5
Primer detonation test
Condition
description
Test data and conclusion
Sharpness of the
There is no significant effect on primer detonation
firing pin tip
with various firing pin diameters.
Travel speed of
127 mm/sec.------no detonation;
the firing pin
133.35 mm/sec.----no detonation;
167.64 mm/sec.--- no detonation;
203.2 mm/sec.---- detonation.
Mass of the
Lowering the travel speed regardless of the mass
firing pin
attached to the firing pin did not detonate the primer.
In some cases the pin pierced the primer with no
detonation.
Position of
Reversing the primer did not help.
the primer
Thickness of
Thinning the primer did very little help: the primer
the primer
with thickness 0.33 mm can be detonated; one primer
detonated but was driven back over the firing pin.
According to the primer detonation test results, the solenoid percussion system should be able to actuate fast enough to fire a bullet. The minimum speed for firing in at least one embodiment has been determined to be approximately 203.2 mm/sec. As will be apparent to the skilled artisan from the foregoing, this minimum speed can be exploited to inhibit firing using the present teachings.
As described above, exemplary embodiments of the disclosed subject matter employ a dynamic grip recognition module 50 to obtain biometric measurements of a user. Now referring to FIGS. 13A-14C , the dynamic grip recognition module 50 in one embodiment includes a plurality of sensors 105 on a printed circuit board (PCB) 110 along with associated electronics for signal processing and system control, all of which are located in the grip of a firearm. In one aspect, the systems described herein above with reference to FIGS. 9 and 12 may be placed on one or more PCBs to operate in conjunction with sensors 105 placed in the grip of a firearm. Temporal signature of user grip pressure immediately before firing is measured by sensors 105 in the firearm grip and analyzed in real-time by the signal processing electronics. Sensors 105 are preferably tactile pressure sensors and may be piezoelectric, piezoresistive, capacitive, etc. The number of sensors 105 shown in the drawings is exemplary only.
Now referring to FIG. 13A a firearm left side hand grip 9 includes a microcontroller 76 , sensors 105 , PCB 110 , power and I/O connector 120 , and BDM port 130 . The PCB in accordance with this embodiment may be designed in a geometric shape similar to that of the grip. The sensors 105 are disposed on the front side as shown in the front view in FIG. 13A . Now referring to FIG. 13 B, the microcontroller 76 and all related electronic components may be located on the opposite side of the grip 9 . Now referring to FIG. 13C , the assembly of the left hand side grip 9 , microcontroller 76 , PCB 110 and sensors 105 are shown.
Now referring to FIG. 14A , the right side grip 11 may include further sensors 105 and power and I/O connector 120 A on another PCB 110 A. Now referring to FIGS. 14B-14C , the power management module 72 and pre-amplifier 73 and associated electronics are located on the opposite side of PCB 110 A. The communication between the two PCBs 110 and 110 A can be established for example via flat flex cable (not shown). Rubberization can be added on top of the assembly for better gripping as well as protection of the components.
Although the systems and methods of the present disclosure have been described with reference to exemplary embodiments thereof, the present disclosure is not limited thereby. Indeed, the exemplary embodiments are implementations of the disclosed systems and methods are provided for illustrative and non-limitative purposes. Changes, modifications, enhancements and/or refinements to the disclosed systems and methods may be made without departing from the spirit or scope of the present disclosure. Accordingly, such changes, modifications, enhancements and/or refinements are encompassed within the scope of the present invention.
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A firing inhibition system for a firearm includes an electromechanical actuator electrically connected to a dynamic grip recognition module including at least one sensor and a microcontroller, wherein the at least one sensor is located in a portion of a firearm operable to receive grip pressure from a user and wherein the at least one sensor is operable to transmit a signal to the microcontroller, wherein the microcontroller is operable to receive programming comprising grip pressure of an authorized user and is operable to interpret whether the grip pressure of the user matches the grip pressure of the authorized user, and to send a signal to the electromechanical actuator to actuate or to not actuate.
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FIELD OF THE INVENTION
This invention is concerned with the recovery of hydrocarbons from deposits of unconsolidated tar sands deep under the surface of the earth and aims to provide a process which is economical to operate, and which permits the recovery of the hydrocarbon values in such deposits, while eliminating the danger of excessive surface sunsidence.
BACKGROUND OF THE INVENTION
North America has vast deposits of tar sands, which are mixtures of viscous hydrocarbons and sand. Some of these deposits are consolidated (sand stone) while others are unconsolidated and disintegrate upon heating. A minor percentage of the deposits are at or close to the surface, and are mined by removing any overburden, and then physically removing the tar sands to plants in which the viscous hydrocarbons are separated from the sand. The adhesive nature of the tar sands, and their abrasiveness, tend to make the operations difficult and expensive, particularly in the upkeep of equipment. In spite of the difficulties, commercial operations are currently being conducted in Canada.
However, over 80% of the tar sands deposits are situated well under the surface of the earth, far enough below so that removal of the overburden is not practical. In many locations, there are beds of tar sands 100 feet and more in thickness, situated 300 feet or more below the surface. There has been no commercial exploitation of this huge reserve of hydrocarbons, which are larger than the known oil reserves of the Persian Gulf.
Workers in the field have approached the problem in various ways. The most logical prior art suggestions known by us are made in the Walker U.S. Pat. No. 3,858,654--Jan. 7, 1975, and the Redford U.S. Pat. No. 3,951,457--Apr. 20, 1976. In those patents, a well is sunk through the overburden into near the bottom of the tar sands deposit, and the well is cemented to the overburden. Hot aqueus alkaline fluid is directed against the tar sands to heat it to the point where the hydrocarbons become sufficiently liquid so that they can be forced up the well to a recovery system where the hydrocarbons are separated from the hot aqueous fluid. During mining, the cavity is maintained at a pressure high enough to support the overbruden, using a non-condensable gas to maintain the pressure. The injected aqueous fluid is maintained at about 180° to 200° F. to obtain a tar sands temperature of 160° F., preferably near 180° F.
The methods suggested by these patents have not been commercialized for a number of reasons. The recovery of the hydrocarbon values will be difficult to accomplish in a single decanter, as suggested in the patents, because the specific gravity of the heavy hydrocarbons is very near that of water. In addition, the patents disclose no effective provision for preventing roof collapse either during mining or after completion of the operation.
It is the principal object of this invention to provide a method of hydraulic mining of unconsolidated tar sands at depths unsuitable for strip mining, which is both energy efficient, and which provides means for preventing collapse of the cavity during, and after completion of, the mining.
STATEMENT OF THE INVENTION
In accordance with the instant invention, we have found that the mining of thick tar sands deposits too deeply situated to permit strip mining can be economically carried out while avoiding surface subsidence and excessive heat losses by using the known techniques of (1) sinking a shaft through the overburden to the bottom of the tar sands deposit, and cementing a casing through the overburden; (2) injecting into the cavity a mixture of steam and inert non-condensing gas to maintain the pressure required to prevent collapse of the cavity roof and to maintain the temperature required to heat the tar above its flow point; (3) directing a high velocity stream of hot aqueous fluid against the tar sand deposit to shear a slurry of aqueous fluid, tar and sand which will flow toward the outlet, bringing said hot slurry to the surface; (4) there separating the hydrocarbons from the sand and hot aqueous fluid, and returning the hot aqueous fluid to the well, and modifying said techniques by:
(a) Maintaining at least a ten foot thick ceiling of tar sands in the cavity throughout the mining operation in order to provide a gas-impermeable seal and hence preventing the roof from falling in.
(b) Maintaining both the subsurface operations, and surface operations for separating oil from sand and water, at sufficiently high pressure so that the water is below its boiling point and the system does not cool off and lose heat by evaporation of water, and,
(c) Backfilling the cavity after primary hydraulic mining is completed and before depressurization with spent sand and aqueous fluid to ensure against collapse of the cavity after depressurization and to dispose of the sand in an ecologically acceptable manner.
The collapse of the cavity, with resultant surface subsidence, is prevented by the combination of the technique of maintaining gas pressure against an impermeable seal during operation, and backfilling with sand and water after mining is complete, and before depressurization. The backfill preferably is the sand taken out of a cavity; in a continuing operation, it will be sand taken out of a subsequent cavity.
By maintaining pressures throughout the system so that the boiling point of the water therein is always above its actual temperature in the system, heat requirements are minimized, since the high energy requirements for converting water into steam are avoided. Additionally, by maintaining the surface plant under pressure the energy for pumping is minimized; the energy for pumping will only be that necessary to overcome the friction losses of the system. Our invention makes it possible to achieve a thermal efficiency of about 90%. In other words, each barrel of oil recovered will require one tenth of a barrel of oil for heat and power. This compares with more than one-half barrel of oil required for each barrel of oil recovered using conventional steam flooding for heavy oil recovery.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a block flow diagram of the complete system used in the process of this invention and also shows the cavity profile versus time during mining.
FIG. 2 details the well tool.
FIG. 3 is a flow diagram of the surface plant.
Referring now to FIG. 1, a thick layer of tar sands (103) lies between an upper layer of overburden (102) and bedrock (104). The tar sands layer (103) is typically 100 feet or more in thickness; the overburden (102) is 500 feet or more. A well (106) is sunk through the overburden (102) and the tar sands layer (103) into the bedrock (104) to form a collection sump (105). The well is cased and cemented (107) through the overburden (102) into the tar sands layer (103). The casing (107) is typically 5 feet in diameter. The tar sands are dislodged from the cavity by the well tool (108) and are removed from the cavity as a slurry of hydrocarbons, sand and aqueous solution through the central pipe (109) of the well tool (108) to the surface plant (101). The mining operation and the progressive change of the cavity with time is described below.
Referring to FIG. 2, the well tool (108) consists of two concentric pipes which enter through the well head and casing (107). The center pipe (109), which is stationary, extends into the sump (105, FIG. 1) at the bottom of the well and serves as the conduit for the removal of the oil, water, sand slurry. The outer pipe (106) which extends about halfway into the tar deposit (103, FIG. 1) can be oscillated 90° about the vertical axis by a motor drive (225), is sealed with rotary seals (235) and (240) to the inlet head (210) and the well head (211), the lower end of which is flanged to the well casing (107). The outlet pipe (109) is welded to the inlet head (210). Recycle mining water and make-up water from the surface plant (101, FIG. 1) is introduced through pipe (206) and passes through the annulus (250) formed between the outlet pipe (109) and the inlet pipe (106). High pressure steam and inert gas for pressurization of the cavity is introduced through pipe (208) in the well head (211). A sleeve (255) with four high velocity-high volume nozzles (270) located at the bottom is placed around the lower end of the outer pipe (106) and sealed at the top to the outer pipe (106) with a slide seal (260) so that the sleeve-nozzle assembly (255-270) can oscillate with the outer pipe (106). The sleeve assembly, which is approximately half the thickness of the tar sand zone, can be raised and lowered with cables (245) connected to a winch (230) in the well head (211). The water pressure in annulus (250) will force the sleeve nozzle assembly (255-270) down when the cables (245) are released. The lower end of the sleeve assembly (255) is equipped with a sliding and rotating seal (265) around a pipe (275) providing a flush liquor annulus (280) around the stationary, center pipe (109), extending from a few feet inside the major annulus (250) to within 5 to 10 feet from the bottom of the well tool.
Injected water passes from the annulus (250) to the four high velocity, high volume nozzles (270) located on the bottom of the sleeve (255). These nozzles (270) can be pivoted a total of 135°, from aiming straight down to 45° upward, by hydraulically operated motors (271) actuated from the surface and equipped with position indicators. When the nozzles are aimed below the horizontal, they will flush accumulated sands toward the outlet thus controlling the amount of sand accumulated on the bottom of the cavity.
Four sonic transmitters and receivers (290), connected with electrical cables to the surface are located above the nozzles to permit monitoring of the cavity development.
A relatively small amount of the injected water passes through the flush liquor annulus (280) to multiple nozzles (285) located a few feet above the sump (105, FIG. 1). This water keeps the sump (105, FIG. 1) agitated and assists in flushing the sand-water-oil slurry into the outlet through slotted openings (295) in the otherwise closed center pipe (109). The openings are sized to prevent entry of stones and debris that can cause problems in the surface plant.
A level sensor (286) close to the bottom of the well tool controls the addition of make up water so that the sump does not run dry. All hydraulic and instrument lines are flexible to accomodate turning of the well tool.
The required pressure in the cavity is maintained equal to the weight of the overburden. The pressure in the recovery plant is equal to the cavity pressure minus the friction losses in the mining tool minus the hydraulic head of the slurry. The maximum temperature of the slurry to avoid heat losses due to evaporation of water in the surface plant is determined by the boiling point of water at the surface plant pressure. Typical cavity pressures and maximum cavity temperatures for different depths are shown in Table 1. This table, and the other tables, are placed for convenience at the end of the specification.
The temperature used depends upon the nature of the tar sand and the desired rate of mining. Generally, the tars are sufficiently fluid at 200° F. to flow readily. When the tar sand is heated to 200° F. or above the sands can be dislodged and flushed away by the hydraulic miner. The rate that this occurs depends on the rate of heat penetration into the tar sands. The heat is transferred from the water jets and vapor space over the surface of the cavity. The higher the cavity temperature and with a certain minimum jet rate, the higher will be the rate of heat penetration and tar sand removal. Typical mining rate versus temperature is shown in Table 2, for a 400 foot diameter cavity in a 100 foot thick seam containing 10% bitumen.
Mining proceeds in a radial direction starting at the tar sand zone floor. Heat is transferred from the hot cavern atmosphere to the water jet and to the tar sand face. This melts the tar, and makes the face weak so that when the water jet hits it, the sand and its contents are dislodged. The high velocity water from the jets (270) sluices the sand, water and oil, into a collection sump (105, FIG. 1). Water from the flush liquor annulus (280) keeps the collection sump agitated. The level controller assures a water seal by controlling the make up water. High pressure inert gas and steam are injected into the well to fill the mining voids, to maintain system pressure to support the roof and to maintain required temperatures. The temerature of the cavity is maintained at 200°-450° F. Use of this temperature and additives, such as polypyrophosphates, EDTA, etc., in the water assist in separating the oil from the sand.
The tar sand layer under the roof is impermeable to gas and therefore the cavity pressure acting on this layer supports the cavern roof and overburden. As the cavity grows, less and less of the dislodged sand is removed to the surface oil recovery plant. By the end of the mining operation, up to 50% of the sand may remain in the cavity.
The formation is mined from the bottom outward and upward. Turning and elevating of the nozzle sleeve and pivoting the nozzles up and down permits mining in all radial directions. FIG. 1 shows the cavity outline at various times (T 1 to T 3 ) during mining. At time T 1 , the jet nozzles are on the floor aiming in a horizontal direction and undercut the cavity to about 100 feet. At time T 2 , the nozzle system is elevated above the cavern floor by about one-quarter of the thickness of the tar zone to the tar sand zone. At this height, the high pressure nozzle can cut out to 150 feet radially aiming the nozzles upward. The nozzle system proceeds up to a height of about one-half the tar zone thickness and cuts radially to about 200 feet and upward toward the roof until the cavern is the shape designated at time T 3 . This is the maximum distance at which the water jets can hydraulically dislodge sand and at this time (about 2 months after start) the system has produced at an average rate of about 10,000 narrels per day. Throughout the mining operation, the sonar sounding system monitors the cavity dimensions, and warns of excess roof penetration through the tar sand seam. At the end of the mining operation, the impermeable ceiling support membrane is at least 10 feet thick, a safe thickness needed to prevent gas breakthrough and collapse of the roof. When the maximum reach of the nozzles is attained, the cavern is refilled by pumping down a sand-water slurry through the well casing under pressure while removing water and residual oil that drains to the well sump.
After completion of filling the cavern, the well is closed in and put on standby for possible future secondary recovery of hydrocarbons. Table 3 lists typical operating parameters for a 1000 ft. deep well in a 100 ft. thick seam.
Referring now to FIG. 3, there is shown a flow sheet of the above ground operation for recovering the hydrocarbon values from the tar-sand-water slurry removed from the cavity. The slurry goes first to hydroclones (300) which separate the bulk of the sand as a heavy slurry in water from the bitumen and the rest of the water. The underflow-sand in water-goes to an agitated receiver (302), whence it is pumped by a pump (304) to a previous mined-out zone to eventually fill that cavity, or to an impounded area for eventual return to the cavity being mined. The overflow goes to an agitated tank (306), where it is mixed with light oil, which reduces the density of the oil phase thus permitting easy gravity separation of the oil-bitumen phase from the water. This light oil is preferrably a naphtha which can be readily separated from the tar oil by distillation. The naptha-oil-water mixture is then sent to a decanter (308) where the tar-naphtha solution is separated from the water and any sand carried over from the hydroclone (300). The bottoms underflow of sand and water from the decanter (308) are pumped by pump (310) back to the feed to the hydroclones (300). Clear hot water is drawn from the center of the tank, and is pumped by pump (312) back into the cavern, along with additional make-up water supplied by pump (313). The overflow passes into heated storage tanks (314), thence through pump (315) to a fired heater (316), and then into a flash stripper (318), where the naphtha is evaporated and separated from the tar product. The naphtha is condensed in a condenser (320) and goes to a storage tank (324) and back to agitated tank (306). There is a small amount of water present from the steam used in the stripper (318); this water is sent to the producing well from the bottom of tank (324) by pump (323). The tar at the bottom of the still is pumped by the stripper pump (330) to heated storage tank (332).
In operation of the above-ground system, all of the system which contains water is maintained under sufficient pressure so that the water is below its boiling point at the temperature employed, in order to avoid the high loss of energy due to the high heat of vaporization of water. This means that the hydroclones (300), the agitated sand slurry tank (302), the agitated tank (306) where the naphtha is added, the decanter tank (308) and all the piping associated with them must be under pressure. The necessary pressures are easy to maintain, since the slurry from the mining operation is under pressure, and can be readily carried over into the separation system. The only additional energy required to keep pressure is that required to overcome the friction losses in the system for recycle of water and sand slurry to the wells and for the supply of make-up water and naphtha to the system.
The details of the operation can obviously be changed without departing from the invention herein, which is set forth in the claims.
TABLE 1______________________________________SYSTEM PRESSURES AND MAXIMUM ALLOWABLETEMPERATURE VS. DEPTH Recovery Cavern System MaximumOverburden Pressure Pressure CavityDepth Ft psia* psia Temperature, °F.______________________________________ 500 500 220 3891000 1000 440 4541500 1500 660 4972000 2000 880 5293000 3000 1320 578______________________________________ *Assuming an average density of 2.30 for the overburden.
TABLE 2______________________________________EFFECT OF CAVITY TEMPERATURE ON MINING RATE(10 wt. % Bitumin - 100 ft. Thick Seam - 200 ft. Reach)Cavity Penetration AverageTemperature °F. Rate, inched/hour Mining, BPSD*______________________________________200 0.5 1350250 1.4 3790300 2.7 7280350 3.8 10240400 4.8 12900450 5.7 15400______________________________________ *BPSD Barrels per Stream Day
TABLE 3______________________________________TYPICAL SYSTEMOPERATING PARAMETERS______________________________________Cavern Depth 1000 ftDeposit Thickness 100 ftCavern Pressure 1000 psiaAverage Production Rate 10,000 BPSD*Design Production Rate 15,000 BPSD*Well Life 60-70 DaysOil Recovery from Well 80%Oil Concentration 10 wt % of sandsDesign Jet Nozzle Water Rate 18,000 GPMDesign Slurry Water Pump Rate 20,000 GPMPump Horsepower 5,000Design Plant Heat Input 375 MM BTU/hrwith Cavity Temperature at 400° F.______________________________________ *Barrels per Stream Day
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A method is provided for mining deep tar sand deposits which minimizes energy losses and surface subsidance due to cavity collapse. A well is sunk through the overburden and tar sands deposit into the bedrock below the deposit; the well is sealed and pressurized with steam and inert gas. Hot aqueous fluid is directed against the deposit to melt the tar and form a tar-sand-water slurry which is passed to a surface recovery plant. Pressure is maintained in the well sufficiently high to hold the overburden. Energy losses are minimized by maintaining the pressure both in the well and the surface plant above the boiling point of the water at the temperature used, which may be as high as 450° F. or more, subsidence is prevented by keeping at least a 10 foot thick ceiling of tar sands throughout the operation, and by backfilling the well with an aqueous slurry of sand after mining operations are complete, before releasing pressure on the well.
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CROSS REFERENCE
[0001] This application is a Divisional application of Ser. No. 11/976,757, filed Oct. 26, 2007, which is a Continuation application of PCT/AT2006/000175, filed Apr. 28, 2006.
BACKGROUND OF THE INVENTION
[0002] The invention concerns a furniture item with a movable furniture part and an ejection device which has an ejection element to move the movable furniture part out of a closed position into a first open position, and an actuator with an energy accumulator. Furthermore, a process for opening and closing the new type of furniture item will be proposed.
[0003] Furniture items of this type are known already in the state of the art in which typical ejection devices are designated as so-called “touch-latch” mechanisms. These require pressure (a touch) to be applied, for example, to the movable furniture part, a switch, button or something of that nature to unlatch the ejection device, which has the effect of moving the movable furniture part by means of the ejection element from its closed position into a first open position. If the actuator comprises a manually loaded energy accumulator, the loading of the latter is usually effected when the furniture item is closed. It has been found that an unsatisfactory aspect of this state of the art is that the user has only part of the closure path immediately by the closed position to load the energy accumulator.
[0004] The invention sets out, therefore, to propose an improved version of the furniture item in question which will avoid the drawbacks recognized in the state of the art. The proposal will include a process for opening and closing the new type of furniture item.
[0005] The invention resolves this task by providing a means of moving one or more ejection elements beyond of the first open position.
[0006] In the case of actuators generally comprising a manually loaded energy accumulator, preferably a tension spring, to preload the energy accumulator, the ejection element on which the accumulator acts over a part of the closure path is in contact with either the movable furniture part or with the furniture body, depending on whether the ejection device is arranged on the furniture body or on the movable furniture part. In those ejection devices known up to the present time, this contact action occurs in the section of the opening or closing path of the movable furniture part located between the closed end position and the first open position of the movable furniture part whereby the first open position of the movable furniture part corresponds to the position of the ejection element after the end of the ejection process. This means that the user, when closing the movable furniture part, may just move it slightly to reach the first open position before having to apply additional pressure in the last section of the closing path to load the energy accumulator.
SUMMARY OF THE INVENTION
[0007] In contrast, in the furniture item according to the invention, an arrangement is proposed whereby, once the ejection process has ended, the ejection element is moved beyond the first open position of the furniture part, and the partial section of the closing path in which the ejection element is in contact with the movable furniture part, or furniture body as the case may be, to load the energy accumulator, is displaced in the direction of the opened end position. This means that, immediately after or simultaneous with the start of the closing motion of the movable furniture part, the user begins to load the energy accumulator of the actuator and, at the end of the loading process, has then to apply a small force to move the movable furniture part into its closed end position. This will give the user the impression that the closure of the movable furniture part is a completely smooth closing motion.
[0008] According to a first design example of the invention, the means directly or indirectly contacting or contactable with the ejection element provided to move at least one ejection element through the first open position are arranged on the movable furniture part regardless of whether the movable furniture part is in the form of a door, lid or drawer.
[0009] This lends itself to a simple design whereby the means include at least a first part arranged on the movable furniture part and at least a second part arranged on the ejection element such that they exert a magnetic attractive force on one another. Other solutions are possible, naturally. Thus, it is possible, for example, that the first part could be formed as a hinged rod arranged on the movable furniture part and the second part of the means could be arranged, for example, in the form of a longitudinal guide on the ejection element.
[0010] According to another design example of the invention, the means directly or indirectly contacting or contactable with the ejection element provided to move at least one ejection element beyond the first open position are arranged on the furniture body and/or in or on the ejection device. A preferred design example according to the invention provides that the actuator in addition to the ejection device has at least one additional auxiliary actuator which constitutes the means for moving the ejection element during the opening of the movable furniture part beyond the first open position.
[0011] A simple but nevertheless sturdy solution for this is if the auxiliary actuator is an energy accumulator, preferably manually loaded and preferably a pressure spring.
[0012] Although it would also be conceivable to configure the movement of the ejection element beyond the first open position to be independent of the movement of the movable furniture part, a technically simple solution is achieved if the one (or more) ejection element in the ejection device stays in contact or follows the movable furniture part in at least one part section of the opening or closing path of the movable furniture part situated between the first open position and the closed end position. Beneficially, the one (or more) ejection element in the ejection device is in contact with the movable furniture part during 50%, or preferably 80%, of the opening or closing path of the movable furniture part.
[0013] According to an alternative design version of the invention, it is arranged that the means for moving the ejection element during the opening of the movable furniture part through the first open position which is directly or indirectly linked with the ejection element is fitted to the furniture body and/or to the ejection device.
[0014] Regardless of whether the ejection element is arranged on the furniture body or on the movable furniture part so that it moves linearly or rotates, a further design example of the invention provides that the furniture part is located translationally movable in or on the furniture body, for example in the form of a drawer. According to another design example of the invention, the movable furniture part can, however, be located rotationally movable in or on the furniture body, again regardless of whether the ejection element is arranged on the furniture body or on the movable furniture part so that it moves linearly or rotates.
[0015] This means that the invention is suitable for all conceivable combinations of a movable furniture part with an ejection element, as long as it is ensured that the location of the ejection element changes in relation to its starting position with a latched ejection device in the first open position, i.e., after completion of the ejection process and at the start of the loading process. In other words, the distance between the contact point of the ejection element in the starting position and the contact point in its position after the end of the ejection process on the one hand, and the distance between the contact point of the ejection element in the starting position and the contact point in its position after the end of the opening process on the other hand must be different.
[0016] A preferred design example is characterised by a rotatable ejection element whereby there is a difference between the opening angle of the ejection element in its position after the end of the ejection process in the first open position of the movable furniture part on the one hand, and the opening angle of the ejection element in its position after the end of the opening process in the opened end position of the movable furniture part on the other.
[0017] In the case where the movable furniture part is pivotably supported, the maximum opening angle of the ejection element is favorably approximately equal (as close as possible) to the maximum opening angle of the movable furniture part, whereby the ejection element can follow the movable furniture part substantially during the entire opening path of the movable furniture part.
[0018] According to a further preferred design version of the invention, the ejection device is formed to at least partly load the energy accumulator of the actuator for the ejection element during a closing movement of the movable furniture part in a part section of the opening or closing path of the movable furniture part located between the opened end position and the first open position. Thus, the closing of the movable furniture part is quiet and smooth if the ejection device is constructed to start the loading process of the energy accumulator in general with each closing movement of the movable furniture part, preferably regardless of the position of the movable furniture part.
[0019] If, in this alternative design, the ejection element is pivoted, it can be further arranged that there is a difference between the opening angle of the ejection element at the end of the ejection process in the first open position of the movable furniture part on the one hand, and the angle at the start of the loading process of the energy accumulator on the other, or, respectively, the distance between the contact point of the ejection element in the home position and the contact point at the end of the ejection process on the one hand, and the distance between the contact point of the ejection element in the home position and the contact point at the start of the loading process of the energy accumulator, on the other.
[0020] According to a preferred example of the invention, the ejection device has a pivoted ejection element and a latchable actuator, preferably a coil tension spring, which interact with a transmission device, preferably a gear train. A simple means can be arranged whereby the ejection element is linked to the actuator through a link element and has a section with gear teeth that is formed to engage with a driving pinion secured to a bearing element which can rotate. This method can save space if at least the ejection element, the bearing element for the driving pinion and the link element are arranged coaxially.
[0021] Latching of the ejection device can be arranged, for example, by using a detent or a catch guided in a heart-shaped slide track, as provided for in a further design example according to the invention, via an elbow lever and/or a dead point mechanism.
[0022] The free running needed between the driving pinion and the link element to move the ejection element beyond the first open position is arranged in a further design example according to the invention, in which one arm of the elbow lever is pivoted at its free end with the link element. The dead point mechanism has a lever which is pivoted at one end with the elbow of the elbow lever and at the other end pivoted with a curved coupling element, whereby the curved coupling element is secured, preferably coaxially with the link element, so that it will rotate.
[0023] It is necessary in loading the energy accumulator to eliminate free movement between the coupling element and the pinion to be able to transfer the force acting on the ejection element to the link element. According to a design example of the invention, this is achieved by connecting the driving pinion, so that it will not turn, to a coaxial brake disk whereby the brake disk is shaped so that it is in contact at its perimeter with the curved coupling element. This means that, immediately following or at the start of the closing process of the movable furniture part, the brake disk is brought into contact at its perimeter with the curved coupling element, thus blocking the rotation of the pinion, and the force of the movable furniture part, which is closing, acting on the ejection element is transferred to the link element, a process which loads the energy accumulator.
[0024] A simple configuration of the ejection device is provided according to a preferred design example if the ejection device is arranged in a housing with an outlet aperture at least for the ejection element. The housing can then be fitted simply in a suitable location either on the movable furniture part or on the furniture body.
[0025] To ensure that the movable furniture part always reaches the same first open position at the end of the closing process, it is necessary to define the opening angle of the ejection element in the first open position. The opening angle is achieved by a preferred design example in which at least one stop for the bearing element of the actuating pinion is arranged in the housing, whereby the bearing element rests on the stop in the first open position of the movable furniture part.
[0026] A further design example of the invention provides that the means to move the ejection element beyond the first open position is in the form of a preferably curved leaf spring whose first leg engages with the ejection element and whose second leg engages with the link element. In this case, the movable furniture part must be held against the force of the preferably curved leaf spring in its closed end position which can be achieved by a retracting device or a hinge.
[0027] According to another example, the means to move the ejection element beyond the first open position is in the form of a spiral spring whose first leg engages with the ejection element and whose second leg, preferably rotatable and held in position, engages with the housing. With an appropriate arrangement of the spiral spring, a form of snap mechanism can be produced such that the spiral or torsion spring holds the ejection element in the exit position but trips when unlatching the energy accumulator and forces the ejection element in the opening direction of the movable furniture part.
[0028] According to a further design example of the invention, the ejection device also has a release mechanism with a release element to unlatch the actuator. A preferred design example in this case provides that the release mechanism is configured for the release element to rest in direct contact on the movable furniture part or the furniture body in the closed position of the movable furniture part, in order to precisely define the release path.
[0029] Furthermore, it is intended to propose a process for opening and, as the case may be, closing a movable furniture part located in or on a furniture body of a furniture item using an ejection device which has an ejection element which is contacted, or can be contacted, by a latchable actuator, preferably a manually loaded energy accumulator. The latchable actuator is loaded during the closing movement of the movable furniture part by an ejection element which is characterised according to the invention in that the loading process of the energy accumulator is started, after the movable furniture part had been opened, beyond a first open position during a closing movement of the movable furniture part in a part section of the opening, or closing, path of the movable furniture part between the first open position and the closed end position.
[0030] In contrast to the state of the art, therefore, the loading process of the energy accumulator is begun right at the start of the closing movement of the movable furniture part whereby, according to a preferred design example of the invention, the loading process for the energy accumulator is started in general with each closing movement of the movable furniture part, preferably independent of the open position of the movable furniture part. In other words, the loading of the energy accumulator occurs based on the ratchet principle, i.e., after the end of the ejection process, the ejection element is free to move in relation to the energy accumulator during the further opening path while, in the reverse direction, it is in constant contact, in every position, with the energy accumulator.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] Other benefits and details of the invention are explained in more detail in the following description of the figures, referring to the design examples illustrated in the drawings, in which:
[0032] FIG. 1 show a first design example of a furniture item according to the invention with a movable hinged furniture part,
[0033] FIGS. 2 a - 2 d show in each case, the movable furniture part and the ejection element in different positions,
[0034] FIGS. 3 a - 3 c are diagrammatic representations of different positions of the movable furniture part,
[0035] FIGS. 4 a - 4 c are diagrammatic representations of different positions of the ejection element,
[0036] FIG. 5 a is an exploded view of a preferred example of an ejection device according to the invention,
[0037] FIG. 5 b is a rear view of the upper part of the ejection element from FIG. 5 a,
[0038] FIGS. 6 a - 15 show different positions of the movable furniture part and the ejection device from FIG. 5 a during opening and closing the movable furniture part,
[0039] FIG. 16 a is an exploded view of a second example of an ejection device according to the invention,
[0040] FIG. 16 b is a rear view of the upper part of the ejection element from FIG. 16 a and
[0041] FIGS. 17-28 show different positions of the movable furniture part and the ejection device from FIG. 16 a during opening and closing the movable furniture part.
DETAILED DESCRIPTION OF THE INVENTION
[0042] FIG. 1 shows a perspective view of the entire furniture item 1 according to the invention in which a movable furniture part 3 is arranged on a furniture body 2 so that it can rotate by means of two hinges 28 . The ejection device 4 is arranged on the furniture body 2 inside, generally level with the front edge of the furniture body 2 such that the pivoted ejection element 5 can move the movable furniture part 3 in the opening direction.
[0043] FIG. 2 a shows a plan view of a detail of the furniture item 1 shown in FIG. 1 whereby the movable furniture part 3 is in its closed end position. The gap remaining between the furniture part 3 and the furniture body 2 is needed to allow the movable furniture part 3 to move from its closed end position to, as seen from the closing direction viewpoint, a released position after it whereby the latch on the actuator for the ejection element has been released. After the actuator is unlatched, the ejection element 5 forces the movable furniture part 3 to a first open position ( FIG. 2 b ). At this point, the energy accumulator for the actuator has now completely discharged and the ejection element 5 had ended the ejection process. The reference symbol 26 indicates the release element of the ejection device, more of which will be explained later. Up to this point shown in FIG. 2 b , the invention has followed the touch-latch operation principle known already in the state of the art.
[0044] The invention now takes over where the movable furniture part 3 is positioned as shown in FIG. 2 c . As also happens with a conventional touch-latch mechanism, the opening of the movable furniture part 3 has to be done by the user beyond the open position shown in FIG. 2 b since the ejection element 5 has already completed the ejection process. However, in the state of the art, the ejection element 5 does not change its location as the furniture part 3 moves beyond the first open position. The ejection device according to the invention has the means to move the ejection element 5 beyond the first open position shown in FIG. 2 b.
[0045] FIG. 2 d shows both the movable furniture part 3 as well as the ejection element 5 in the completely open position whereby the condition where the ejection element 5 is no longer in contact with the movable furniture part 3 in the fully open position is simply a simplification of the design of the ejection device. Naturally it is also possible, however, to locate the ejection element 5 in the ejection device such that the ejection element 5 rests on the movable furniture part 3 in the fully open position.
[0046] Different positions of the movable furniture part 3 are illustrated in FIGS. 3 a - 3 c . Here, the movable furniture part 3 is shown, in FIG. 3 a in closed position S in which the movable furniture part 3 is aligned essentially parallel to the front of the furniture body 2 . In FIG. 3 b , the movable furniture part 3 is located in its first open position O corresponding to the position of the movable furniture part 3 after the end of the ejection process. The opening angle is designated by β which represents the change in position of the movable furniture part 3 from its closed position S to its first open position O. At the end of the ejection process, the movable furniture part 3 is moved by the user beyond the first open position O to its opened end position E. The opening angle β′ extends in this case between the closed position S to the opened end position E of the movable furniture part 3 .
[0047] It should be pointed out that the opened end position E does not necessarily have to be the completely open position of the movable furniture part 3 —as shown in FIG. 3 c —that is, the opening angle β′ must simply be greater than the opening angle β in the closed position S of the movable furniture part 3 and smaller or equal to the maximum opening angle when the movable furniture part 3 is in its fully open position.
[0048] Similarly, FIGS. 4 a - 4 c show different positions of the ejection element 5 which is pivoted in the ejection device 4 in the design example shown. FIG. 4 a shows the ejection element 5 is the home position S′ corresponding to the position of the ejection element 5 with a latched ejection device 4 and the movable furniture part 3 in the closed end position. FIG. 4 b shows the position O′ of the ejection element 5 after the end of the ejection process. The opening angle α here extends between the position O′ of the ejection element 5 and the position of the ejection element 5 in the exit position S′. d is used to designate the distance between the contact point of the ejection element 5 in the closed position S′ and the contact point of the ejection element 5 after the end of the ejection process, while d′ denotes the distance between the contact point of the ejection element 5 in the closed position S′ and the contact point of the ejection element 5 after the end of the opening process of the movable furniture part.
[0049] If FIGS. 4 b and 4 c , which show the position E′ of the ejection element 5 after the end of the opening process of the movable furniture part 3 , are compared, it can be seen that the distances d, d′, or, respectively, the opening angles α, α′ are different in both positions.
[0050] A basic idea of the invention consists of sending the ejection element 5 , after the end of the ejection process, to, viewed in the opening direction, a position E′ located beyond position O′ which represents the position of the ejection element 5 after the end of the opening process of the movable furniture part 3 . This is done by linking the movable furniture part 3 right at the start or immediately after the start of the closing process with the ejection element 5 , whereby, with an appropriate linking of the ejection element 5 with the ejection device, the loading process for the energy accumulator can begin as early as the first section of the closing path, during which the loading of the energy accumulator can be completed using known devices in the part section of the closing path of the movable furniture part 3 immediately before the closed position.
[0051] This means that, essentially, the whole of the path traveled by the movable furniture part as it closes can now be used to load the energy accumulator. This is due to the invention and the construction of the ejection device using the ratchet principle such that the ejection element, at the end of the ejection process, is free to move in relation to the energy accumulator of the actuator during the further opening path, during which it is in constant contact, i.e., in every position, with the energy accumulator in the opposite direction. Thus, on the one hand, the path traveled by the movable furniture part as the energy accumulator is being loaded can be made greater than the path traveled by the movable furniture part during the ejection process, so that a user requires less force to load the energy accumulator due to the lengthened path.
[0052] A second possibility is to make the length of the path traveled by the movable furniture part during the charging and ejection processes essentially the same but to move this section to the immediate vicinity of the opened end position of the opening and closing path of the movable furniture part. The result of this is that the user will apply a force to load the energy accumulator right at the start of the closing process, giving the user the feeling of a smooth process when closing the movable furniture part.
[0053] Using two of the design examples presented in FIGS. 6 a - 15 and FIGS. 16 a - 28 , the functioning sequence of a furniture item according to the invention during the opening and closing processes will be described below.
[0054] FIG. 5 a shows an exploded view of a first example of an ejection device 4 according to the invention. All parts of the inventive ejection device 4 are arranged in an enclosed housing 20 , whereby the housing cover is not shown to allow a clear overall view. The rotatable ejection element 5 arranged in the housing 20 is in the form of a single-arm lever and has an upper part 27 and a lower part 27 ′. A rotatable roller 29 is arranged on its end furthest from the pivot point, whereby the axes of rotation of the roller 29 and the ejection element 5 are essentially parallel. This roller 29 provides the means of linking the ejection element 5 with the movable furniture part.
[0055] A bearing element 13 , a coupling element 16 and a link element 14 are also rotatable and arranged coaxially with the ejection element 5 between the lower part 27 ′ and the upper part 27 . A pinion 12 and a brake disk 19 , connected together and unable to rotate relative to each other, are anchored and can rotate about an axis which is essentially parallel to the rotation axis of the ejection element 5 or, respectively, that of the bearing element 13 . The pinion 12 is constructed so that it engages with a toothed section Z ( FIG. 5 b ) on the upper part 27 of the ejection element 5 , while the brake disk 19 is constructed to engage with a toothed section Z′ arranged on the coupling element 16 . Furthermore, a guide element 30 is arranged between the coupling element 16 and the brake disk 19 , and the guide element 30 serves to provide a secure engagement with the teeth in the toothed section Z′ of the coupling element 16 arranged around the perimeter of the brake disk 19 (i.e., this prevents a tooth tip on the brake disk 19 from coming into contact with a tooth tip on the toothed section Z′ on the coupling element 16 when the brake disk 19 engages with the coupling element 16 ).
[0056] In the example shown, the means to move the ejection element 5 through a first open position comprise two auxiliary actuators 23 , 23 ′ whereby the first auxiliary actuator 23 ′ in the form of a spiral spring bears on the bearing element 13 in the opening direction, whose movement is restricted by a stop 22 arranged in the housing, which allows the required freedom of movement for the ejection element 5 between the brake disk 19 and the coupling element 16 . The second auxiliary actuator 23 ′ is in the form of a torsion spring whose first leg 24 engages with the upper part 27 of the ejection element 5 while the second leg 24 ′ is rotatable but fixed in position to the housing 20 of the ejection device 4 .
[0057] Furthermore, the actuator 6 for the ejection element 5 is arranged in the ejection device 4 , where the actuator 6 has a manually loaded energy accumulator 8 in the form of a tension spring, a retainer 7 for the energy accumulator 8 and an adjusting element 9 to adjust the energy accumulator 8 . The adjusting element 9 is arranged in the housing 20 such that it is accessible externally to make adjustment of the energy accumulator 8 simple and uncomplicated. At its open end, the energy accumulator 8 constructed as a tension spring for the actuator 6 is hooked over a projection 10 on the link element 14 , so that, as the energy accumulator 8 discharges, the link element 14 is moved in the direction of the actuator 6 .
[0058] The actuator 6 is latched, in the design example shown, by an elbow lever 17 and a dead point mechanism. In this system, the first arm 18 of the elbow lever 17 is pivoted at its free end with the link element 14 , while the second arm 18 ′ is pivoted to the housing 20 of the ejection device 4 . The dead point mechanism comprises a pivoted lever 15 and is connected at one end to the elbow of the elbow lever 17 and at the other end, also pivoted, to the coupling element 16 . The actuator 6 is latched, when charging the energy accumulator 8 by the ejection element 5 , when the link element, due to its engagement with the brake disk 19 and with the coupling element 16 of the link element 14 is moved so far to the right until the energy accumulator 8 is fully loaded and the lever 15 crosses the dead point of the elbow lever 17 , which latches the elbow lever 17 , and, therefore, the link element 14 .
[0059] The actuator 6 is unlatched by a release mechanism 25 which comprises a release element 26 , an eccentric rotating element 33 , a restoring spring 32 for the rotating element 33 , a wedge-shaped adjusting element 34 , a release lever 35 , a damping element 36 and a restoring element 37 , contacted by the damping element 36 , to restore the rotating element 33 . The release mechanism 25 is linked to the lever 15 of the dead point mechanism by a connecting part 38 , preferably in the form of a lever, which can rotate at one end with the release lever 35 and at the opposite end with the lever 15 of the dead point mechanism, or, respectively, the coupling element 16 .
[0060] FIG. 6 a shows the ejection device 4 with the energy accumulator 8 in the latched condition. The movable furniture part 3 is in the closed position whereby the release element 26 of the release mechanism 25 rests directly on to the movable furniture part 3 . More will be explained later about the direct contact of the release element 26 with the movable furniture part 3 which is essentially accomplished by means of the wedge-shaped adjusting element 34 which is contacted by the restoring element 37 .
[0061] The view of the device is clarified by omitting the cover of the housing 20 and the upper part 27 of the ejection element 5 from the drawing. In the situation shown, the energy accumulator 8 for the actuator 6 is loaded. This means that the tension spring which constitutes the energy accumulator 8 is anchored in the retainer 7 and tensioned by the link element 14 . On its front side facing the movable furniture part 3 , the housing 20 has an exit aperture 21 for the ejection element 5 and the release element 26 . All of the remaining components of the ejection device 4 are contained inside the enclosed housing 20 except the adjusting element 9 for the energy accumulator 8 .
[0062] The energy accumulator 8 is latched by means of an elbow lever 17 acting on the link element 14 where the lever 17 is latched in the position shown by a lever 15 in a dead point mechanism. The ejection element 5 is latched in its home position S′ by the auxiliary actuator 23 constructed as a torsion spring. In this, the auxiliary actuator 23 is arranged such that the one leg 24 ′ of the spring is arranged in a bearing point 40 in the housing and the second leg 24 of the auxiliary actuator 23 is arranged in a bearing point 39 on the lower part 27 ′ of the ejection element 5 so that they swivel.
[0063] By locating the bearing point 39 , with the ejection element 5 in the home position, on the right side of the connecting line V of the pivot point of the ejection element 5 and the bearing point 40 ( FIG. 6 b ), this ensures that the auxiliary actuator 23 locks the ejection element 5 in its home position. Due to the rotational motion of the ejection element 5 during the ejection process this bearing point 39 moves to the left until it crosses the connecting line V, so that the auxiliary actuator 23 pushes the ejection element 5 in the opening direction. This means that the auxiliary actuator 23 constructed as a torsion spring is latched, similar to the actuator 6 , by means of a dead point mechanism.
[0064] In the position shown, therefore, the link element 14 , the coupling element 16 and the ejection element 5 are not free to move due to the latched elbow lever 17 or, respectively, the position of the auxiliary actuator 23 , while the bearing element 13 and, thus, the pinion 12 and the brake disk 19 can rotate. In this, the bearing element 13 is contacted by an auxiliary actuator 23 ′ formed as a curved spring which forces the bearing element in the opening direction of the movable furniture part whereby the teeth on the pinion 12 engage with the tooth-shaped section Z of the upper part 27 of the ejection element 5 .
[0065] By having the bearing element 13 forced away from the coupling element 16 by the auxiliary actuator 23 ′, the required freedom of movement can be obtained between the coupling element 16 and the brake disk 19 during the opening process. If this brake disk 19 were to engage with the tooth-shaped section Z′ of the coupling element 16 during the opening process, this would block the pinion 12 and, thus, the ejection element 5 as a result, that is, the ejection of the movable furniture part 3 by the ejection element 5 would not have been possible in this type of configuration.
[0066] FIG. 6 b differs from FIG. 6 a in that it shows the upper part 27 of the ejection element 5 , on which a catch 41 is formed.
[0067] FIG. 7 shows the movable furniture part 3 in the release position A which, viewed in the closing direction SR, is located beyond the home position S of the movable furniture part 3 , whereby the movable furniture part 3 , in the design example shown, is being moved by the user who is pressing the movable furniture part from the home position S to the release position A. The motion of the movable furniture part 3 pushes the release element 26 back into the housing 20 and the release lever 35 moves leftwards over the wedge-shaped adjusting element 34 . The release element 26 , the wedge-shaped adjusting element 34 and the release lever 35 are thus constructed and arranged as components in a rolling contact joint. The L-shaped lever 35 and the lever-type link 38 also move the lever 15 in the dead point mechanism to the left which releases the catch on the elbow lever and, thus, the latching of the energy accumulator 8 .
[0068] Even though the illustrated release mechanism represents a preferred design example, the invention is not to be seen as restricted to the design example shown. To this end, instead of using the movable furniture part 3 to release the ejection device, it is completely possible and conceivable to do this by means of a switch, a button or by direct pressure on the release element 26 itself.
[0069] In FIG. 8 , the ejection process has ended and the movable furniture part 3 has reached its first open position O. With the release of the energy accumulator 8 , the link element 14 was moved to the left which moved the ejection element 5 out of the housing 20 in the opening direction OR. The link between the ejection element 5 and the movable furniture part 3 is made by means of the idler roller 29 , which allows the movable furniture part 3 to slide smoothly on the ejection element 5 . The coupling element 16 was also moved in the opening direction OR by the lever 15 which is connected at one of its ends to the elbow of the kinked elbow lever 17 , the movement continuing until a gap appears between the brake disk 19 and the toothed section Z′ of the coupling element 16 , or, respectively, the guide 30 , so that the pinion 12 which is still engaging with the toothed section Z on the upper part 27 of the ejection element 5 (not shown) is allowed to turn.
[0070] The bearing element 13 , still being forced by the auxiliary actuator 23 ′ in the opening direction OR, is prevented from moving further outwards by the stop 22 ( FIG. 5 a ) arranged in the housing 20 .
[0071] It is further evident from FIG. 8 that the bearing element 39 for the leg 24 of the auxiliary actuator 23 formed as a torsion spring, lies between the pivot point of the ejection element and the bearing point 40 of the auxiliary actuator 23 so that the auxiliary actuator 23 ′ is still forcing the ejection element 5 in the opening direction OR. This requires the force exerted by the auxiliary actuator 23 to be arranged such that it can just move the ejection element 5 out, but is not enough for the ejection element 5 to open the movable furniture part 3 further, which is still in contact with the ejection element 5 .
[0072] It is, of course, also possible to make the acting force of the auxiliary actuator 23 so large that the auxiliary actuator 23 would not only be able to move the ejection element 5 but also the movable furniture part 3 beyond the first open position O to an opened end position E. A construction of this type would lead to the situation where the user, in closing the movable furniture part 3 , would have to apply, additional to the force to load the energy accumulator 8 , the relatively large force to load the auxiliary actuator which would give the user the impression of a movable furniture part which is stiff to move. Nevertheless, if the level of the acting force by the auxiliary actuator 23 is appropriate, a furniture item 1 with a movable furniture part 3 and an ejection device 4 can be produced where the user, in moving the movable furniture part 3 from a closed position to an opened end position, simply has to release the ejection device 4 by, for instance, applying pressure to the movable furniture part whereby the movable furniture part 3 would then be moved in a first section by the ejection element 5 and in a further section by the auxiliary actuator 23 to its opened end position without requiring any further action on the part of the user.
[0073] By contrast, in the example shown, the force exerted by the auxiliary actuator 23 is just enough for the ejection element 5 to stay in contact with the movable furniture part 3 such that the user is scarcely aware, when closing the movable furniture part, of the force applied to load the auxiliary actuator 23 .
[0074] An opened end position E of the movable furniture part 3 is illustrated in FIG. 9 . It is evident that, compared with FIG. 8 , the position of the movable furniture part 3 , the ejection element 5 and the auxiliary actuator 23 has changed. The discharging of the auxiliary actuator 23 and the movement of the movable furniture part 3 by the user to an opened end position E has enabled the ejection element 5 to follow the movement of the movable furniture part 3 . Similarly, the position of the pinion 12 has changed relative to the toothed section Z arranged on the upper part 27 of the ejection element 5 . In other words, the pinion 12 on this toothed section Z is now engaged with a point on the toothed section Z furthest from the idler roller 29 .
[0075] If the movable furniture part 3 is now moved from its opened end position E in the closing direction SR, the brake disk 19 is brought into engagement with the toothed section Z′ of the coupling element 16 , as shown in FIG. 10 . This will block the rotation of the pinion 12 along the toothed section Z on the ejection element 5 and the coupling element 16 will be forced back in the closing direction into the housing 20 by the movement of the ejection element 5 . The link element 14 is moved so far to the right by the coupling element 16 and the elbow lever 17 linked to it until the energy accumulator 8 of the actuator 6 is fully loaded. At the same time, this movement also loads the auxiliary actuators 23 , 23 ′ ( FIG. 11 a ).
[0076] As shown in FIG. 10 , the action of the guide 30 ensures that the brake disk 19 and the toothed section Z′ of the coupling element 16 engage with each other such that each tooth tip of the brake disk 19 engages with each tooth root on the toothed section Z′ of the coupling element 16 which is able to prevent any jerky movements of the ejection element 5 and, thus, of the movable furniture part 3 .
[0077] FIG. 11 b differs from FIG. 11 a in that the lever 15 of the dead point mechanism has now passed beyond the dead point of the elbow lever 17 so that the energy accumulator 8 of the actuator 6 is latched. Thus, the loading process for the energy accumulator 8 is concluded before the movable furniture part 3 has reached its first open position O. After the energy accumulator 8 has been loaded, the release element 26 of the release mechanism 25 remains in contact, with no play, with the movable furniture part 3 during the remaining section of its closing path.
[0078] Moreover, as can be seen in FIG. 11 b , the upper part 27 of the ejection element 5 has a catch 41 which is formed to engage with an eccentric rotating element 33 of the release mechanism 25 . The rotating element 33 is forced in the closing direction SR of the ejection element 5 by a restoring spring 32 to ensure that the catch 41 engages with the rotating element 33 as the ejection element 5 retracts into the housing 20 .
[0079] In FIG. 12 , the catch 41 is now engaged with the eccentric rotating element 33 , and carries it along with it in the closing direction SR of the ejection element 5 . As the ejection element 5 retracts, the locking elements of the ejection device 4 remain unchanged for the energy accumulator 8 , thus keeping the actuator latched.
[0080] In FIG. 13 , the bearing point 39 of the auxiliary actuator 23 has now passed beyond the connecting line V between the pivot point of the ejection element 5 and the bearing point 40 of the auxiliary actuator 23 on the housing 20 , whereby the auxiliary actuator 23 continues to press on the ejection element 5 in the opposite direction, that is, the ejection element 5 is now pushed back into its home position by the auxiliary actuator 23 where it is latched. The catch 41 on the ejection element 5 has restored the rotating element 33 to an end position which has tensioned the restoring element 37 completely. The eccentric rotating element 33 is connected via a toothed section (not shown) to the pinion of a damper 36 to dampen the return movement of the rotating element 33 when tensioning the restoring element 37 in the form of a tension spring, as well as avoiding noise which might arise as the rotating element 33 returns to its other end position. By locating the wedge-shaped adjusting element 34 in a ball socket arranged on the eccentric rotating element 33 by means of a ball head, the wedge-shaped adjusting element 34 is moved in conjunction with the eccentric rotating element 33 .
[0081] In FIG. 14 , the movable furniture part 3 is now back in its closed position S, in which, for example, it can be retained by the hinge 28 . The catch 41 on the ejection element 5 now snaps past the eccentric rotating element 33 which is moved to the left by the restoring element 37 . The rotating element 33 moves the wedge-shaped adjusting element 34 to the left also. Due to the rolling contact joint formed between the wedge-shaped adjusting element 34 and the release element 26 , the release element 26 is moved out of the housing 20 towards the movable furniture part 3 and just far enough so that the release element 26 rests on the movable furniture part 3 with no play between them ( FIG. 15 ).
[0082] The configuration shown in FIG. 15 corresponds to that shown in FIG. 6 b , that is, the ejection element 5 is in the home position, with the actuator 6 latched, the movable furniture part 3 is in the closed position and the release element 26 rests on the movable furniture part 3 with no play between them.
[0083] FIG. 16 a , as in FIG. 5 a , shows an exploded view of a second example of an inventive ejection device 4 . The same parts have the same identification symbols, so a repeat description of these parts will be dispensed with.
[0084] The second example shown in FIGS. 16 a - 28 differ from the first design example shown in FIGS. 5 a - 15 mainly in the design of the release mechanism 25 and its linking with the coupling element 16 via the lever-type link 38 .
[0085] As in the first example, the release mechanism 25 has a release element 26 , an eccentric rotating element 33 and a damper 36 , whereby the damper 36 comprises a bearing 42 , a rotary damper 43 and a pinion 44 . Differing from the first design example, the release element 26 in the second design example is connected directly to the eccentric rotating element 33 via a rolling contact joint. The release mechanism 25 is connected to the coupling element 16 via a lever-type link 38 which, however, is pivoted at one of its ends to the bearing 42 on the damper 36 . This means that the bearing 42 , or rotating damper 43 respectively, in the second design example assumes the function of the release lever 35 , or restoring element 37 respectively, in the first design example.
[0086] The lever-type link 38 is no longer pivoted at its opposite end with the coupling element 16 . Instead, a notched end 45 is arranged at the free end of the lever-type link 38 which is formed to engage with a projection 46 formed on the coupling element 16 . The coupling element 16 , for its part, is pivoted with the lever 15 of the dead point mechanism for the elbow lever 17 .
[0087] In contrast to the first example, the second design example has just one auxiliary actuator 23 , formed as a curved spring and acting between the link element 14 and the ejection element 5 . The difference extends to the construction of the peripheral surface of the brake disk 19 and the corresponding section Z′ on the coupling element 16 . Whereas in the first example engagement between the brake disk 19 and the coupling element 16 was positive due to the toothed design, in the second example the brake disk 19 and the coupling element 16 form a friction contact with one another.
[0088] FIG. 17 shows the ejection device 4 with the energy accumulator 8 latched. The movable furniture part 3 is in the closed position S whereby the release element 26 of the release mechanism 25 rests on the movable furniture part 3 with no play between them. In the position shown, the energy accumulator 8 is loaded and the actuator 6 latched. The latch action is brought about by the action of an elbow lever 17 on the link element 14 , where the lever 17 is locked by a lever 15 in a dead point mechanism in the position illustrated.
[0089] The ejection element 5 is locked in its home position S by the hinge 28 . The link element 14 , the coupling element 16 and the ejection element 5 are not free to move due to the locked elbow lever 17 and the movable furniture part 3 held in its closed position by the hinge 28 , while the bearing element 13 and, thus, the pinion 12 as well as the brake disk 19 can rotate. The freedom of movement required for free motion between the coupling element 16 and the brake disk 19 is provided by simply having a stop 22 ′ for the bearing element 13 in the housing 20 .
[0090] In this example, it must be ensured that the retention force of the hinge is greater than the force exerted by the auxiliary actuator 23 which maintains the ejection element 5 in permanent contact in the opening direction OR with the movable furniture part 3 .
[0091] FIGS. 18 and 18 b differ only in that the upper part 27 of the ejection element 5 is shown transparently (dotted line). Otherwise, pressure is being exerted in FIG. 18 on the movable furniture part 3 , denoted by the changed position of the release lever 15 .
[0092] FIG. 19 shows the movable furniture part 3 in the release position A which, viewed in the closing direction SR, is located behind the closed position S of the movable furniture part 3 , whereby the user is applying pressure to move the movable furniture part 3 from the closed position S to the release position A. The movable furniture part 3 pushes the release element 26 further back into the housing 20 whereby, via the rolling contact joint, the eccentric rotating element 33 and, with it, the bearing 42 , are moved to the left. Simultaneously, the coupling element 16 and, therefore, the lever 15 in the dead point mechanism are also moved to the left by the notched end 45 ( FIG. 16 a ) arranged on the lever-type link 38 , unlatching the elbow lever 17 and so unlatching the energy accumulator 8 .
[0093] In FIG. 20 , the ejection process has ended and the movable furniture part 3 has reached its first open position O. With the release of the energy accumulator 8 , the link element 14 was moved to the left which moved the ejection element 5 out of the housing 20 in the opening direction OR. The link between the ejection element 5 and the movable furniture part 3 is made by means of the idler roller 29 , which allows the movable furniture part 3 to slide smoothly on the ejection element 5 . The bearing element 13 is prevented from moving further outwards by the stop 22 ( FIG. 16 a ) arranged in the housing.
[0094] In order to allow the eccentric rotating element 33 which, during the opening process is moved to the left by the catch 41 on the ejection element 5 , to return to a position once the catch 41 has passed, in which the catch 41 can again engage with the eccentric rotating element 33 when closing the movable furniture part 3 , a restoring spring 32 in the form of a compression spring is arranged between the housing 20 and the eccentric rotating element 33 .
[0095] An opened end position E of the movable furniture part 3 is illustrated in FIG. 21 a . It is evident that, compared with FIG. 21 a , the position of the movable furniture part 3 , the ejection element 5 and the auxiliary actuator 23 has changed. The movement of the movable furniture part 3 by the user to an opened end position E has enabled the auxiliary actuator 23 to discharge and the ejection element 5 to follow the movement of the movable furniture part 3 . Similarly, the position of the pinion 12 has changed relative to the toothed section Z arranged on the upper part 27 of the ejection element 5 . In other words, the pinion 12 on this toothed section Z is now engaged with a point on the toothed section Z furthest from the idler roller 29 .
[0096] FIG. 21 b relates to the position of the ejection device 4 shown in FIG. 21 a and differs only in that the peripheral surface of the brake disk 19 and the corresponding section Z′ of the coupling element 16 are toothed as in the first design example. Again, to avoid a jerky engagement of the brake disk 19 with the coupling element 16 , a guide 30 is arranged on the coupling element 16 .
[0097] If the movable furniture part 3 is now moved from its opened end position in the closing direction SR, the brake disk 19 is brought into engagement with the toothed section Z′ of the coupling element 16 , as shown in FIGS. 22 a and 23 . This will block the rotation of the pinion 12 along the toothed section Z on the ejection element 5 and the coupling element 16 will be forced back in the closing direction SR into the housing 20 by the movement of the ejection element 5 . The link element 14 is moved so far to the right by the coupling element 16 and the elbow lever 17 linked to it until the energy accumulator 8 of the actuator 6 is fully loaded. At the same time, this movement also loads the auxiliary actuator 23 .
[0098] FIG. 22 b again shows an alternative in which the peripheral surface of the brake disk 19 and the corresponding section Z′ of the coupling element 16 are toothed. It can be seen that the action of the guide 30 ensures that the brake disk 19 and the toothed section Z′ of the coupling element 16 engage with each other such that each tooth tip of the brake disk 19 engages with each tooth root on the toothed section Z′ of the coupling element 16 which is able to prevent any jerky movements of the ejection element 5 and, thus, of the movable furniture part 3 .
[0099] FIG. 24 differs from FIG. 23 in that the lever 15 of the dead point mechanism has now passed beyond the dead point of the elbow lever 17 so that the energy accumulator 8 of the actuator 6 is latched. Thus, the loading process for the energy accumulator 8 is concluded before the movable furniture part 3 has reached is first open position O. After the energy accumulator 8 has been loaded, the release element 26 of the release mechanism 25 remains in contact, with no play, with the movable furniture part 3 during the remaining section of its closing path.
[0100] Moreover, as can be seen in FIG. 25 , the upper part 27 of the ejection element 5 has a catch 41 which is formed to engage with an eccentric rotating element 33 of the release mechanism 25 . This rotating element 33 , as already mentioned, is acted on by a restoring spring 32 to ensure that the catch 41 engages with the rotating element 33 as the ejection element 5 retracts into the housing 20 .
[0101] In FIG. 25 , the catch 41 is now engaged with the eccentric rotating element 33 , and carries it along with it in the closing direction SR of the ejection element 5 . As the ejection element 5 retracts, the locking elements of the ejection device 4 remain unchanged for the energy accumulator 8 , thus keeping the actuator latched.
[0102] In FIG. 26 , the catch 41 on the ejection element 5 has restored the eccentric rotating element 33 to its one end position. The eccentric rotating element 33 is connected via a toothed section (not shown) to the pinion 44 and the rotary damper 43 of the damper 36 to dampen the return movement of the rotating element 33 .
[0103] In FIG. 27 , the movable furniture part 3 is now back in its closed position S, in which it can be retained by the hinge 28 . The catch 41 on the ejection element 5 now snaps past the eccentric rotating element 33 which is moved to the left by the damper element 36 . Due to the rolling contact joint formed between the eccentric rotating element 33 and the release element 26 , the release element 26 is moved out of the housing 20 towards the movable furniture part 3 and just far enough so that the release element 26 rests on the movable furniture part 3 with no play between them ( FIG. 28 ).
[0104] The configuration shown in FIG. 28 corresponds to that shown in FIG. 17 , that is, the ejection element 5 is in the home position, with the actuator 6 latched, the movable furniture part 3 is in the closed position S and the release element 26 rests on the movable furniture part 3 with no play between them.
[0105] The design examples shown should not, of course, be regarded as limiting but rather simply as individual samples of innumerable possibilities for inventive concepts for producing a movable furniture part with an ejection element by means of which the movable furniture part is moved further in the opening direction after the end of the ejection process.
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The invention relates to an item of furniture including a furniture body, a furniture part which is displaceably received in or on the furniture body, and an ejection device having at least one ejection element for displacing the moveable furniture part from a closed position into a first open position. At least one lockable drive device is provided for driving the at least one ejection element. The invention is characterized by means for displacing the at least one ejection element beyond the first open position.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to footwear, and in particular the present invention relates to an article of footwear with a reflective outsole.
[0003] 2. Description of Related Art
[0004] Attempts to add provisions for illuminating portions of an article of footwear so that it may be seen in the dark have been proposed. The first category of these disclosures makes use of phosphorescent or ‘glow in the dark’ technology. Van Cleef et al. (U.S. Pat. No. 5,716,723) discloses a glow in the dark shoe sole. The shoe sole includes phosphorescent polymer containing compositions. Likewise, Saruwatari et al. (JP patent number 6,125,801) discloses a light condensing resin molding that is embedded into a transparent shoe sole. The light condensing resin molding is formed by dispersing phosphors such as florescent pigments or fluorescent dyes. Akira (JP patent number 3,280,901) further discloses a shoe coated in a luminous paint. Luminous paints are paints embedded with phosphorescent compounds that may be activated by visible or ultra-violet light. A drawback of these disclosures is that phosphorescent compounds release captured light slowly, resulting in a dim glow, and a far from instantaneous response to incoming light such as a driver's headlights.
[0005] Retro-reflective materials reflect incoming light regardless of the angle of incidence. Unlike phosphorescent materials, which emit light slowly, retro-reflective materials emit light almost instantaneously, allowing for a very bright response to incident light. Previous disclosures including retro-reflective materials (often referred to simply as reflective materials) have focused on embedding strips or pieces of a reflective material into an article of footwear. Chiu (U.S. Pat. No. 5,611,156) discloses a reflective shoe having reflective surfaces between a covering layer and an underlying layer. Here, the reflecting layer is disposed along the sides of the outsole. Goldberg et al. (U.S. Pat. No. 6,312,782) discloses an article of footwear that includes discreet shaped colored polymeric objects in a transparent or translucent matrix. The polymeric objects preferably include reflective materials. Both the Goldberg and Chiu designs include the drawback of requiring both the incident and reflected light to pass through a secondary medium (which is different from air). This may reduce the intensity of the reflected light in some circumstances, reducing the ability of the reflective material to alert others to the presence on the wearer of the article of footwear.
[0006] Pearson (U.S. Pat. No. 2,607,130) discloses an article of footwear composed of rubber, having light-reflecting areas. The top of the article of footwear comprises a knitted fabric coated on the outside with vulcanized rubber, including a light-reflector mounted on the rubber coating. Lin et al. (U.S. Pat. No. 6,754,985) also discloses an article of footwear including a reflective alert strip that is fixed to the middle sole. These designs include reflectors that have been attached to the upper of an article of footwear, but do not teach a means of adhering reflective materials to the bottom of the outsole. During walking and running motions, the bottom surface of an article of footwear is often the most exposed portion, as viewed from a driver behind the walker/runner.
[0007] Along these lines, Tomlinson (U.S. Pat. No. 6,312,782) discloses an article of footwear including a shoe instep reflector. In this design, the reflector may be mounted along the bottom surface of the outsole, disposed close to the ground. A primary drawback to this design is the bulky design of the instep reflector. The reflector has a thickness that requires the instep region of the sole to be depressed in a manner that prevents the reflector from dragging against a bottom surface. Haynes (U.S. Pat. No. 4,233,760) discloses an article of footwear with a light reflective means on the upper portion and on the bottom sole portion of the article of footwear. Along the bottom of the sole potion, the light reflective means includes bars of reflective material that have been embedded in the bottom portion of the outsole. This design is also somewhat cumbersome, in that it requires the outsole to be embedded with solid strips of reflecting material. This may reduce the overall flexibility of the outsole. Furthermore, manufacturing this design requires holes to be cut out of the outsole prior to insertion of the reflective strips. In particular, both the Tomlinson and Haynes designs make it very difficult to cover the large portions of the outsole surface.
[0008] There is a need in the art for an outsole including a bottom surface with a large portion that is covered in its entirety with a reflective material. Furthermore, this reflective material should not substantially reduce the flexibility of the outsole.
SUMMARY OF THE INVENTION
[0009] The invention discloses an article of footwear with a reflective outsole. In one aspect, the invention provides an article of footwear configured to receive a wearer's foot, comprising: an outsole; the outsole including a lower surface disposed opposite the wearer's foot; at least one tread element extending away from the lower surface; the lower surface including a first portion; the first portion comprising a majority of a region of the lower surface; and where a reflective device is disposed in the first portion of the lower surface.
[0010] In another aspect, the first portion is a forefoot region of the outsole.
[0011] In another aspect, the first portion is a central region of the outsole.
[0012] In another aspect, the first portion is a heel region of the outsole.
[0013] In another aspect, the first portion is a forefoot region and a central region of the outsole.
[0014] In another aspect, the first portion is a heel region and a central region of the outsole.
[0015] In another aspect, the first portion is a combination of a forefoot region, a central region, and a heel region of the midsole.
[0016] In another aspect, the reflective device covers the entire first portion except the tread element.
[0017] In another aspect, the reflective device is flexible.
[0018] In another aspect, the reflective device includes a base layer.
[0019] In another aspect, the invention provides an article of footwear configured to receive a wearer's foot, comprising: an outsole; a reflective device attached to the outsole; the reflective device being composed of a flexible material; and where the reflective device covers a first portion of an outer surface of the outsole.
[0020] In another aspect, the reflective material includes a base layer.
[0021] In another aspect, the first portion is a forefoot portion.
[0022] In another aspect, the first portion is a heel portion.
[0023] In another aspect, the first portion is a forefoot and heel portion.
[0024] In another aspect, the invention provides an article of footwear configured to receive a wearer's foot, comprising: an outsole; a reflective device associated with the outsole; and where the reflective device is disposed along a portion of an outer periphery of the outsole.
[0025] In another aspect, outer periphery is disposed along a forefoot region of the outsole.
[0026] In another aspect, the outer periphery is disposed along a heel region of the outsole.
[0027] In another aspect, the outer periphery is disposed along a forefoot region and a heel region.
[0028] In another aspect, the reflective device is disposed along an outer periphery of the outsole.
[0029] Other systems, methods, features and advantages of the invention will be, or will become, apparent to one of ordinary 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 and this summary, be within the scope of the invention, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views.
[0031] FIG. 1 is an isometric view of a preferred embodiment of an article of footwear as seen from behind;
[0032] FIG. 2 is an isometric view of a preferred embodiment of an outsole of an article of footwear;
[0033] FIG. 3 is a close up of a preferred embodiment outsole of an article of footwear;
[0034] FIG. 4 is a schematic view of a preferred embodiment of an outsole of an article of footwear including three regions;
[0035] FIG. 5 is a schematic view of a preferred embodiment of an outsole of an article of footwear with a reflective device applied to one or more regions;
[0036] FIG. 6 is a schematic view of a preferred embodiment of an outsole of an article of footwear with a reflective device applied to one or more regions;
[0037] FIG. 7 is a schematic view of a preferred embodiment of an outsole of an article of footwear with a reflective device applied to one or more regions;
[0038] FIG. 8 is a schematic view of a preferred embodiment of an outsole of an article of footwear with a reflective device applied to one or more regions;
[0039] FIG. 9 is a schematic view of a preferred embodiment of an outsole of an article of footwear with a reflective device applied to one or more regions;
[0040] FIG. 10 is a schematic view of a preferred embodiment of an outsole of an article of footwear with a reflective device applied to one or more regions;
[0041] FIG. 11 is a schematic view of a preferred embodiment of an outsole of an article of footwear with a reflective device applied to one or more regions; and
[0042] FIG. 12 is a schematic view of a preferred embodiment of an outsole of an article of footwear with a reflective device applied to one or more regions, including the periphery of these regions.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0043] FIG. 1 is a preferred embodiment of an article of footwear 100 in the form of an athletic shoe. For clarity, the following detailed description discusses a preferred embodiment, however, it should be kept in mind that the present invention could also take the form of any other kind of footwear including, for example, skates, boots, ski boots, snowboarding boots, cycling shoes, formal shoes, slippers, sandals, flip-flops or any other kind of footwear. That is, the properties of the reflective outsole disclosed throughout this specification and in the claims may be applied to any article of footwear.
[0044] In a preferred embodiment, article of footwear 100 includes upper 102 and outsole 104 . Upper 102 is preferably configured to receive a wearer's foot. Preferably, upper 102 is associated with outsole 104 , and in some embodiments, upper 102 is attached to outsole 104 . Upper 102 may be attached to outsole 104 by a variety of different methods, including, but not limited to, stitching, glue, staples, as well as other methods. In some embodiments, such as sandals or flip-flops, upper 102 may be very simple and include one or more straps.
[0045] In a preferred embodiment, outsole 104 includes a first side and a second side 120 . The first side of outsole 104 is preferably enclosed within upper 104 . In some embodiments, the first side of outsole 104 may be configured to contact a wearer's foot. In other embodiments, the first side of outsole 104 may be configured to contact a midsole, an insole, or another type of liner. In a preferred embodiment, second side 120 of outsole 104 is configured to contact the ground. In particular, second side 120 of outsole 104 is preferably disposed along the outside of article of footwear 100 along the bottom.
[0046] Outsole 104 is preferably constructed from a lightweight and flexible material. However, outsole 104 may be constructed from any material or a combination of several materials. Some examples of material from which outsole 104 may be constructed include rubber, plastic, fabric, and metal. This list is not meant to be exhaustive as outsole 104 may also be constructed from other materials as well.
[0047] In this embodiment, article of footwear 100 includes a shock absorbing system 180 disposed proximate to a heel region 110 of outsole 104 . Preferably, shock absorbing system 180 helps reduce stresses to a wearer's foot during walking and/or running. Large tread elements 185 may be disposed along heel region 110 of outsole 104 , proximate to shock absorbing system 180 . Outsole 104 further includes indents 190 , disposed along a central region 108 of outsole 104 . Shock absorbing system 180 , large tread elements 185 , and indents 190 are included in this embodiment as additional aesthetic and performance features and need not be included in every embodiment of an article of footwear with a reflective outsole.
[0048] The orientation of FIG. 1 is intended to demonstrate a typical position of the article of footwear during a walking or running motion. In particular, during a running or walking motion, the outsole of the article of footwear will be displayed to someone viewing the wearer from behind. This situation may occur when a motor vehicle approaches from behind. At night the driver may not be aware of the runner's presence.
[0049] For this reason, article of footwear 100 preferably includes provisions for improving the visibility of article 100 in low light conditions. In one embodiment, a reflective device is associated with article 100 . In an exemplary embodiment, a reflective device is associated with the outsole of article 100 . Preferably, reflective device 115 is disposed along forefoot region 106 of outsole 104 . Reflective device 115 is preferably constructed of a retro-reflective material.
[0050] At night, an illumination source, including headlights of a motor vehicle, would illuminate reflective device 115 as outsole 104 is exposed during walking or running, alerting the driver to the runner's presence along the roadside. Although reflective device 115 is positioned to enhance visibility from the rear, it is also possible to view reflective device 115 from other directions. For example, if a person is running towards an oncoming motor vehicle, the driver may still see reflective device 115 illuminated along outsole 104 as the wearer's feet are raised upwards during forward strides and heel kicks.
[0051] Referring to FIG. 2 , a preferred embodiment of second side 120 of outsole 104 preferably includes tread elements 112 . In the exemplary embodiment, tread elements 112 comprise a cylindrical shape. However, tread elements 112 may comprise any shape. Furthermore, tread elements 112 may be constructed from any material. In a preferred embodiment, tread elements 112 may be constructed of rubber. In this embodiment, tread elements 112 are disposed along forefoot region 106 of outsole 104 . In other embodiments, tread elements 112 may be disposed along central region 108 and/or heel region 110 . In a preferred embodiment, the spacing between tread elements may be one to two times the size of the diameter of the tread elements, though this diameter may vary among tread elements.
[0052] In a preferred embodiment, outsole 104 includes lower surface 122 . Lower surface 122 generally defines a lower reference surface, and preferably, tread elements 112 extend away from lower surface 122 . In some embodiments, lower surface 122 of outsole 104 includes a first portion 130 . In a preferred embodiment, first portion 130 is a forefoot region. That is, first portion 130 is preferably associated with forefoot region 106 of outsole 104 . In other embodiments, first portion 130 may be a central region or a heel region. In these embodiments, first portion 132 may be associated with central region 108 and/or heel region 110 of outsole 104 .
[0053] In the exemplary embodiment, first portion 130 of lower surface 122 may be configured to receive reflective device 115 . Reflective device 115 is preferably a thin and flexible material with retro-reflective properties. Reflective device 115 is preferably configured to cover the entirety of first portion 130 of lower surface 122 with the exception of substantially small areas surrounding tread elements 112 . In the exemplary embodiment, first portion 130 comprises a majority of lower surface 122 .
[0054] Tread elements 112 are preferably disposed through holes 170 in reflective device 115 . As previously mentioned, tread elements 112 extend away from lower surface 122 . As a result, lower surface 122 of outsole 104 may have limited contact with the ground during the use of article of footwear 100 . This may result in less wear on reflective device 115 .
[0055] In some embodiments, reflective device 115 may include one or more large holes 175 . Large holes 175 are distinct from holes 170 because large holes 175 are large enough to accommodate multiple tread elements. Large holes 175 are included primarily for aesthetic purposes in this embodiment. Large holes 175 need not be included as part of reflective device 115 in other embodiments.
[0056] Preferably, outsole 104 may include peripheral treads 160 . Peripheral tread elements 160 are distinguished from tread elements 112 in that peripheral tread elements 160 are flat on one side, rather than completely round. Peripheral tread elements are preferably disposed along a second outer periphery 165 of forefoot region 106 . Because peripheral tread elements 160 are raised with respect to lower surface 122 and reflective device 115 , peripheral tread elements 160 may help to prevent reflective device 115 from contacting the ground. This is particularly the case along a first outer periphery 135 .
[0057] Preferred embodiments of the construction of reflective device 115 can be seen in FIG. 3 . Referring to FIG. 3 , a preferred embodiment of reflective device 115 preferably includes two layers. A first side 302 of a base layer 304 of reflective device 115 is preferably configured to contact lower surface 122 of outsole 104 . A second side 306 of base layer 304 of reflective device 115 is preferably configured to contact a first side 308 of a reflecting layer 310 of reflective device 115 . Here, a first tread element 320 and a second tread element 322 are seen to extend from lower surface 122 of outsole 104 . Furthermore, first tread element 320 and second tread element 322 extend through a first hole 330 and a second hole 332 of reflective device 115 .
[0058] In some embodiments, base layer 304 of reflective device 115 may be a fabric or cloth material. In some embodiments, base layer 304 may be constructed from a non-woven synthetic material. Examples of such materials include Woven, Tricot, PET film, napping cloth such as Nylex, as well as other materials. Preferably, base layer 304 is constructed from a durable and flexible material. Reflecting layer 310 is preferably composed of a reflective film. Different types of reflective film include sublimated reflective film and colored reflective film. Typically, reflective films include a glass beading structure that creates the desired reflectivity property.
[0059] Preferably, base layer 304 and reflecting layer 310 are attached to one another prior to attaching base layer 304 to outsole 104 . Once reflective device 115 , which is preferably comprised of base layer 304 and reflecting layer 310 , is assembled, the two layers can then be attached to outsole 104 . Prior to attaching reflective device 115 to outsole 104 , reflective device 115 can first be cut to incorporate holes allowing for tread elements. Preferably, reflective device 115 is then added to a mold with rubber for curing. In a preferred embodiment, base layer 304 of reflective device 115 is attached to lower surface 122 during the molding process of outsole 104 . The finished product is a molded rubber outsole attached to reflective device 115 along lower surface 122 . This construction provides a flexible reflective device 115 . This flexibility allows reflective device 115 to be applied to large areas of outsole 104 without adversely affecting flexibility or performance.
[0060] As discussed previously, a reflective device need not be associated with only a forefoot region of an outsole. In some embodiments, the reflective device may be disposed along other portions of the outsole. Referring to FIG. 4 , which is a preferred embodiment of a schematic outsole 400 , three distinct regions can be observed. Outsole 400 can include a forefoot region 404 , a central region 406 , and a heel region 408 . Outsole 400 further includes three distinct groupings of treads as well as lower surface 402 . In a preferred embodiment, forefoot region 404 , central region 406 , and heel region 408 of outsole 104 are associated with first tread element group 410 , second tread element group 412 , and third tread element group 414 respectively.
[0061] FIG. 4 is intended to be a schematic representation of a preferred embodiment of a generic outsole configured to be used in an article of footwear. The three regions of outsole 104 are intended as examples of possible divisions of outsole 104 . Other embodiments may include a different number of regions. The size and/or shape of these regions may also vary. Likewise, the three tread element groups are intended to represent examples of possible tread element patterns. In other embodiments, tread elements may be arranged into any desired pattern and/or design. The following figures are intended to demonstrate that a reflective device may be configured to cover any region of the outsole. They are not meant to limit the use of a reflective device to only a combination of the three pre-defined regions.
[0062] The position and size of the reflective device may be varied. The reflective device is preferably disposed along a first portion of lower surface 402 . In a preferred embodiment, first portion 402 may include forefoot region 404 , central region 406 , or heel region 408 . The first portion may also include a combination of forefoot region 404 , central region 406 and heel region 408 . Referring to FIGS. 5-11 , a preferred embodiment of outsole 400 includes a reflective device disposed along a first portion comprising forefoot region 404 , central region 406 , and/or heel region 408 . All the possible combinations of the location of the first portion including each of the three regions are disclosed below.
[0063] In each of the following figures, a reflective device is disposed along a first portion of lower surface 402 of outsole 400 . The region or regions defining the first portion may be varied. Referring to FIG. 5 , first portion 500 comprises forefoot region 404 . Referring to FIG. 6 , first portion 600 comprises central region 406 . Referring to FIG. 7 , first portion 700 comprises heel region 408 . Referring to FIG. 8 , first portion 800 comprises forefoot region 404 and central region 406 . Referring to FIG. 9 , first portion 900 comprises central region 406 and heel region 408 . Referring to FIG. 10 , first portion 1000 comprises forefoot region 404 and heel region 408 . Finally, referring to FIG. 11 , first portion 1100 comprises forefoot region 404 , central region 406 and heel region 408 . In these embodiments, a second portion may be any portion other than the first portion.
[0064] As the reflective device disclosed here is preferably constructed with a lightweight backing material, the reflective device may be extended to cover a portion of an outer periphery of an outsole. Referring to FIG. 12 , outsole 1200 includes a lower surface 1202 . Outsole 1200 also preferably includes a forefoot region 1204 and a heel region 1206 . In a preferred embodiment, outsole 1200 further includes an outer periphery 1250 that can extend to the extreme edges of outsole 1200 . In the embodiment shown in FIG. 12 , forefoot region 1204 and heel region 1206 each extend to outer periphery 1250 .
[0065] In this embodiment, a first portion 1210 of lower surface 1202 comprises forefoot region 1204 and heel region 1206 . Preferably, first portion 1210 of lower surface 1202 includes reflective device 1220 . In a preferred embodiment, first portion 1210 of lower surface 1202 is covered by reflective device 1220 . In particular, reflective device 1220 is disposed along at least one portion of outer periphery. In this case, a first portion 1230 and a second portion 1232 of outer periphery disposed along forefoot region 1204 and heel region 1206 respectively. FIG. 12 is intended only as an example of the way in which a reflective device may be extended to cover a portion of an outer periphery of an outsole. Other embodiments may include a first portion having different regions and including different portions of the outer periphery of the outsole.
[0066] While various embodiments of the invention have been described, the description is intended to be exemplary, rather than limiting and 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. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents. Also, various modifications and changes may be made within the scope of the attached claims.
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An article of footwear including a reflective outsole is disclosed. The article of footwear has an outsole including a reflective device that covers one or several portions of the outsole. The reflective device is composed of a thin and flexible material that does interfere with the natural flexibility of the outsole. The reflective device may extend over a substantial majority of a lower surface of the outsole, including a portion of the outer periphery of the outsole.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a device for sensing the load current for a control circuit of a H-bridge comprising MOS transistors and operating in class AB.
It applies for example to a control circuit of a voice coil used for positioning the actuator or the read/write heads of a control circuit of a disk on a desired track. The position of the heads is controlled through the current in the coil. The control of the movable coil uses a transconductance amplifier wherein the output current is proportional to the input voltage. Therefore, it is necessary to know the direction and the magnitude of the load current. The transconductance amplifier or control amplifier operates on the coil through a H-bridge, the coil being arranged in a diagonal of the bridge.
2. Discussion of the Related Art
Conventionally, in such a control circuit of a movable coil, the transconductance loop is closed through a sensing resistor serially connected with the load.
FIG. 1 shows a first example of a conventional circuit. The illustrated H-bridge includes four N-channel MOS transistors connected between a supply voltage Vdd and ground. The bridge is controlled by a control amplifier (not shown) connected to the gates of the four transistors. The drains of the two first transistors M1, M2, or high-side transistors, are connected to the supply voltage Vdd. Their respective sources are connected to the drains of two other transistors M3, M4, or low-side transistors, whose sources are grounded. The source of the first high-side transistor M1 is connected to a first terminal of a load 1 while the second terminal of the load 1 is connected through a sense resistor Rs to the source of the second high-side transistor M2. The two terminals of resistor Rs are connected to a sense amplifier (not shown) that transmits the voltage across resistor Rs to the control amplifier for controlling its gain. The load 1 corresponds for example to a resistor R serially connected with an inductor L.
FIG. 2 shows a second conventional control circuit of a moving coil. The difference with the circuit of FIG. 1 is that the load current sense resistor Rs is connected between the common sources of the two low-side transistors M3, M4 and ground. The terminals of resistor Rs are still connected to a sense amplifier.
In both circuits, the load current flows in the sense resistor Rs wherein a relatively high power dissipation occurs. Additionally, this causes a limitation of the load current for a given supply voltage Vdd.
A third conventional circuit is shown in FIG. 3. It includes three MOS transistors M1, M2, M3, an operational amplifier 2 and two mirror-connected NPN transistors T1, T2. Two high-side transistors M1, M2 have their respective drains connected to the supply voltage Vdd and their gates connected to a first terminal of the control amplifier. The source of transistor M1 is connected to the inverting input of the operational amplifier 2 and to the source of the low-side transistor M3. The output of the operational amplifier 2 is connected to the gate of transistor M3 whose source is connected to the collector of a first bipolar transistor T1. The two transistors T1, T2 have their bases connected with the collector of transistor T1 and their emitters grounded. The collector of transistor T2 is connected to the second terminal of the control amplifier. The non-inverting input of the operational amplifier 2 is connected to the source of the high-side transistor M2 and to a first terminal of load 1. The second terminal of load 1 is grounded. Such a circuit limits the power dissipated in as much as no serial resistor is used for sensing the load current. However, this circuit is operative only for class A control circuits where the current of the high-side power transistor M2 always flows in the load 1. Such a circuit cannot be used when the output is operated in class AB where the load current is different from the current flowing through the power transistor.
An object of the present invention is to avoid the above drawbacks of the existing sense circuits and to provide a load current sense circuit operable in class AB with a low dissipated power.
SUMMARY OF THE INVENTION
To attain this object, the present invention provides a current sense device for a load arranged in a diagonal of a H-bridge comprising MOS transistors and operating in class AB, comprising first means, independent from the H-bridge, for measuring the current flowing in the load.
According to an embodiment of the invention, the current sense device includes a current-voltage converter for converting the current measured by a sensor into a voltage proportional to the current. This voltage is applied to a sense amplifier that determines the transconductance gain of a control amplifier of the transistors of the H-bridge.
According to an embodiment of the invention, the current sense device further includes a proportionally device for maintaining the voltage linearly proportional to the current flowing in the load, by making said voltage independent from the current in the two high-side transistors of the H-bridge.
According to an embodiment of the invention, the sensor includes current mirrors for reproducing the currents flowing in the two low-side transistors of the H-bridge.
According to an embodiment of the invention, the current-voltage converter includes an operational amplifier whose inputs are connected to the terminals of a resistor arranged in a diagonal of an auxiliary bridge having MOS transistors. The currents reproduced by the current mirrors constitute the control signals of the auxiliary bridge.
According to an embodiment of the invention, the proportionally device includes two current comparators. Each comparator receives one of the currents reproduced by the current mirrors and a biasing current. Each comparator provides a current representing the difference between the biasing current and one of the currents reproduced by the mirrors; if it is positive, the result of the comparison and its inverted value are reproduced at the terminals of the resistor of the auxiliary bridge.
According to an embodiment of the invention, each of the current mirrors includes a MOS transistor, whose source is grounded, whose gate is connected to the gate of one of the low-side transistors of the H-bridge, and whose drain constitutes one of the terminals of the transconductance control amplifier.
According to an embodiment of the invention, the value of the resistor of the current-voltage converter determines, through the sense amplifier, the transconductance gain of the control amplifier of the H-bridge.
According to an embodiment of the invention, the load includes a moving coil for positioning the read/write head of a hard disk.
The provision of a device independent from the H-bridge for sensing the load current reduces the power dissipated in the bridge. This power corresponds only to the power dissipated in the load. Additionally, as no current is absorbed in the bridge for sensing the current, the maximum operational current of the bridge is higher.
Indeed, in all the prior art circuits, the current sense depends upon the H-bridge. In the case of the circuit of FIG. 2, the sense resistor Rs shifts the voltage of the sources of the low-side transistors of the bridge. The circuit of FIG. 3 cannot operate in class AB and the bipolar transistors have an effect on the bridge.
The use of MOS transistors for making current mirrors is motivated by the fact that those transistors are voltage-controlled whereby the mirror ratio is optimum.
Comparing the currents reproduced by the mirrors to a biasing current additionally improves the control of the H-bridge by suppressing the errors due to the operation in class AB which could cause the current-voltage characteristic of the converter to be non linear, in particular for low load currents.
The use, inside the current-voltage converter, of an auxiliary bridge of MOS transistors enables an easy arrangement for determining the transconductance gain of the control amplifier.
BRIEF DESCRIPTION OF THE DRAWINGS
Those objects, features and advantages, and others, of the present invention will be explained in more detail in the following description of specific embodiments made, in a non-limitative way, in connection with the attached drawings wherein:
FIGS. 1-3, above-disclosed, illustrate schematically conventional H-bridge and current sense arrangements;
FIG. 4 is a schematical block diagram of an embodiment of a sensing device according to the present invention;
FIG. 5 shows an embodiment of the current mirrors of the device of FIG. 4;
FIG. 6 shows an embodiment of a currant-voltage converter of the device of FIG. 4; and
FIG. 7 is a block diagram of an embodiment of the current comparators of the device of FIG. 4.
DETAILED DESCRIPTION
As shown in FIG. 4, the H-bridge includes, like in FIG. 2, four N-channel MOS transistors M1, M2, M3, M4. The respective drains of the first two, high-side, transistors M1, M2 are connected to a supply voltage Vdd. The respective sources are connected to the drains of two low-side transistors M3, M4 whose sources are grounded. A load 1 is connected between the sources of transistors M1, M2. The gates of transistors M1, M2, M3, M4 are connected to a transconductance control amplifier (not shown). The gates of the low-side transistors M3, M4 additionally constitute two input terminals (Is+, Is-) of the sense circuit according to the invention.
The sense circuit according to the present invention includes a current-voltage converter 3, two current mirrors 4, 5 and two current comparators 6, 7.
Each current mirror 4, 5 attempts to reproduce the current flowing in one of the lower transistors M3, M4 so that the difference between the two currents can be converted into a voltage by the current-voltage converter 3. This difference is sent, as a voltage, by the converter 3 to the sense amplifier that determines the transconductance of the control amplifier. The control amplifier, by acting on the gates of the transistors of the H-bridge, modifies the current in load 1.
As shown in FIG. 5, each current mirror 4, 5 includes a N-channel MOS transistor M5, M6 whose source is grounded. The gate of each transistor M5, M6 is connected to the gate of the associated transistor M3, M4. The drains of transistors M5, M6 are connected to the sense amplifier (not shown). As the difference between the currents flowing in the low-side transistors M3, M4 corresponds to the current flowing in load 1, the use of the mirrors provides this current without perturbating the circuit. One of the benefits is that the MOS transistors are voltage-controlled. For bipolar transistors, the base current would have an influence on the outputs Is+ and Is-.
The currents flowing in the mirror transistors M5, M6 are respectively proportional to the currents in transistors M3, M4 with a ratio equal to the ratio between the gate widths (W) of two associated transistors. The gate lengths (L) are considered identical for two associated transistors, respectively M3-M5 and M4-M6, and the modulation due to the drain-source voltage of transistors can be neglected. The ratio between the gate lengths of two associated transistors can be easily precisely determined for this type of mirror. When the power MOS transistors are vertical DMOS transistors of a plurality of identical cells, some cells of the power transistor are used for implementing the mirroring transistor. Thus, the channel length of the cells of the mirroring transistor is strictly identical to the channel length of the cells of the power transistor.
The reason the modulation due to the drain-source voltage of transistors can be neglected is that the polarization voltage of the transistors operating in class AB is generally fixed so that the output voltage of the bridge is about half of the supply voltage Vdd. Therefore, with a low load current, the output voltage varies within a small range with respect to its initial value.
The current-voltage converter 3 is schematically shown in FIG. 6. This converter provides an output voltage Vout that is proportional to the difference between the currents reproduced by the mirroring transistors M5, M6. The voltage Vout is proportional to the current flowing through a resistor Rg. If this current through resistor Rg is proportional to the current in the load 1, the voltage Vout is proportional to the current in the load 1.
The gate of transistor M5 that corresponds to a first input terminal Is+ of the converter 3 is connected to the gate of an enhancement DMOS transistor M7, whose parasitic diode is symbolized by a diode D1. The source of transistor M7 is grounded. The drain of transistor M7 is connected to the gate of a P-channel MOS transistor M8 that constitutes a first high-side transistor of an auxiliary bridge formed around resistor Rg. The drain of transistor M8 is connected to the supply voltage Vdd while its source is connected to the drain of a first low-side N-channel MOS transistor M9. The source of transistor M9 is grounded. The same circuit is reproduced on the side of the second input terminal Is- of the converter 3. The gate of transistor M6 is connected to the gate of an enhancement DMOS transistor M10, its parasitic diode being symbolized by a diode D2, and whose source is grounded. The drain of transistor M10 is connected to the gate of a P-channel MOS transistor M11 that constitutes a second high-side transistor of the auxiliary bridge. The drain of transistor M11 is connected to the supply voltage Vdd while its source is connected to the drain of a second low-side N-channel transistor M12. The source of transistor M12 is grounded.
To reproduce in transistor M8 the current I1 flowing in transistor M5, the gate of transistor M8 is connected to the gate of two mirror-connected P-channel MOS transistors M13, M14. The drains of transistors M13, M14 are connected to the supply voltage Vdd. The transistor M14 is diode-connected, its source being connected to its gate, while the source of transistor M13 is connected to the drain of an N-channel MOS transistor M15, also diode-connected. The source of transistor M15 is grounded while its gate is connected to its drain and to the gate of a second low-side transistor M12 of the auxiliary bridge. The same circuit is implemented to reproduce the current I2 flowing through transistor M6 in transistor M11. The gate of transistor M11 is connected to the gate of two mirror-connected P-channel MOS transistors M16, M17. The drains of transistors M16, M17 are connected to the supply voltage Vdd. Transistor M17 is diode-connected, its gate being connected to its source, while the source of transistor M16 is connected to the drain of a diode-connected N-channel MOS transistor M18. The source of transistor M18 is grounded and its gate is connected to its drain and to the gate of transistor M9.
Resistor Rg is inserted in a diagonal of the bridge and its terminals are respectively connected to the inputs of an operational amplifier 14. This operational amplifier is connected as a current-voltage converter. Its non-inverting input is connected, through a resistor R1, to the source of transistor M8, that is to a terminal A of resistor Rg. This non-inverting input is also connected, through a resistor R2, to a reference voltage Vref. Its inverting input is connected, through a resistor R3, to the source of transistor M11, that is to the second terminal B of resistor Rg. The feed-back loop between the output and the inverting input of the operational amplifier 14 comprises a resistor R4. The output Vout of the operational amplifier 14 varies around the reference voltage Vref.
It will be shown that the amplitude of the variation of Vout with respect to Vref is proportional to the current I flowing in the load 1. The direction of the oscillation corresponds to the direction of the current in load 1.
Indeed, for a given load current I, the difference between the currents flowing in the transistors M3, M4 (FIG. 4) is equal to the value of this load current I. The direction of the current corresponds to the sign of this difference. The difference between currents I1 and I2 flowing in the mirror transistors M5, M6 is proportional to the value of the load current I. The direction of this current always corresponds to the sign of this difference.
If we assume, for example, that all the load current I flows in the transistor M3, that is the current flowing in the transistor M4 is null, the current I1 is I1=W(M5)/W(M3)*I, where W(M5)/W(M3) represents the ratio between the widths (W) of the gates of transistors M5 and M3. As the current I1 is reproduced in transistor M8 and as no current flows in transistors M11 and M9 (I2 being null), the current I1 flows in resistor Rg. So, Vout=W(M5)/W(M3)*I*Rg*Av, where Av is the gain of the operational amplifier 14.
Conversely, if we assume that all the load current I flows in transistor M4, that is the current flowing in transistor M3 is null, I2=W(M6)/W(M4)*I, where W(M6)/W(M4) is the ratio between the widths (W) of the gates of transistors M6 and M4. As the current I1 is reproduced in transistor M11 and as no current flows in the transistors M8 and M12 (I1 being null), the current I2 flows in resistor Rg. The potential across resistor Rg is -I2*Rg and Vout=-W(M6 )/W(M4)*I*Rg*Av.
The output voltage Vout varies between these two values as a function of the variations of the load current I. The output voltage Vout is provided to the sense amplifier so that the latter determines a suitable transconductance of the control amplifier. As this voltage is proportional to the value of resistor Rg, resistor Rg is sized so that the sense amplifier can vary the transconductance as desired.
The H-bridge arranged around load 1 is polarized to operate in class AB to avoid distortions in the bridge and transistors M1, M2 are permanently conducting. Accordingly, the current flowing in the low-side transistors M3, M4 corresponds to the sum of the current in load 1 and of the currents in the high-side transistors M2, M1. To avoid that the additional current originating from the high-side transistors M1, M2 causes the voltage across resistor Rg to be non-linear, in particular for low load currents, the currents I1 and I2 are compared to a biasing current Ibias. This comparison is made by comparators 6, 7 (FIG. 4) that compare the currents I1 and I2 with a biasing current Ibias. They provide the difference between the current Ibias and the currents I1 and I2 to the current-voltage converter 3.
FIG. 7 illustrates the compensation realized by the comparators 6, 7. The transistors M8, M9, M11, M12 constituting the auxiliary bridge around the resistor Rg are symbolized by the current sources 8, 9, 10, 11. The transistors M7, M13, M14, M15 and M10, M16, M17, M18 reproducing the currents I1 and I2 are symbolized by current sources 12, 13. The mirror transistors M5, M6 in which flow the currents I1 and I2 are symbolized by current sources 4, 5. The dotted lines symbolize the control links of the current sources implemented by the connections between the gates of the various transistors.
The comparators 6, 7 are respectively implemented by two mirror-connected current sources 15, 16 and 17, 18. The biasing current Ibias provided to each comparator 6, 7 is respectively symbolized by a current source 19, 20 between the supply voltage Vdd and the current source 4, 5 to which the comparator is associated. The inputs of sources 15, 17 are connected to the junction of sources 19, 4 and 20, 5. The outputs of the two sources 15, 17 are connected to the node A corresponding to one terminal of resistor Rg. The two mirror sources 16, 18 are connected between the node B, corresponding to the second terminal of resistor Rg, and ground.
In such a circuit, the difference between the biasing current Ibias and the current I1 or I2, if it is positive, is drawn from node B and sent to node A. Only the positive difference is taken into account. Indeed, if, for example, I1 is higher than Ibias, the difference Ibias-I1 is sent by source 15 to node A. This difference is also drawn by source 16 from node B. On the other hand, if I2 is higher than Ibias, the value Ibias-I2 is negative. This value cannot be drawn from node A as a negative current cannot be absorbed by the source 18 which is connected to ground. The same explanation applies to node B and to source 16 if I1 is higher than Ibias, that is if the direction of current I in load 1 is inverted.
Accordingly, the current in resistor Rg is always proportional to the current in the load I with a fixed ratio corresponding to the ratio between the gate widths of transistors M3, M5 and M4, M6. The functional circuit illustrated in FIG. 7 relative to comparators 6, 7 can easily be implemented by these skilled in the art.
Of course, the invention is liable to various variants and modifications that will appear to those skilled in the art. In particular, the invention applies to any load 1 arranged in the diagonal of a H-bridge operating in class AB. Additionally, each of the disclosed components can be replaced by one or a plurality of elements having the same function.
Having thus described at least one illustrative embodiment of the invention, various alterations, modifications and improvements will readily occur to these skilled in the art. Such alterations, modifications and improvements are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description is by way of example only and is not intended as limiting. The invention is limited only as defined in the following claims and the equivalents thereto.
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The present invention relates to a current sense device for a load arranged in a diagonal of a H-bridge comprising MOS transistors (M1, M2, M3, M4) and operating in class AB, characterized in that it includes sensor, independent from the H-bridge, for measuring the current flowing in the load. A current-voltage converter converts the current measured by said sensor into a voltage proportional to said current. The voltage is applied to a sense amplifier that determines the transconductance gain of a control amplifier of the transistors of the H-bridge.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This application relates to devices and methods for harvesting of marine bivalve mollusks. More particularly it concerns devices and methods for the harvesting of clams with minimum damage to the environment.
2. Description of the Prior Art
Submarine farming is an extremely complicated undertaking because the marine environment is many times more complex than traditional terra firma agriculture farming. Hence, three major labor intensive phases of such an endeavor, planting (or stocking), nurturing and harvesting must be accomplished with even greater attention paid to the consequences of methodology and equipment design.
The submarine interface between bottom sediment and the water just above it is a very important region of any body of water. Physically this is a result of currents, sediment transport, etc. in the area over a period of time. Grain size, stratification and contour reflect an established balance. Man's alterations result in processes which will seek to re-establish this balance. A change in contour, for example, will mean increased sediment transport in the area, increasing turbidity levels, changes in light transmission characteristics and biological productivity.
It has been established that a delicate chemical balance exists, at least with organic nutrients, between the available nutrients in the water and nutrients trapped in the sediment. This "bank" is important to the long term biological productivity of the area. It is believed that some toxic materials, heavy metals, and other containments are trapped in the sediment, removing them as a hazard to most of the food chain.
Biologically, the bottom interface is the home of a diverse community, containing elements of the entire food chain, from bacteria to predator. The particular area of concern here is the infauna, or animal population living in the sediments just below the interface. Some members of the population are of commercial value, a good example being the hard clam, Mercenaria mercenaria.
The clam is a filter-feeding shellfish. This animal, encased in a pair of hard, protective shells, positions itself just below the interface and extends its siphon or "neck" into the water above. Water is pumped through the clam and expelled through a second passage in the siphon. Food, mostly microalgae, is strained from the water and utilized. At the same time, oxygen necessary for respiration is obtained from the pumped water. The clam has no parallel in agriculture. It would constitute a hard-shelled animal, buried like a potato, deriving both its nutritional and respiration needs from breathing air.
While the clam has many natural predators, man is perhaps the most serious. Harvesting of clams in the wild ranges from digging by hand to the use of powerful ships and specialized mechanical equipment. Traditional manual harvest tools include rakes, tongs and the like. Harvesting clams with such tools becomes commercially inefficient because of their inefficiency under conditions of high clam densities. Also with use of such tools, it is difficult to assure that all of the planted area has been fully harvested.
Mechanical harvesting equipment currently available include hydraulic dredges (see U.S. Pat. No. 3,462,858) and suction dredges (see U.S. Pat. No. 3,624,932). However, with such equipment, the substrate is removed and then the shellfish are recovered. This results in undesirable habitat damage.
Another type of shellfish harvesting equipment less destructive to the habitat are sledge-type devices that comprise inclined tines or teeth which penetrate the substrate (see U.S. Pat. Nos. 4,112,602; 4,425,723 & 4,827,635). The present invention relates to this class of shellfish harvesters and provides improvements in the construction and operation thereof.
For example, the amount of energy required to drag sledge-type devices of the prior art through dense clam beds is formidable thereby limiting the size of the rake that can be incorporated in the sledge. Also, any propeller driven craft requires considerable thrust to pull such sledge devices forward. In shallow water, this can resuspend bottom sediments and increase turbidity. The present invention makes it possible to reduce the drag created by a given size rake contained in sledge-type shellfish harvesting devices.
All of the prior methods and equipment, including digging by hand, accomplish their goal by disturbing, and in most cases removing, much more sediment than surrounds the clam itself.
If one could grow a clam with a string attached, and harvest was accomplished by pulling on that string, the bottom interface would be disturbed, but the disturbance would be limited to that which was absolutely necessary to remove the clam. While this is not practical, the harvest of infauna should be pursued in that light in view of the extreme importance and delicacy of the region in which they exist.
The culture of shellfish as a "crop" compounds the problem, and again, the hard clam will serve as a good example. The density of clams in the wild may be several per square foot. As in agriculture, the farmer needs maximum yield to succeed in business, so juvenile clams ("seed") are planted in densities up to 100 per square foot, the "beds" are covered with nets to discourage natural predators while allowing water circulation. These nets are cleaned and changed as necessary, much as the dry land farmer protects his crop from weeds, birds, and other factors which constitute competition for his crop. While the farmer (or rancher) of the land is equipped for efficient harvest, the aquatic farmer harvesting infaunal organisms is not. The equipment available does not reflect the complexities of this new environment. The equivalent may be likened to a potato farmer harvesting his fields with a bulldozer, then separating the potatoes from the pile of dirt.
Harvest size clams, planted in the densities described, form a "bed" similar to a cobblestone road bed. Harvesting by hand is difficult due to the density. The "ideal density" which will produce a sustainable harvest over a long period of time has not been determined. Meanwhile, an environmentally benign method of harvesting and novel equipment for carrying out the method has been the focus of this present invention.
OBJECTS
A principal object of the invention is the provision of apparatus capable of harvesting marine bivalve mollusks more efficiently than related prior known equipment.
A further object is the provision of such shellfish harvesters that cause less environmental damage than even traditional manual harvesting tools, when tested on a per-clam basis.
Another object is the provision of new methods for harvesting clams and like shellfish with minimal environmental damage.
Yet another object is the provision of new sledge-type apparatus and methods for harvesting clams and like shellfish that reduces sledge drag thereby increasing the potential size of the rake and lowering energy requirements to move the sledge along the submarine surface.
Other objects and further scope of applicability of the present invention will become apparent from the detailed descriptions given herein; it should be understood, however, that the detailed descriptions, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent from such descriptions.
SUMMARY OF THE INVENTION
In light of the foregoing background explanation the "clam on a string" viewpoint has been used in the development of methodology for infaunal harvest. The task is to provide a method and the equipment to efficiently harvest a crop living in the substrate below the sediment/water interface beneath a body of water. In accomplishing this, there must be minimum disturbance of the sediment, minimum release of fine particles which might increase turbidity in the water, a minimum impact on small and immature creatures, and no mortality or damage to the harvested crop.
A rake-like device was chosen as the basis for the improved device, although perhaps for slightly different reasons than conventional gear. A rake is generally regarded as a row of parallel or staggered tines which is pulled through the sediment at some acute angle. It is pulled with sufficient force to cause obstructions, such as clams, to move up the angled tines to the surface where they are then harvested. Our research has shown that such a device, operated in that manner, causes great quantities of sediment to be raised also, due to cohesive forces. The range of sediments in which clams are found changes the amount of the substrate excavated, but the fact remains that the clams do not live in sediments which lack some cohesive or "sticky" quality. Even rocking the tines back and forth (changing the acute angle) does not solve the problem. This, in effect, is the action used with the manual clam rake. The accumulated sediment is washed from the rake and accumulated clams in the water column before the harvest is brought to the surface.
With the foregoing factors in mind, the objects of the invention are, in part, accomplished by the provision, in shellfish harvesting devices comprising a frame having means to move over the submarine surface of a shellfish growing substrate and a plurality of tines extending downward therefrom for penetration into the substrate, of the improvement which comprises vibrator means to impart a vibratory motion to the tines. In one preferred embodiment, the frame is a sledge having a pair of runners designed to slide over the submarine surface and includes shock absorber means to mitigate vibration of the runners by the vibrator means.
As an alternative to the active vibratory rake-like device being carried on a frame equipped with sled-like runners to maintain its design configuration with respect to the bottom, the device can be carried on wheels to ride on rail-like borders along the margins of a planted area on the submarine bottom.
The essential vibratory motion is applied to the tines causing a fluidization of the sediment surrounding the tines. As the pathway immediately ahead of an individual tine is fluidized (that is, the sediment grains pushed aside and replaced with interstitial water), the tine is free to move slightly, coming in contact with the next sediment grains, which are then pushed aside, etc. As the tine proceeds, the space is closed behind it by the sediment reclaiming the void. An object larger than the space between the tines will be forced upward, but not by brute force. Some of the micromotion will be transmitted to the shell, helping to fluidize the path to the surface, bit by bit. A constant tension, horizontal pull on the device insures that forward motion will progress as conditions permit.
The frequency and magnitude of the vibration will depend on varying factors. Some of the obvious variables are sediment composition and cohesive strength (i.e. damping effect), depth of crop (amount of sediment to be penetrated), density of crop (amount of energy transmitted to objects to be raised to the surface). Some of the less obvious include shell strength (this will vary with the crop) and effect on the bivalve (an intact shell full of lifeless jelly is not a successful harvest). A mature line of equipment will consist of models specific for crop and bottom type.
In preferred embodiments, the vibrator means comprises a turbine-like device that vibrates the tines at a rate of between about 1 and 200 times per second and the amplitude of such vibrations is between about 1 and 10 millimeters. Advantageously, the vibratory motion is vertically oriented, i.e., has a major vector oriented 80-90° and a minor vector oriented 0-10° relative to the plane of surface of the bivalve substrate being harvested.
There are two ways of producing the vibratory motion in the tines from the rotary motion of a turbine-like device. If an off-center weight is placed in the turbine wheel itself, a vibratory force is produced and transmitted through the bearings and housing to the attached tines. The frequency will be constant, depending only on water flow, but the amplitude of the resulting motion will vary depending on the loading (damping) on the tines.
Alternatively, when the rotating turbine wheel is mechanically coupled through an eccentric to the frame, the amplitude remains constant while the frequency varies with the loading on the tines. Both of these device arrangements are useful as automatic regulators in some circumstances.
In a preferred embodiment, the vibrator means comprises a rotatable, off-center mass and a hydraulic motor for rotating the mass and the shock absorber means comprises rubber mounts for the runners.
The exhaust water from the rotary device may be diverted to an enclosed collecting device resembling a flattened funnel. Its purpose is to wash the harvested product back to the apex where a large diameter suction hose delivers the shellfish to a surface vessel.
In commercial use, any harvest equipment will require some means to collect the harvest and transport it to the consumer. Therefore, it is assumed that the new devices will be used in conjunction with a vessel of some sort. This vessel can therefore not only store the harvest, but supply the energy for pulling the equipment across the bottom and powering the active vibratory portion on the bottom. The transmission of power to the active device on the bottom presents an additional set of problems.
Conventional power transmission technology is available in the mechanical, electrical and hydraulic fields. From the viewpoint of a waterborne harvesting vessel, all of the conventional designs have serious drawbacks. A design which would be adaptable to the varying depths and conditions would have to be extremely flexible and isolated from the corrosive water medium.
Mechanical transmission would be expensive to build and maintain, although it can be done. Electrical power transmission is quite common, is controllable and flexible. However, it is conceivably quite hazardous to the crew when used in the marine environment and requires isolation from the water, again expensive to build and maintain. Conventional closed circuit hydraulics is the most appealing for this service. However, conventional hydraulic fluids are toxic and any spill or accident would be deleterious to the environment. Advantageously, the new devices of the invention employ an unused variation of hydraulic technology using low pressure (less than 100 PSI) water in an open circuit.
Water in which the tending vessel floats is pumped through flexible hose to the active equipment where it turns a low pressure turbine to produce mechanical power for the vibrating action. A turbine-like device is necessary because the water being pumped from the surface will not be clean and sediment free. Close tolerances will be difficult to maintain, so a free flowing, self cleaning device is employed.
Objects of the invention are further accomplished by the provision of a method of harvesting shellfish from a submarine shellfish growing substrate which comprises (A) providing a frame designed to move over the surface of the substrate and a plurality of tines extending downward therefrom, (B) penetrating the tines into the substrate while moving the frame over the surface, and (C) vibrating the tines during such movement of the sledge. In a preferred method, the frame is a sledge that moves on runners and no significant vibration of the runners occurs during the tine vibrating step.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the invention can be obtained by reference to the accompanying drawings in which:
FIG. 1 is a perspective view of a first embodiment of a shellfish harvesting device of the invention.
FIG. 2 is a perspective view of a second embodiment of a shellfish harvesting device of the invention.
FIG. 3 is an exploded view of a first embodiment of a vibrator unit for devices of the invention.
FIG. 4 is an enlarged view of the first embodiment of vibrator unit.
FIG. 5 is an exploded view of a second embodiment of a vibrator unit for devices of the invention.
FIG. 6 is an exploded view of a third embodiment of a vibrator unit for devices of the invention.
FIG. 7 is a sectional view of a shock absorber means for the devices of the invention.
FIG. 8 is a diagrammatic view of a device of the invention in operation harvesting clams from a submarine substrate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring in detail to the drawings, the subtidal shellfish harvesting device 2 basically comprises a frame 4 designed to move over the submarine surface 6 of a shellfish growing substrate 8 and a plurality of tines 10 extending downward therefrom for penetration into the substrate 8.
The frame 4 has a pair of runners 12 fixed thereto by shock absorber means 14 and includes vertical panels 16 and an arch member 18.
A funnel unit 20 is bolted to the panels 16 and its exhaust end 22 connects to the exhaust hose 24 to transport to the surface vessel (not shown) clams that are raised by the tines 10 onto the collection plate 26.
A hydraulic pressure hose 28 is fixed by spaced-apart clamps 30 to the hose 24 to reach the surface vessel for connection to a hydraulic pressure source (not shown).
The second embodiment of the subtidal shellfish harvesting device 2a basically comprises a frame 4a designed to move over the submarine surface 6 of a shellfish growing substrate 8 and a plurality of tines 10 extending downward therefrom for penetration into the substrate 8.
The frame 4a has vertical panels 16a fixed thereto by shock absorber means 14 and these panels carry concave wheels 32 that roll along the rails 34 positioned on the submarine surface 6.
A hood 36 is provided over the tines 10 to confine the clams 38 harvested by the tines 10 from the substrate 8 and guide them onto the belt conveyor 40 which delivers the clams 38 to the surface vessel (not shown).
Also, the device 2a includes hydraulic pressure hose 28a that connects at its upper end (not shown) to a hydraulic pressure source (not shown) carried on the surface vessel.
FIGS. 3 & 4 show a first embodiment of a vibratory means 42 for vibration of the tines 10 of the device 2. The means 42 comprises a tubular housing 44 that extends across the width of device 2 and to which the tines 10 are fixed at their rear ends 46. The starboard end 48 of housing 44 is rigidly fixed to a first mounting brace 50 and its port end 52 is similarly fixed to a second mounting brace 54.
With reference to FIG. 8, the shock absorber means 14 comprises a housing 56 and a bolt 58, the head 60 of which is encased in an elastomer pad 62 molded into the housing 56. The braces 50 & 54 have a bore 64 in their forward ends through which the bolts 58 of means 14 extend to partially mount the housing 44 on the panels 16. This shock mount allows limited motion of the front ends of the braces 50 & 54 in any direction.
The rear ends of the braces 50 & 54 carry pins 66 which extend into the elliptical slots 68 in the panels 16 to complete the mounting of the housing 44 on the panels 16. This mass coupling allows movement of the braces 50 & 54 relative to the panels 16 in the fore/aft plane only.
The starboard panel 16 includes a bore 70 to which a hose elbow 72 is fastened, e.g., by screws, on the outboard side. As seen in FIG. 1, elbow 72 joins to the hose 28.
The port side of device 2 is similarly fitted with an elbow 74 which can discharge directly into the ambient or be fitted with a hose (not shown) to discharge fluid onto the plate 26 to wash sediment from harvested clams.
The end 48 of housing 44 is fitted with a flexible coupling 76 to make a fluid-tight connection between the end 48 and the elbow 72. Elbow 74 and housing end 52 are similarly connected with a flexible coupling (not shown).
The vibrator means 42 comprises a rotor 78 with integral vanes 80 and a shaft 82 having a concentric portion 84 and an eccentric portion 86. The eccentric portion rotates in the bearing 88 fixed in the bore 70 of starboard panel 16 and the concentric portion 84 rotates in the bearing 90 that is fixed in the lumen of housing 44. The port end of the rotor 78 (not shown) is similarly structures with concentric and eccentric shaft portions and related bearings.
In view of the wearing forces that will be imposed on the bearings 90, the rotor 78 may be made of keyed segments (not shown) with a plurality of such bearings being spaced apart internally along the length of the housing 44 mating with an equal number of concentric shaft portions 84.
The vibrator means 42a of device 2a shown in FIG. 5 comprises a rotor 78a, a shaft 82a with only a concentric portion 84, but with an eccentric weight portion 92. In this embodiment, the bearings 90 in which the shafts 82a at each end of the rotor 78a rotate are carried in the lumen of the housing 44. As in the case of vibrator means 42, rotor 78a may be segmented to function with more than two bearings 90.
The vibrator means 42b of device 2b shown in FIG. 6 comprises a rotor 78b and shafts 82a that rotate in bearings 90 fixed in the lumen of the housing 44. The port bore 70 of device 2b is closed by the plate 94 so that water under pressure entering the starboard bore 70 (not shown) of housing 44b is forced to exit the housing via the side outlets 96 to flow over the collector plate 26. Such flow of water will also pass through vanes 82b thereby causing the rotor 42b to rotate in the housing 44b.
Vibratory action can be obtained in means 42b either by use of eccentric shafts as in device 2 or an offset weight rotor as in device 2a. Also, the rotor 42b may be segmented to operate with more than two bearings 90 as previously discussed.
The new methods of clam or like bivalve harvesting are illustrated in a general way in FIG. 8. Thus, the device 2 moves over the surface 6 of said substrate 8 having a plurality of tines 10 extending downward from device frame 4. Such movement can be accomplished in a variety of ways. Typically, it will occur by having a surface vessel pull the device 2, e.g., by applying tension to the exhaust hose 24.
The substrate 8 being harvested will constitute a typical cultured population 100 of clams 38. The tines 10 of device 2 perpetrate the surface 6 of the substrate 8 usually at a depth of about 4-6 inches as frame 4 moves over surface 6. During such movement, the tines 10 are vibrated in accordance with the invention. This produces liquidization of the matrix of the substrate 8 enabling the tines 10 to lift the harvest size clams 38 out of the substrate with a minimum of disturbance to the substrate and, at the same time, permit the undersized claims 102 to remain relatively undisturbed in such substrate.
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Shellfish harvesting devices including a frame to move over the submarine surface of a shellfish growing substrate and a plurality of tines extending down from it for penetration into the substrate, are improved by addition of a vibrator to impart a vibratory motion to the tines, but not appreciably vibrate other parts of the frame, e.g., runners. The harvesting of clams or like bivalves with the tines vibrating while being pulled through the substrate mitigates environmental damage to the shellfish growing area and reduces the energy required to pull the devices forward on the substrate.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a plasma display panel (PDP) and, more particularly, to a front substrate of the PDP and its fabrication method.
2. Description of the Background Art
In general, with the development and growing spread of in an information processing system, an importance of a next-generation multimedia display device as a visual information transmission means is increasing. Especially, because a conventional CRT (Cathode Ray Tube) fails to go with the recent tendency aiming at a large and flat screen, researches on an LCD (Liquid Crystal Display), an FED (Field Emission Display), a PDP (Plasma Display Panel), and an EL (ElectroLuminesence) are actively ongoing.
As a self-emission display device using a plasma gas discharge, the PDP is advantageous in that it can be enlarged in size, its picture quality is excellent and an image response speed is fast.
In addition, the PDP receives an attention in the market as a wall-mounted display device together with the LCD or the like.
A discharge cell of a three-electrode AC surface discharge type PDP having such characteristics will now be described with reference to FIG. 1 .
FIG. 1 illustrates a structure of a general three-electrode AC surface discharge type PDP.
As shown in FIG. 1 , the general three-electrode AC surface discharge PDP is constructed such that a front substrate 10 and a back substrate 20 are coupled and a discharge gas is injected therebetween.
The front substrate 10 includes: an upper glass substrate 11 ; transparent electrode 12 and bus electrode 13 formed on the glass substrate; an upper dielectric layer 14 formed entirely on the transparent and bus electrode-formed upper glass substrate 11 ; and a protection layer 15 formed on the upper dielectric layer 14 .
The upper dielectric layer 14 serves to limit a plasma discharge current and accumulate a wall charge when plasma is discharged.
The back substrate 20 includes: a lower glass substrate 25 ; an address electrode 24 formed on the lower glass substrate 25 ; a lower dielectric layer 23 formed entirely on the address electrode-formed lower glass substrate 25 ; a barrier rib 22 formed on the lower dielectric layer 23 ; and a phosphor 21 formed entirely on the lower dielectric layer 23 and the barrier rib 22 .
The operation principle of the general PDP constructed as described above will now be explained.
First, as a discharge sustain voltage is applied to the transparent electrode 12 and the bus electrode 13 , charges are accumulated on the upper dielectric layer 14 , and as a discharge starting voltage is applied to the address electrode 24 , a discharge gas comprising He, Ne and Xe or the like injected in each discharge cell of the PDP is separated to electron and ion to turn to plasma.
Thereafter, in the PDP, when the phosphor 21 is excited by ultraviolet generated at a moment when the electron and ion are re-coupled, a visible light is generated by which a character or a graphic is displayed. Herein, in order to prevent thermal deformation of the dielectric layer or the phosphor 21 caused as the accelerated gas ions collide with each other, the PDP uses Ne gas having a relatively greater molecular weight as a principal component.
However, since Ne gas generates an orange-colored visible light (585 nm) when discharged, color purity and a contrast of the PDP deteriorate.
In order to avoid such a problem, a PDP having a color filter layer or a black strip layer additionally formed on the upper substrate has been proposed.
FIG. 2 is a sectional view showing a front substrate of the PDP in accordance with a conventional art.
As shown in FIG. 2 , the front substrate of the conventional PDP includes an upper substrate 11 ; transparent electrode 12 and bus electrode 13 formed on the upper glass substrate 11 ; an upper dielectric layer 14 formed on the transparent and bus electrode-formed upper glass substrate 11 ; a color filter layer 14 A formed on the upper dielectric layer 14 ; and a protection layer 15 formed on the color filter layer 14 A. The color filter layer 14 A can control a light transmittance and prevent a surface reflection by an external light.
Accordingly, in the conventional PDP, the color purity of the PDP can be enhanced by controlling the light transmittance of a color filter by virtue of the color filter layer, and the contrast of the PDP can be enhanced by preventing a surface reflection by an external light.
However, in the conventional PDP, formation of the color filter layer on the upper dielectric layer of the PDP complicates a fabrication process of the PDP.
In addition, in the conventional PDP, since the light transmittance of a blue (B) visible light is relatively low compared to the red (R) and green (G) visible light, the color temperature of the PDP is approximately 6000K. Thus, in order to compensate the low color temperature, input signals corresponding to R, G and B are controlled, the barrier rib structure is formed asymmetrically or the light transmittance and dye of the color filter layer are controlled, but in this case, the luminance of the PDP is reduced.
Meanwhile, the color filter layer may be replaced by a black stripe layer. However, the black strip layer has a small aperture plane, a light emitting efficiency of the PDP is degraded.
As mentioned above, the conventional PDP has the following problems.
That is, since the color filter layer is additionally included, the fabrication process of the PDP is complicated.
In addition, since the light transmittance of the B visible light is relatively low compared to the R and G visible light, the color temperature of the PDP is low.
SUMMARY OF THE INVENTION
Therefore, one object of the present invention is to provide an upper dielectric layer of a PDP formed containing a colorant capable of controlling a light transmittance to thereby enhance a color temperature of the PDP, and its fabrication method.
Another object of the present invention is to provide an upper dielectric layer of a PDP formed containing a colorant capable of controlling a light transmittance to thereby enhance a color purity of the PDP, and its fabrication method.
Still another object of the present invention is to provide an upper dielectric layer of a PDP formed containing a colorant capable of controlling a light transmittance to thereby enhance a contrast of the PDP, and its fabrication method.
Yet another object of the present invention is to provide an upper dielectric layer of a PDP formed containing a colorant as much as a prescribed rate capable of controlling a light transmittance to thereby simplify a fabrication process of the PDP, and its fabrication method.
To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described herein, there is provided a front substrate of a PDP including a colorant-added upper dielectric layer.
To achieve the above objects, there is also provided a method for fabricating a front substrate of a PDP including: forming a colorant-added upper dielectric layer.
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
The accompanying drawings, which are included to provide a further understanding of the invention and 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.
In the drawings:
FIG. 1 is a view showing a structure of a general three-electrode AC surface discharge type PDP;
FIG. 2 is a sectional view showing a front substrate of a PDP in accordance with a conventional art;
FIG. 3 is a sectional view showing a front substrate of a PDP in accordance with the present invention;
FIG. 4 is a flow chart of a method for fabricating the front substrate of the PDP in accordance with the present invention;
FIG. 5 is a flow chart of a method for fabricating an upper dielectric layer of FIG. 3 ;
FIG. 6 is a graph showing an experimentation result of the light transmittance of a PDP in accordance with a first embodiment of the present invention; and
FIG. 7 is a graph showing an experimentation result of the light transmittance of a PDP in accordance with a second embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.
A PDP having an upper dielectric layer containing a colorant that is able to control a light transmittance to thereby enhance a color temperature, color purity and a contrast, and a fabrication method of the upper dielectric layer in accordance with a preferred embodiment of the present invention will now be described with reference to the accompanying drawings.
FIG. 3 is a sectional view showing a front substrate of a PDP in accordance with the present invention.
As shown in FIG. 3 , a front substrate of a PDP in accordance with the present invention includes: an upper glass substrate 11 ; transparent electrode 12 and a bus electrode 13 formed on the upper glass substrate 11 ; an upper dielectric layer 14 B entirely formed on the transparent and bus electrode-formed upper glass substrate 11 and containing a colorant; and a protection layer 15 formed on the upper dielectric layer 14 B.
A method for fabricating the front substrate of the PDP constructed as described above will now be explained with reference to FIG. 4 .
As shown in FIG. 4 , the method for fabricating the front substrate of the PDP in accordance with the present invention includes: forming the upper glass substrate 11 (step S 41 ); forming the transparent electrode 12 and bus electrode 13 on the upper glass substrate 11 (step S 42 ); forming the upper dielectric layer 14 B containing a colorant at a prescribed rate entirely on the transparent and bus electrode-formed upper glass substrate 11 (step S 43 ); and forming the protection layer 15 on the upper dielectric layer 14 B.
The method for fabricating the front substrate of the PDP will now be described.
First, the upper glass substrate 11 is formed (step S 41 ), on which the transparent electrode 12 and the bus electrode 13 are formed (step S 42 ).
And then, the upper dielectric layer 14 B with the colorant added as much as a prescribed rate is formed entirely on the upper glass substrate 11 on which the transparent electrode 12 and the bus electrode 13 have been formed.
A method for fabricating the upper dielectric layer of the PDP will now be described with reference to FIG. 5 .
FIG. 5 is a flow chart of a method for fabricating an upper dielectric layer of FIG. 3 .
As shown in FIG. 5 , the method for forming an upper dielectric layer of the PDP in accordance with the present invention includes: forming glass powder containing a colorant at a prescribed rate (step S 51 ); forming a dielectric paste by mixing the glass powder, binder and solvent (step S 52 ); coating the dielectric paste entirely on the transparent and bus electrode-formed upper glass substrate to form a dielectric paste layer or a green sheet layer (step S 53 ); and firing the dielectric paste layer or the green sheet layer to form an upper dielectric layer (step S 54 ).
The method for forming the upper dielectric layer of the PDP in accordance with the present invention will now be described in detail.
First, glass is fabricated by mixing a colorant that can control a light transmittance at a prescribed rate to parent glass. Herein, preferably, a material used as the colorant includes at least one of Nd 2 O 3 and cobalt oxide such as CoO, Co 3 O 4 and Co 2 O 3 . The prescribed rate means a ratio of the colorant to the parent glass, and Nd 2 O 3 is added in the range of 0˜40 wt % and cobalt oxide such as CoO, Co 3 O 4 and Co 2 O 3 is added in the range of 0˜10 wt %.
As shown in Table 1˜Table 4 shown below, the parent glass comprises one of components shown in the Table 1 and Table 2 (PbO—B 2 O 3 —SiO 2 —Al 2 O 3 —RO-based glass), Table 3 (P 2 O 5 —B 2 O 3 —ZnO-based glass) and Table 4 (ZnO—B 2 O 3 —RO-based glass). The unit representing each component in Table 1 to Table 3 is weight %.
The method for adding the colorant that can control the light transmittance to the parent glass at a prescribed rate will now be described with reference to first to fourth embodiments of the present invention.
First, in the method for adding a colorant to parent glass in accordance with a first embodiment, Nd 2 O 3 is added in the range of 0˜40 wt % to PbO—B 2 O 3 —SiO 2 —Al 2 O 3 —RO-based glass as shown in Table 1. Herein, RO, a constituent of the parent glass in Table 1, is one of BaO, SrO, La 2 O, Bi 2 O 3 , MgO and ZnO.
TABLE 1
PbO
B 2 O 3
SiO 2 + Al 2 O 3
RO
50
10
25
15
55
15
20
10
60
20
10
10
65
10
20
5
A result of an experimental measurement of the light transmittance of the PDP in accordance with the first embodiment of the present invention will now be described with reference to FIG. 6 .
FIG. 6 is a graph showing an experimentation result of the light transmittance of a PDP in accordance with a first embodiment of the present invention.
As shown in FIG. 6 , a light transmittance of the orange-colored visible light (585 nm) is lower than that of the blue visible light (454 nm), green visible light (525 nm) and red visible light (611 nm). Accordingly, through this experimentation result, an improvement of the color temperature, color purity and contrast of the PDP in accordance with the present invention can be expected.
Second, in a method for adding a colorant to parent glass in accordance with the second embodiment of the present invention, cobalt oxide is added in the range of 0˜10 wt % to PbO—B 2 O 3 —SiO 2 —Al 2 O 3 —RO-based glass as shown in Table 2. Herein, cobalt oxide is one of CoO, Co 3 O 4 and Co 2 O 3 each having a lower light transmittance of the red visible light (611 nm) and green visible light (525 nm) than that of the blue visible light (454 nm).
TABLE 2
PbO
B 2 O 3
SiO 2 + Al 2 O 3
RO
65
10
25
0
60
12.5
22.5
5
55
15
20
10
50
20
17.5
12.5
A result of an experimental measurement of the light transmittance of the PDP in accordance with the first embodiment of the present invention will now be described with reference to FIG. 7 .
FIG. 7 is a graph showing an experimentation result of the light transmittance of a PDP in accordance with a second embodiment of the present invention.
As shown in FIG. 7 , a light transmittance of the blue visible light (454 nm) is higher than that of the red visible light (611 nm) and green visible light (525 nm). Accordingly, through this experimentation result, a remarkable improvement of the color temperature, color purity and contrast of the PDP can be expected.
Third, in a method for adding a colorant to parent glass in accordance with a third embodiment, both Nd 2 O 3 in the range of 0˜40 wt % and cobalt oxide in the range of 0˜10 wt % are added to P 2 O 5 —B 2 O 3 —ZnO-based glass as shown in Table 3.
TABLE 3
wt %
B 2 O 3
ZnO
P 2 O 5
00.0
46.2
53.8
03.3
44.7
52.0
06.8
43.1
50.1
10.4
41.4
48.2
14.1
39.7
46.2
18.0
37.9
44.1
22.0
36.1
41.9
Fourth, in a method for adding a colorant to parent glass in accordance with a fourth embodiment of the present invention, both Nd 2 O 3 in the range of 0˜40 wt % and cobalt oxide in the range of 0˜10 wt % are added to ZnO—B 2 O 3 —RO-based glass as shown in Table 4. Herein, RO, a constituent of parent glass of Table 4, is one of BaO, SrO, La 2 O, BiO 3 , MgO and ZnO.
TABLE 4
ZnO
B 2 O 3
RO
19.8
42.4
37.8
24.6
37.9
37.5
29.3
33.4
37.3
34.0
29.0
37.0
The thusly fabricated glass is crushed to a prescribed particle size to from glass powder. The prescribed particle size is preferably in the range of 1˜5 μm.
The formed glass powder is mixed together with an ethylcellulose binder in a solvent such as α-terpineol or BCA (Butyl Cabitol Acetate) which dissolves the binder, to form a dielectric paste.
At this time, the formed dielectric paste is coated at the entire surface of the upper glass substrate on which the transparent electrode and bus electrode have been formed. This will now be described in detail.
First, the formed dielectric paste is coated at the entire surface of the transparent and bus electrode-formed upper glass substrate through a screen-printing method or a thick film coating method, to form a dielectric paste layer.
Second, the dielectric paste is shaped in a sheet by a doctor blading method and then dried to be formed as a green sheet. The green sheet is coated at the entire surface of the transparent and bus electrode-formed upper glass substrate by a laminating method, to form a green sheet layer.
The thusly formed dielectric paste layer or the green sheet layer is fired at 550° C.˜600° C. for 10˜30 minutes to be formed as an upper dielectric layer containing Nd 2 O 3 and cobalt oxide to serve as a color filter. The thickness of the upper dielectric layer is approximately 20˜40 μm.
As so far described, the front substrate of the PDP and its fabrication method in accordance with the present invention has the following advantages.
That is, first, since the upper dielectric layer contains the light transmittance-controllable colorant at a prescribed rate, its light transmittance can be controlled and thus a color purity of the PDP can be enhanced.
Second, since the upper dielectric layer contains the light transmittance-controllable colorant at a prescribed rate, light transmittance of the blue visible light is enhanced and thus a color temperature of the PDP can be improved.
Third, since the upper dielectric layer contains the light transmittance-controllable colorant at a prescribed rate, a surface reflection of an external light is prevented and thus a contrast of the PDP can be enhanced.
Fourth, since the upper dielectric layer contains the light transmittance-controllable colorant at a prescribed rate, a filter layer is not necessary and thus a fabrication process of the PDP can be simplified.
As the present invention may be embodied in several forms without departing from the spirit or essential characteristics thereof, it should also be understood that the above-described embodiments are not limited by any of the details of the foregoing description, unless otherwise specified, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalence of such metes and bounds are therefore intended to be embraced by the appended claims.
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A front substrate for a plasma display panel (PDP) and an associated fabrication method are provided. An upper dielectric layer of the front substrate includes a colorant, which causes the dielectric layer to also act as a color filter. The resulting front substrate enhances at least one of color temperature, color purity, or contrast of the PDP without increasing complexity or cost.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to post pulling implements and especially to such implements which can be conveniently attached to the three point hitch of a tractor.
2. Discussion of Related Art
Fence maintenance requiring removal of old fence posts and replacement with new posts is often a laborious and time consuming job. It is, therefore, desirable to effect the removal of old posts with as little time and energy consumed as is possible. This then calls for a mechanized device which can easily be transported to and from the various posts requiring removal.
Several devices of this type have been suggested. For instance, U.S. Pat. No. 2,482,950, issued Sept. 27, 1949, to Toftey, shows a post puller which is connectible to the three point hitch of a tractor. The Toftey device includes a pair of transverse rock shafts which are supported in longitudinally spaced relation on a frame member with one of their ends projecting laterally from a side of the frame member. A pair of post-engaging arms oppositely arranged on the rock shafts are mounted for movement between closed positions in a substantially common plane and open positions extending upwardly and inwardly toward each other. The jaws are initially engaged with the post and the frame is elevated by use of the three point hitch. U.S. Pat. No. 3,525,502, issued Aug. 25, 1970, to Fisher, shows a post puller comprising a frame structure detachably secured to the side of a tractor. The slide structure is reciprocally supported by the frame for movement laterally with respect to the longitudinal axis of the tractor and a vertical mast is supported on one end of the slide structure for movement therewith. There is provided on the mast a puller frame assembly which is movable up and down with respect to the mast and which has engagement means thereon for effecting detachable engagement with a post. An extensible frame assembly is provided adjacent the lower end of the mast and is moved into ground engaging position when it is desired to pull a post from the ground. The puller frame assembly is then moved upwardly and thus pulls the post from the ground. U.S. Pat. No. 3,647,185, issued Mar. 7, 1972, to Phibbs, shows a pulling implement which includes a pair of opposed pivotally connected gripping jaws with the toggle linkages arranged to exert force to close the jaws on an object to be pulled when the supporting framework is raised. U.S. Pat. No. 4,026,522, issued May 31, 1977, to Dranselka, shows a self-engaging post pulling apparatus which is adapted for attachment to the rear lifting mechanism of most tractors. The apparatus comprises a horizontal support having two opposed plates pivotably mounted for frictionally engaging a post positioned therebetween. The plates are biased into a gripping position by helical springs, but may be remotely moved to a non-gripping position by cables affixed to the plates.
SUMMARY OF THE INVENTION
One object of the present invention is to provide a post pulling device which can easily be attached to the three point hitch of a tractor for transportation to and from a post pulling site.
A further object of the present invention is to provide a post pulling device which can be positioned in ground contacting engagement during the pulling process in order to avoid use of the hitch in the pulling operation.
Yet another still further object of the present invention is to provide a post pulling device which can be operated by a single person.
Another further object of the present invention is to provide a post pulling device which can be easily connected to the existing hydraulic system of a tractor.
In accordance with the above objects, the post pulling device of the present invention includes an upstanding rectangular framework having a base and two upstanding side members. The three point hitch of a tractor is connected to the lower portion of the upstanding side members and also to a center cross bar attached between the side members. A plate has a pair of sleeves attached to its ends which sleeves are positioned in surrounding relation to the side members for vertical movement thereon. A first hydraulic cylinder is connected between a top member of the frame and the plate. A pair of clamping jaws are attached to the plate with one jaw being fixed thereto and a second jaw being movable parallel to the front surface of the plate. The movable jaw is connected to a second hydraulic cylinder. The frame is positioned with the fixed jaw against a post to be pulled and the base of the frame in ground engaging position close to the post. The movable jaw is actuated to grasp the post and the vertical hydraulic cylinder moves the plate and jaws upwardly pulling the post from the ground.
These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the post pulling device in operation.
FIG. 2 is an elevational view of the post pulling device.
FIG. 3 is a side elevational view of the post pulling device.
FIG. 4 is a side elevational sectional view taken substantially along a plane passing through section line 4--4 of FIG. 1.
FIG. 5 is a top plan sectional view taken substantially along a plane passing through section line 5--5 of FIG. 1.
FIG. 6 is a perspective view of the movable jaw of the clamping device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Now with reference to the drawings, a post pulling device incorporating the principles and concepts of the present invention and generally referred to by the reference numeral 10 will be described in detail. It will be noted that the post pulling device 10 can be connected to a three point hitch 12 of a standard tractor 14. In this manner, the three point hitch can be raised lifting the frame 16 from ground engaging relationship and the entire device 10 can be easily transported. At the same time, when use of the device 10 is not required, it can easily be removed from the tractor 14 and the tractor used for other purposes.
The frame 16 includes a base plate 18 which is the ground engaging element of the device. Attached to the base plate are a pair of upstanding side members 20 and 22 which are connected at their upper ends by a top frame member 23. Each side member comprises a rectangular steel frame section attached to a substantially planar flange. The flanges 24 and 26 mount the attachment points for the three point hitch. Two attachment points comprise mounting boss pairs 28 and 30, respectively. The third attachment point includes a cross member 32 which is welded between the flanges 24 and 26. A pair of bosses 34 are welded to the cross member and serve as the connection point. The flanges 24, 26 are used in order that the bosses 28, 30 and the cross member 32 can be mounted at a position spaced from the surface of side members 20, 22. This spacing is required in order that there is room on each face of each side member to accommodate sleeves 36, 38 which slide vertically along the side members 20, 22, respectively. Each sleeve is essentially a rectangular box beam section having an inner circumference slightly larger than the outer circumference of the side members. Slots 40, 42 are cut into the sleeves to provide a space through which the flanges 24, 26 extend. A plate 44 is welded between the sleeves 36, 38 and travel with them throughout their vertical movement. Vertical movement of the plate and sleeves is effected through the use of hydraulic cylinder 46, the piston 48 of which is pivotally mounted to a boss extending downwardly from the top member 23. The piston body is attached to a pair of bosses 50 which are connected directly to plate 44. The cylinder 46 can be attached to the existing hydraulic system of the tractor 14 with valves appropriately mounted to allow actuation of the cylinder from the driver's seat. Accordingly, it can easily be seen that when a post is connected to the plate 44, cylinder 46 is actuated to pull plate 44 upwardly. In order to accommodate the strain of such an endeavor, a pair of gussets 52 are connected to the top member 23 longitudinally thereof and another pair of gussets 54 are connected laterally of the top member 23.
Post 56 is held stationary relative to the plate 44 and sleeves 36, 38 through the use of a clamping mechanism which includes a stationary jaw 58 which is welded directly to the plate 44 in approximately the middle of the plate. Stationary jaw 58 can be spaced from the plate by the use of a pair of mounting arms 60. A movable jaw 62 is welded to a single mounting arm 64 which extends through a slot 66 formed in the plate 44. The jaw 62 and the mounting arm 64 can move linearly in the slot 66 to clamp or release a post 56 contained between the jaws 62 and 58. In order to provide adequate clamping pressure, a hydraulic cylinder 68 is mounted behind the plate 44 with one end pivotally attached to sleeve 38. The piston 70 is received in the enlarged end of mounting arm 64 which is shown generally at 72. The enlarged end 72 slides on the tractor side of plate 66 and has one surface which abuts that plate. End 72 is substantially rectangular in shape and fits within a channel member 74 which is welded to plate 44 and serves as a guide for the mounting arm 64.
In operation, once the post pulling device 10 is attached to the three point hitch 12, the hitch can be raised and the device 10 transported to the site at which it is to be used. The tractor 14 is backed to the post 56 and the three point hitch 12 is lowered so that base 18 contacts the ground in the vicinity of the post. The tractor is maneuvered so that stationary jaw 58 contacts one side of the post. Cylinder 68, which may also be connected to the hydraulic system of the tractor and should be provided with a operating valve which is actuatable from a position in the driver's seat, is actuated drawing the movable jaw 62 into engagement with the post. The cylinder 46 is then actuated drawing the plate 44 together with sleeves 36 and 38 upward to draw the post 56 from the ground. Naturally, the post can be carried by the post pulling device to a desired position for disposal or the clamps can be released as soon as the post is pulled from the ground and the tractor moved to another position to remove additional posts from the ground.
The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A frame having a pair of upstanding side members is attached to the three point hitch of a tractor. The frame includes a base which can rest upon the ground adjacent a post to be removed from the ground. A plate is slidably attached for vertical movement along the side members and includes a hydraulically operated clamp for attachment to the post. A hydraulic cylinder is attached between the top of the frame and the plate and pulls the frame vertically after the clamp is attached to the post.
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CROSS-REFERENCE TO RELATED APPLICATIONS
None.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The preferred embodiments of the present invention are directed generally to producing a revenue stream for computer manufacturers apart from revenue associated with the sale of hardware. More particularly, the preferred embodiments are directed to user-selectable desktop customizations that indirectly promote the products and services of participating corporations.
2. Background of the Invention
Computer manufacturers of the related art seek revenues, and therefore profits, not only from the sale of computer hardware, but also under an internet-based web traffic advertising system. In particular, computer manufacturers of the related art provide many “features” with their computers which increase traffic to internet web sites. For example, many computer manufacturers of the related art have keyboard “hot keys” that are not part of the standard or extended QWERTY keyboard, but instead are programmed to perform very specific functions, like directing the computer user's browser to a particular website. In the related art business systems, this feature is noted by the target website and the computer manufacturer receives a bounty for assisting the user in finding the website.
In related revenue models, the owner and operator of one website may have many “banner advertisements” at various locations throughout the site. If the user of the first web site transitioned to a website identified in one of the banner advertisements by activating the banner advertisement, the main web site owner may be paid a bounty for inducing the secondary web traffic.
However, as the state of the art of capitalism progresses in the internet age, companies are no longer willing to pay bounties for mere internet traffic. Stated otherwise, the advertising model of internet usage is starting to wain, lessening computer manufacturers' revenue based on the advertising type add-ons and features for consumer-based computer systems.
Thus, what is needed in the art is a new method of monetizing electronic-commerce opportunities by personal computer manufacturers.
BRIEF SUMMARY OF SOME OF THE PREFERRED EMBODIMENTS
The problems noted above are solved in large part by a method that monetizes an electronic-commerce partner of the computer manufacturer through the presentation of personal computer customizations that provide brand exposure to the partner, as well as direct links to that partner's internet sites for electronic-commerce purposes. More particularly, in the preferred embodiments, personal computer manufacturers supply computer systems where each user of a particular computer, for example each member in a household, is capable of selecting a customization having a theme that is related to the sponsor or partner's goods and/or services. Thus, in a family of four it may be possible to have four different customizations, each customization providing different thematic elements and a brand exposure to the personal computer manufacturers' partners. Further, each customization may be automatically updated over time to reflect changes in the goods and/or services of a sponsor of each theme. Revenue streams for the personal computer manufacturer in the preferred embodiments are based, in part, on an up-front cost to the partner for configuring the personal computer to support the possible selection as a customization option. An additional revenue stream of the computer manufacturer of the preferred embodiment is realized each time an end-user selects a customization that is based on the sponsor or partners goods and/or services. The computer manufacturer may also realize revenue associated with the end-user making electronic-commerce purchases from links associated with the customization. Additionally, the computer manufacturer realizes revenues based on use of programmable “hot buttons” on the key-board, each button programmable based on the particular desk-top theme, which are utilized by the end-user to view or possibly purchase products or services of the sponsor.
The disclosed devices and methods comprise a combination of features and advantages which enable it to overcome the deficiencies of the prior art devices. The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description, and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which:
FIG. 1 shows a computer system of the preferred embodiment;
FIG. 2 shows a sequence for creation of a customization of the preferred embodiments;
FIG. 3 shows an exemplary screen shot of a financial customization system;
FIG. 4 shows an exemplary browser software screen customization; and
FIG. 5 shows an exemplary set of hot-keys of the preferred embodiments.
NOTATION AND NOMENCLATURE
Certain terms are used throughout the following description and claims to refer to particular system components. As one skilled in the art will appreciate, computer companies may refer to a component by different names. This document does not intend to distinguish between components that differ in name but not function.
In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”. Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices and connections.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention are directed to providing desktop themes and other customizations adapted for each user of a personal computer system which are based on products and services offered by entities associated with the manufacturer of the personal computer system. These personal computers may comprise desktop computers, laptop or portable computers, servers, and the like. Thus, the preferred embodiments will be described in this context; however, one of ordinary skill in the art, after reading and understanding the discussion below, could easily expand this technology to other computer systems that link consumers to the internet, such as, but not limited to, hand-held electronic-mail receiving and sending devices, cell phones, personal digital assistants, and the like. Thus, the term computer system should be read in its broadest sense to comprise personal computer systems as well as other digital computing and communication devices.
The preferred embodiments of the present invention are embodied in personal computers running under the Windows® XP operating system produced by Microsoft, Inc. of Redmond, Wash. While Windows® XP is preferred, any suitable operating system may be used such as, but not limited to, prior and future versions of Windows®, WinCE, Linux, Macintosh, and the like. The personal computer system of the preferred embodiment couples to and preferably is in communication with other computers acting as servers on the internet. FIG. 1 exemplifies that a computer system 10 of the preferred embodiment comprises a monitor 12 , keyboard 14 , mouse 16 , and CPU enclosure 18 coupled to the internet 20 . The computer system 10 of the preferred embodiments is a Compaq® computer; however, one of ordinary skill in the art, after reading and understanding the discussion below, could easily implement the systems and related methods on any computer system. FIG. 1 shows the computer 10 coupled to the internet 20 , and this coupling may be through any suitable means, such as a dial-up connector, Ethernet connection, digital subscriber line (DSL) connection, cable modem, or the like.
In the Windows® XP operating system, each user has the capability of having an independent logon and computer use experience. In an exemplary family of four comprising a mother, a father, an older child, and a younger child, each of the four family members may have an individual logon. The preferred embodiments of the present invention leverage the Windows® XP technology and allows the user to select from customized themes provided by the computer manufacturer that are based, in whole or in part, on the products and services of the computer manufacturers' partners or sponsors.
FIG. 2 exemplifies the preferred sequence for a user to create a customization of the preferred embodiment. In particular, the process starts (step 30 ) and in the first step a user of a new computer registers the Windows® XP operating system and creates the necessary profiles (step 31 ). Thereafter, the user drops to a log-in screen for the desktop and logs in, for the first time (step 32 ). In a computer system that does not provide customizations of the preferred embodiments, the user simply moves to the standard Windows® XP desktop at that point. However, in the preferred embodiments, dropping to the desktop for the first time preferably invokes a program that gives the user the ability to choose a customization from a customization set to be associated with their particular profile (step 34 ). As will be discussed more fully below, these customization sets may take on many variations, such as sports, kids, home/garden, financial and the like, which are, on an underlying basis, linked to the products and services of the computer manufacturers' partners. If a customization is selected (step 35 ), the customization deploys (step 36 ). If, however, at step 35 the user elects not to choose a customization step, the process immediately ends (step 38 ). Preferably, the steps shown in FIG. 2 occur each time a user logs in with their particular profile for the first time. Each time the user logs in thereafter, the customization appears automatically. The customizations offered may be generic and may comprise one or more of the following: music, movies, television, gaming, kids, sports, women's interests, education and research, travel, geography, news, and finance. Further, any individual high-level customization category may have sub-categories thereunder. For example, in the music category, users may be able to select from different types of music, for example, RAP, country, rock, classical, jazz and the like. Likewise, a user selecting a movie category as an overall customization may be able to further select subcategories such as action movies, love stories, comedies, foreign language films, particular movies of interest, and the like. The categories and/or subcategories may also be may also be brand specific, for example the sports category may be the ESPN Sports Zone, or the kids category may be identified as the Disney Kids Channel. One of ordinary skill in the art, now understanding the concepts of providing the customizations could easily create many equivalent customizations, and sub-customizations, and all such customizations would be within the contemplation of this invention.
For purposes of further discussion it is assumed that the user selects a financial customization. In the preferred embodiments, the financial customization selection may do many things. The desktop itself, for example, the desktop wallpaper, icon and cursor and colors, may change from the standard desktop. FIG. 3 shows an exemplary screen shot of a financial customization system. Note the financially oriented theme of the desktop of FIG. 3 comprising money wallpaper 22 . Additionally, the customization may set a custom screen saver following the thematic elements of the customization. Importantly for the monetization of the customization for the computer manufacturer, selection of the particular customization may also add desktop icons that are not part of the Windows® XP standard package, such as links to accounting software or software upgrades 24 . The desktop icons may include links to the computer manufacturer's partners, which in the case of a financial customization could be banks, mutual funds, stock brokers, accountants, and the like. Further customizations comprise setting the default or home website and button 26 on internet browsers to point to the computer manufacturer's partners internet sites, as well as adding links to tool bars 28 in the user's internet browser, as shown in FIG. 4 .
Another customization comprises use of keyboard shortcut, “hot-keys” or “hot-buttons” to launch the internet browsers to show internet destinations of the computer manufacturers' partners. FIG. 5 shows an exemplary set of hot-keys 29 . What should be understood about this customization is that these buttons are reprogrammed depending on a particular user's selected customization and corresponding theme. Thus, the internet hot-buttons for a financial customization preferably point to the possible partners listed above, while the hot-button internet shortcuts for young children may be directed to websites for those individuals. One of ordinary skill in the art, now understanding the various desktop elements and possible additional programs that could change in the customization could easily devise many equivalent such customizations, and such equivalents would be within the contemplation of this invention.
The revenue stream of the preferred embodiment has many facets. Preferably, the computer manufacturer charges the sponsor or partner an up-front cost for installing the customization set on each personal computer manufactured. That is, regardless of whether a user actually chooses a customization that is based on the sponsor's goods and/or services, the computer manufacturer obtains a revenue stream. A second facet of the revenue stream for the computer manufacturer is when a particular customization is selected. That is, while many customizations may be available, the computer manufacturer receives a fee or bounty when a user selects the customization of a particular sponsor. The computer manufacturer preferably realizes an additional revenue stream when the customization is updated. In the preferred embodiments, updates to the customizations are provided to the user's computer automatically and over time, without (or with only minimal) interference with the user's internet use experience. After all the required information exists on the user's computer, the user is notified by way of a messaging interface that a new customization has been downloaded to their system for selection
For example, if the customization has as an underlying sponsor a movie studio, then periodically with the release of a new movie, additional customization updates may be available, such as new movie-specific screen savers and wallpaper for the desktop. If an end-user elects to install the updated customization, the computer manufacturer receives a revenue stream based on those subsequent updates.
Additional revenue streams for the computer manufacturer comprises bounties associated with generation of web traffic from the customization, for example by the user's selection of desktop icons, whose initial pages have been set to the sponsor's site, favorites links, hot buttons on keyboards and the like. The computer manufacturers' revenue stream may also be based on a percentage of net sales at electronic-commerce sites where the initial contact was based on customizations.
Many of the features of the customizations are controlled in standard application program interface (API) calls by software. Thus, in the preferred embodiments the program to prompt the user for a particular customization and apply those customizations across the standard interfaces such as wallpaper, desktop themes, and the like, may be written in any suitable programming language such as SAP, C, C++, Visual C, Visual Basic, and the like. Moreover, prompting a user of a customization as to whether they are interested in receiving an update, when available, may be done by contacting the computer manufacturer over an internet connection detected using standard internet connection software.
The above discussion is meant to be illustrative of the principles and various embodiments of the present invention. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. It is intended that the following claims be interpreted to embrace all such variations and modifications.
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The specification describes a method for realizing revenue streams for computer manufacturers apart from hardware sales. More particularly, the specification discloses a method where personal computers are configured such that each user has an individual login capability, and each user may experience a different desktop theme and related overall customization. The end-user may select a particular theme, and each theme is based on the goods and/or services of a sponsor of that theme. The computer manufacturer realizes revenue initially for enabling the end -user to select particular themes, but also realizes a revenue for end-users selecting themes. Further, the specification discloses a method where computer manufacturers realize revenue by generation of internet traffic to, and electronic-commerce on, a sponsor's internet sites.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 11/871,288, filed Oct. 12, 2007, which claims the benefit of U.S. provisional application 60/829,451, filed Oct. 13, 2006, both of which are hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] Several communication tower manufacturers construct triangular self-supporting towers utilizing vertical columns constructed of triangular trusses. These tower columns (often referred to as the tower legs) resemble miniature triangular shop-welded tower sections. When additional loads are added to the tower, these truss legs may no longer be adequate to safely support the calculated tensile or compressive loads. To alleviate this overstress, the structural capacity of the truss columns must be enhanced. Field welding additional steel onto these truss legs is expensive and creates the potential for several problems. The heat of the welding operation destroys the galvanized coating on the existing steel members creating a corrosion problem. The heat of the welding operation may warp the existing steel and the sparks create a fire hazard. This invention was developed to address these problems.
SUMMARY OF THE INVENTION
[0003] Provided is a method of reinforcing a triangular truss column comprising: providing two generally vertical pipe reinforcing columns each having a first pipe reinforcing plate attached at the top of the column and a second pipe reinforcing plate at the bottom of the column; attaching the first pipe reinforcement plate to a first existing plate of the triangular truss column; attaching the second pipe reinforcement plate to a second existing plate of the triangular truss column; and connecting each vertical pipe reinforcing column to the truss column at one or more connection points along the pipe reinforcing column length. Also provided is a reinforced triangular truss column having two generally vertical pipe reinforcing columns attached to the outside of a portion of a triangular truss column.
[0004] The pipe reinforcing columns are connected to the truss column in the vertical direction using any suitable means as known in the art without undue experimentation. Some examples are described and shown herein. As one example, a metal strap or band that spans one side of the triangular truss column is connected to two legs of the triangular truss column. The strap or band may be connected to the legs of the triangular truss column using any suitable means, including bolts. The band or strap is any suitable width and thickness that provides the desired amount of support. It is not necessary, and is not preferred, that the metal strap be so wide that that it results in wind resistance or excess weight. In another embodiment, the pipe reinforcing columns are connected to the truss column using a band or strap which surrounds the truss column and the pipe reinforcing columns.
[0005] In one embodiment, the pipe reinforcing plates are attached to the existing plate of the triangular truss column using bolts. The pipe reinforcing column may be made from any suitable material, and do not need to be made from the same material. Each pipe reinforcing column may be hollow or solid.
[0006] As used herein, “generally vertical” or “generally horizontal” indicates the direction does not need to be exactly vertical or exactly horizontal with respect to a fixed point, but includes those situations where there is a small amount of variance, for example, ±10 degrees of variance. Other degrees of variance are included, for example ±5, ±15 and ±20 and all intermediate ranges and values therein.
BRIEF DESCRIPTION OF THE FIGURE
[0007] FIG. 1 shows one embodiment of the invention in three views.
DETAILED DESCRIPTION OF THE INVENTION
Truss Columns:
[0008] A single truss column is constructed of three individual solid round bars shop-welded at the top and bottom to a common plate. These three solid bars are connected to each other with horizontal and diagonal bracing forming a three-dimensional triangular truss. It requires three truss columns to form a single triangular tower section. These tower sections are then stacked vertically and bolted together at the truss column plates.
Solution:
[0009] Presented here is a method to enhance the structural capacity of the existing truss columns that does not require field welding. Two vertical pipes are added to the three solid round rods of the truss column. These pipes have plates welded at the top and bottom. Several of the existing truss column splice bolts are removed. A new pipe column is inserted with new longer splice bolts inserted to connect the top and bottom plates of the new pipe column to the top and bottom plates of the truss column. There are also straps or other devices that connect the new pipe column to the truss column at intermediate intervals to prevent the pipe column from buckling away from the existing truss column. These straps are connected to the truss column with U-bolts or other suitable connecting means, as known in the art. This invention is useful for any towers with truss-type legs (columns).
[0010] The result is that the truss column is no longer comprised of just three solid round rods but is now is comprised of the original three solid round rods plus two round pipes which may be hollow.
[0011] FIG. 1 shows one embodiment of the invention. Elevation 1 shows a large-scale view. Elevation 1 shows two sections, section 2 and section 3 , also shown in FIG. 1 . Section 2 shows the use of the invention at the existing tower leg splice plate, as described herein. Section 3 shows an intermediate brace, as described herein.
[0012] All elements of the invention may be made from any suitable material, as known to one of ordinary skill in the art. The materials used may depend on the environment where the tower is used, as known in the art. The diameters of the vertical pipes may vary, depending on the application. The vertical pipes may be made from any suitable material, as known to one of ordinary skill in the art. The vertical pipes may be metal, composite or polymer, for example. The vertical pipes may be hollow or solid. The connecting bands may be constructed from any suitable material, as known to one of ordinary skill in the art.
[0013] Although the invention is described with respect to triangular truss towers, it is well known in the art that the invention may be used with four-legged towers, as well, without undue experimentation, using two, three, or four vertical pipe reinforcing columns, using the information provided here and that information known in the art.
[0014] It should be understood that although the present description has been disclosed by specific 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.
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A reinforced triangular truss column having two vertical pipe reinforcing columns added to the three rods of the truss column is provided. Also provided is a method of reinforcing triangular truss columns comprising adding two vertical pipe reinforcing columns to a triangular truss column.
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FIELD OF THE INVENTION
The present invention relates to a system and method for finishing fenestration openings.
BACKGROUND
General contractors engaged in the construction of a commercial or residential building are responsible for scheduling various subcontractors to complete their assigned tasks in a timely manner. When a certain subcontractor's work is delayed for some reason, further delays may be caused for other subcontractors whose tasks are dependent on the first subcontractor. For instance, plumbing and electrical work must be completed before interior drywall can be hung; likewise painting and finishing cannot proceed until the drywall is hung. To the extent that a job can be planned so that as few subcontractors are dependent on the completion of each other's work as possible, a smoother job with fewer delays is likely to result.
While better scheduling and planning on the part of the general contractor can reduce these bottlenecks, some are unavoidable due to requirements imposed by current building materials. For example, fenestration openings are unfinished openings in the side of a building which will ultimately receive a window or door assembly. Currently, windows are delivered by the manufacturer having a frame which is attached to the framing members of the fenestration opening. Until this frame is installed, the finishing crews, which apply the exterior finish such as plastering to the building as well as the interior drywall crews, cannot complete their work. Accordingly, delays in shipment and installation of the windows and frames lead to significant problems in work scheduling for the building as a whole, which can potentially cause an entire job to fall behind schedule.
A need exists for a system and method which reduces the need for a high degree of coordination between subcontractors. With such a system and method, the burden on the window and door manufacturers to deliver on a tight schedule is reduced, and the general contractor regains a degree of control over his schedule without worrying about being held up by his custom window and door suppliers not delivering on time.
SUMMARY OF THE INVENTION
Accordingly, a fenestration cap system is provided as a separate piece from the frame of the window. The fenestration cap can be installed prior to the delivery of the widows and accompanying frames, and allows interior and exterior finishing to be completed without having to install the window and door systems. This allows more time for custom window and door orders to be filled by the supplier without holding up progress in other areas of the job. The waiting for the actual windows to arrive and be installed is no longer one of the critical paths of the job schedule, and may be completed at the convenience of the contractor.
This system is compatible with the frames of major door and window suppliers, and gives consumers the flexibility to choose the windows and doors that best fit their specific needs without being forced to make a selection due to manufacturer lead times. Furthermore, the present system is easy to install, and can be done by tradesmen with minimal training. The inclusion in certain embodiments of the present invention of flanges and stops reduces the need for careful measuring and placement of finishing materials such as drywall sheeting.
The fenestration cap system allows window and door openings to be made ready to receive their corresponding accessories, while at the same time being easily made weatherproof in the absence of these accessories with the addition of a simple piece of panel or sheeting.
Additional benefits are provided if accessories such as windows and doors are installed after finishing crews complete their work, which may include the application of plaster to the outside of the storefront, or the installation of drywall along the inside. In this case, The window and door systems installed within the fenestration cap do not need to be masked off by the finishing crews, and they are not in danger of being damaged by the finishing crews.
In one embodiment of the present fenestration cap system, future window replacement can be achieved by simply removing the window fasteners holding the window and possibly the frame within the fenestration cap, cutting out the perimeter window sealant, and sliding the window out leaving the integrity of the structural and building substrates in a finished undisturbed state.
In an exemplary embodiment, a window sill comprises a structural base having a first side and a second side, a fenestration cap attached to the structural base, a window frame mounted on the fenestration cap, and finish elements applied to the structural base and adjacent to the fenestration cap. The window frame may be removed from the fenestration cap without disturbing the finish elements.
In an alternative embodiment, a fenestration cap comprises a first surface for receiving a window and a second surface attached to the first surface for attachment to a fenestration opening. The window is separably detachable from the first surface and the fenestration opening is detachable from the second surface. Furthermore, detachability of the window from the first surface is independent of detachability of the fenestration opening from the second surface.
A method of installing a window in a window opening comprises providing a window opening and preparing the window opening for receiving a fenestration cap, installing a fenestration cap by placement within and attachment to the window opening in a primary step, and installing a window within the window opening by placement within and attachment to the fenestration cap in a secondary step.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a side view of a prior art commercial window assembly;
FIG. 2 shows an isometric view of a prior art window assembly;
FIG. 3 shows a fenestration cap according to one embodiment of the present invention;
FIG. 4 shows a fenestration cap having a built in plaster key and a channel in the interior side according to another embodiment of the present invention;
FIG. 5 shows a recessed fenestration cap having a built in plaster key and a flush interior side according to one embodiment of the present invention;
FIG. 6 shows a recessed fenestration cap having a channel in the interior side according to one embodiment of the present invention;
FIG. 7 shows a recessed fenestration cap having a flush interior side according to one embodiment of the present invention;
FIG. 8 shows a fenestration cap having a built in plaster key which is attached to a window pane using a caulked butt joint;
FIG. 9 shows a recessed fenestration cap having a built in plaster key which is attached a window pane using a caulked butt joint;
FIG. 10 shows a sill detail of a fenestration cap anchored to a concrete slab;
FIG. 11 shows a fenestration cap according to an alternative embodiment of the present invention; and
FIG. 12 shows a head detail of a fenestration cap anchored to a concrete slab.
Before any embodiment of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and arrangements of components set forth in the following description, or illustrated in the drawings. The invention is capable of alternative embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the terminology used herein is for the purpose of illustrative description and should not be regarded as limiting.
DETAILED DESCRIPTION OF THE INVENTION
The present fenestration cap was designed to systematically coordinate and weatherproof fenestration openings before the installation of commercial or residential windows or doors. In one embodiment, the fenestration cap is a permanent fixtures in the building in which it is installed. The present cap allows for plastering and installation of interior drywall to be completed after installation of the fenestration cap itself, all of which may be completed at the leisure of a general contractor before delivery of the windows and associated frames is even taken. As such, a delay in such delivery will not unnecessarily inconvenience the contractor and delay the job; plasterers and finishing crews no longer need to wait for the delivery of windows to a job site to complete their portions of the build.
Once the windows and frames do arrive, they can be installed separately by attachment to the fenestration cap with sheet metal screws or other appropriate fastening means. Furthermore, if the window panes themselves ever need to be replaced, the frames in which they are mounted can be easily detached from the fenestration cap without the need to remove the cap itself. Formerly, the unitary frame in which windows were mounted and which was attached directly to the window opening necessitated a complete tear-out of the window opening to replace the window itself. As such, windows and doors are made independent and easily replaceable building components rather than permanent parts of the building structure.
FIG. 1 is a side view of a prior art commercial window assembly showing a nail on concrete slab detail. A sill can 150 is attached directly to a concrete slab 101 using a fastener 102 . A pair of caulk beads 152 are also shown at the periphery of the interface between the sill can 150 and the concrete slab 101 . A sealant 106 is used to waterproof the intersection of the fastener 102 and the sill can 150 . A shim 107 may be used to position the sill can 150 on the concrete slab 101 . Also, backer rods 108 may be used to provide a stop for the application of the caulk bead 152 .
Such an arrangement is known by those skilled in the art to be prone to leakage. The sill can 150 , together with a sill can filler 155 and a sill can stop 160 forms a frame assembly which secures a window 170 . One or more top load gaskets 171 as well as a setting block 172 may also be used with this assembly to further secure, cushion and waterproof the window 170 .
With the embodiment shown, finish work on the window opening may only be completed once the window 170 and frame arrives. As such, the scheduling problems discussed above are common with this prior art embodiment. Furthermore, if the window 170 and frame needed to be changed, any plastering and drywall used to finish the window opening would have to be removed at that time.
FIG. 2 shows an isometric view of a prior art window assembly of a similar type to that shown in profile in FIG. 1 . Here, a vertical sill can 250 forms an assembly together with a sill can filler 255 and a sill can stop 260 to receive a window. The vertical sill can 250 is sealed to a jamb 201 using a caulk bead 25 . The vertical sill can 250 is shown at right angles to a horizontal sill can 250 which is secured to its mounting platform using a fastener 202 .
FIG. 3 shows a fenestration cap 300 according to a simplified embodiment of the present invention. Alternative fenestration caps are discussed in greater detail with reference to the following figures. Here, a fenestration cap 300 is shown having a side 311 defining a vertical flashing 312 , a drywall channel 345 and a plaster key 346 , in addition to one or more screw races 305 . The dry wall channel is defined between a mounting flange 305 a and a top side 305 b . In the shown exemplary embodiment, the fenestration cap has a base 315 , a top side 317 generally parallel to the base and a support 319 extending between the base and the top side. In the shown exemplary embodiment, the key 346 extends perpendicularly from the side 311 and generally along the same plane as the to side. The fenestration cap 300 is an independent piece separate from any sill can or window frame assembly which may be independently installed from the window to act as a terminal point for plaster and drywall installation as well as other finish work.
FIG. 4 shows one embodiment of a fenestration cap 400 according to the present invention. The cap shown in FIG. 4 is being used in a window opening framed by wood framing members 435 and faced on the exterior side by plywood sheeting 437 . FIG. 4 shows a sill can 450 supporting a window 470 . As is known to one skilled in the art, a head can of a like, though not necessarily identical design, may be used to support the top edge of the window 470 in a storefront. Similarly, the fenestration cap 400 may be used to finish the top of the window opening rather than the bottom as is shown in FIG. 4 so as to provide a platform for attachment of the head can.
As discussed above, finishing crews are responsible for the installation of the plaster 436 and drywall sheeting 438 , but these elements cannot be installed until a terminal point is provided for them to be finished against. In the prior art, this terminal point was provided by the sill can or frame of the window itself. However, this caused the previously mentioned problems of delays in construction while the finishing crews waited for the window and associated sill can and frame to be delivered.
In the embodiment shown in FIG. 4 , a fenestration cap 400 is provided as a single piece separate from any sill can or window frame; as such it may be independently installed and acts as a terminal point for plaster and drywall installation. To this end, the fenestration cap 400 includes a plaster key 446 on its exterior side. The front edge of the plaster key 446 is designed to act as a guide for the tradesperson applying the plaster 436 ; a trowel may easily be drawn along this edge of the plaster key 446 to quickly and neatly apply an even layer of plaster to the assembly. In one embodiment, the plaster 436 is applied to a depth of ⅞″. As mentioned above, because the fenestration cap 400 is provided as a single separate piece, plaster may be applied to the plaster key 446 prior to the installation of the window or frame, avoiding the risk of damage to these elements.
Similarly, in the shown exemplary embodiment, the fenestration cap 400 includes a base 415 , a top side 417 generally parallel to the base, as well as a first support 419 and a second support 421 between the base and the top side. The key 446 has at least a portion that extends perpendicularly from a side 411 defining a flashing 412 , and along the same plane as the top side 417 . The exemplary embodiment fenestration cap also includes a drywall channel 445 provided as a guide to receive a piece of drywall sheeting 438 such as standard ⅝″ sheetrock. This channel aids an unskilled laborer in the installation of interior drywall, plaster or paneling. The built in receiving and self-aligning channel creates a level fit for the installation of interior finish materials. Accordingly, the sheeting running from a corner bead 439 to the fenestration cap 400 can be quickly and accurately installed in a level position without the time consuming process of shimming or manual adjustment of the sheeting necessary with prior art systems.
In the embodiment of the present invention shown in FIG. 4 , inserting the drywall sheeting 438 into the drywall channel 445 is all that is necessary to present a finished appearance for the inside of the window assembly. It is not necessary to tape or spackle the exposed joint between the drywall sheeting 438 and the fenestration cap 400 which lies below the water dam 411 . Thus, further time and expense is saved in the installation process. The drywall channel 445 may include one or more vertical fins 417 therein, which aid in gripping the portion of drywall sheeting 438 inserted into the drywall channel 445 . These fins also provide a cushioning effect for the drywall sheeting 438 during seismic activity.
In one embodiment of the present invention, the fenestration cap 400 is installed in the window opening using one or more wood screws 430 through the vertical flashing 412 and a mounting flange 415 to secure the fenestration cap 400 to the underlying structure of the window opening, namely the wood framing members 435 and/or the plywood sheeting 437 . A vertical flashing 412 may be provided allowing the fenestration cap 400 to be attached to the plywood sheeting 437 . A self healing membrane 434 may be placed between the vertical flashing 412 and the plywood sheeting 437 to provide further waterproofing for the underlying structure of the window opening. The self healing membrane 434 may be in one embodiment a continuous waterproof self healing rubberized membrane is manufactured from polypropylene. The vertical flashing 412 also provides additional waterproofing to the finished window assembly by providing a water barrier to any water which infiltrates behind the plaster 436 . The fenestration cap 400 may be attached by its interior side with one or more additional wood screws 430 to the wood framing members 435 .
An expansion cavity 433 may be provided between the fenestration cap 400 and the wood framing members 435 which may contain a foam strip, 3/16″ thick in one exemplary embodiment to act as a shock absorber in the event of thermal or other expansion of the underlying members or seismic movement.
It will be understood by one skilled in the art that the inventive concepts of the invention described herein are not limited to a fenestration cap for use only with the specific materials discussed above, such as plaster and drywall for instance. In lieu of plaster for example, a variety of siding materials can be used to finished the exterior of the storefront assembly shown in FIG. 4 . Likewise, plaster or paneling or a variety of other interior finishing materials may be used instead of the drywall sheeting 438 discussed above.
The fenestration cap 400 shown in FIG. 4 can be made from aluminum, vinyl, steel, plastic and other appropriate materials known to those skilled in the art. In one exemplary embodiment, the fenestration cap may be manufactured as an extruded aluminum piece in twenty-four foot lengths. This exceeds the length of typical extruded pieces used in window openings such as j-molds, for which the industry standard length is ten feet. Accordingly, with this embodiment of the present invention, the need for making time consuming splices between the lengths is reduced.
Furthermore, the width of the fenestration cap may be designed in various widths to fit various windows and window openings. The present invention is designed to work with window systems from multiple companies. As is known to one skilled in the art, the width of a commercial window is customarily measured with reference to its mullion width. These widths come in standard sizes including 2, 3, 4, 4.5 and inches in width, among others. It is envisioned that a fenestration cap may be designed to match each of these standard window widths, although one skilled in the art will understand that a fenestration cap according to the present invention can be made to match any width window. FIG. 4 shows a window 4.5 inches in width, and the fenestration cap 400 shown therein has been designed to match a window of this width.
The fenestration cap 400 may be assembled in the contractor's shop or on the job site itself into a custom system for any size window opening by cutting stock lengths of the fenestration cap 400 at forty-five degree angles (or any other set of complementary angles). These lengths can then be attached to each other using fasteners passing through the integral screw races 405 of adjacent lengths of fenestration cap 400 . For an aluminum fenestration cap, stainless steel sheet metal screws can be used as fasteners.
If the fenestration cap 400 is assembled in the contractor's shop and transported to the job site, a blank made of styrofoam or other material may be inserted into the center of the fenestration cap assembly to stiffen it for transport. This blank may be secured within the assembly using double-sided tape. Furthermore, after the fenestration cap is installed in the window opening, a blank secured within the fenestration cap 400 assembly using double sided tape may be also used to weatherproof the capped window opening in lieu of the window itself. Taped plastic sheeting may also be used for this purpose. In any event, fenestration cap assembly provides and easy base from which to tape or otherwise weatherproof a window opening prior to the installation of the window assembly.
The sill can 450 shown in FIG. 4 is an industry standard sill can having a number of interlocking parts. A sill can filler 455 and a sill can stop 460 snap into place within the sill can 450 to lock a window 470 in position. The window 470 is firmly held by a pair of top load gaskets 471 , which may be neoprene gaskets. The sill can 450 is shown engaging window 470 through the pair of top load gaskets 471 and a setting block 472 . These top load gaskets 471 are held partially snapped into receiving tracks in the sill can filler 455 and the sill can stop 460 . These gaskets are also known to those skilled in the art as self-locking gaskets, given that the weight of the window 470 bears on these gaskets to create a seal between the gaskets 471 and the window 1470 .
In one embodiment of the present invention, at some point after the fenestration cap 400 itself has been installed in the window opening, the sill can 450 , having a window 470 therein, may be lifted onto the length of fenestration cap 400 shown in FIG. 4 . The sill can 450 can then be attached to the fenestration cap 400 using one or more sheet metal screws 451 . In an exemplary embodiment, the window 470 may be surrounded on multiple sides by either a sill can or frame which abuts a length of fenestration cap to which the sill can or frame may be attached.
If the fenestration cap 400 is used with a frame such as the sill can 450 and related components shown in FIG. 4 , the point of attachment of the sill can 450 to the fenestration cap 400 must be made waterproof. Accordingly, before the sill can 450 is attached to the fenestration cap 400 using the sheet metal screws 451 , a caulk bead 452 is laid down therebetween to waterproof the joint. In one embodiment, the caulk used for the caulk bead 452 is structural grade silicone. At the portion of the joint nearest the exterior side of the storefront, a gap of set height 453 is provided which is designed to match the warranty requirements of the standard window sealants used in the industry. In the embodiment shown in FIG. 4 , this gap has a height of ⅜ inches.
A water dam 411 may be provided at the interior side of the caulk bead 452 as a further moisture barrier in the event that water is able to infiltrate through to the interior side of the caulk bead 452 . The water dam 411 also provides a stop allowing for easy installation of the window and sill can 450 . Once the fenestration cap 400 is in place in a window opening, an unskilled laborer would easily be able to install the sill can 450 and related components to provide a finished storefront by lifting the window assembly up and into the opening within the fenestration cap assembly, placing the interior edge of the sill can 450 firmly against the water dam 411 . As such, no measuring is required for the installation of the window assembly itself when the fenestration cap 400 has been used to frame the window opening ahead of time.
Furthermore, even if despite all the precautions built into the design of the fenestration cap 400 , water is able fully infiltrate the joint in the area of the caulk bead 452 and pass over the water dam 411 , the fenestration cap 400 fully spans the width of the window opening in which it is placed so that any water which does manage to flow over the fenestration cap 400 is directed over, rather than into, the wall on which the fenestration cap 400 rests.
The fenestration cap 400 may be provided with a thermal break 410 to reduce the transfer of heat through the fenestration cap 400 to help meet energy efficiency building requirements such as California's Title 24 requirements. Accordingly, an insulation material is formed in a cavity of the fenestration cap 400 . This insulation material has sufficient strength such that after it is formed in the cavity, a portion of the fenestration cap 400 can be removed in the vicinity of the insulation such that the fenestration cap 400 becomes two thermally separate pieces joined only by the insulation. This helps to substantially thermally isolate the interior from the exterior of the finished storefront by preventing heat transmission through the fenestration cap 800
The fenestration cap 400 has the additional advantage that over prior art systems in that it can span doorway openings in a storefront and need not be trimmed to the jamb of a doorway. With the addition of a separate threshold unit, the section fenestration cap 400 , spanning the bottom of a doorway, presents a finished appearance. Accordingly, a single length or series of lengths of the fenestration cap 400 can be made to span the base of an entire storefront serving as both a sill of a window and a door threshold.
FIG. 5 shows a fenestration cap 500 for use with a frameless window system. While the fenestration cap 500 shares many of the same elements as the cap shown in FIG. 4 , the cap 500 is shown engaging the window 570 through a top load gasket 571 and a setting block 572 , rather than incorporating a separate sill can, as is the case in the cap of FIG. 4 . In one embodiment, the top load gasket 571 may be provided by a silicone glazed bead.
As in the previous embodiment, the fenestration cap 500 is attached to the wood framing members 535 and plywood sheeting 537 using a series of wood screws 530 . The fenestration cap 500 is provided with a drywall channel 545 and plaster key 546 designed to receive drywall sheeting 538 and plaster 536 . A spacer 509 may be provided to support the drywall sheeting 538 in the area of a corner bead 539 .
FIG. 6 shows a recessed fenestration cap having a channel in the interior side according to one embodiment of the present invention. In FIG. 6 , the top and front edges of the plaster key 647 and the top edge of the lip 649 are designed to act as guides to the tradesperson applying the plaster 436 to the assembly; a trowel may easily be drawn along these edges to quickly and neatly apply an even layer of plaster in the space between the plaster key 647 and the lip 649 . The surface created by plastering between the plaster key 647 and the lip 649 will not be completely horizontal however; the fenestration cap 600 is designed so that when level, the top edge of the plaster key 647 lies on a 2% decline from the horizontal with respect to the top edge of the lip 649 . This encourages water to shed off of the architectural reveal created by this plastered surface toward the exterior of the storefront. Furthermore, the fenestration cap 600 is provided with a serrated texture 648 to better anchor the plaster to the fenestration cap 600 . Also, the plaster key 647 is provided with holes drilled therein (not shown) so that the plaster applied below the plaster key 647 and the plaster applied to the side of the plaster key 647 is able to form one contiguous and stable mass, leading to increased durability. FIG. 6 also depicts one of two sheet metal screws 651 entering a cavity. In some embodiments of the present invention, one or more sheet metal screws is used to affix the sill can 650 to the fenestration cap. If water leaks under the sill can and above the fenestration cap, it could leak down through the sheet metal screw 651 hole. However, if the screw hole goes through a portion of the fenestration cap into the cavity, the cavity will serve as a reservoir to hold the water, preventing water from entering into the interior, and trapping water in the cavity until it evaporates.
FIG. 7 shows a recessed fenestration cap 700 having a flush interior side according to one embodiment of the present invention. The fenestration cap 700 is attached to the wood framing members 735 and plywood sheeting 737 using a series of wood screws 730 . The fenestration cap 700 is attached to an assembly comprising a sill can 750 , sill can filler and 755 sill can stop 760 using sheet metal screws 751 and a caulk bead 752 . This assembly is shown engaging the window 770 through a top load gasket 771 and a setting block 772 . In contrast to FIGS. 4 , 5 and 6 however, the fenestration cap 700 is not provided with a drywall channel designed to receive drywall sheeting. Instead, the fenestration cap 700 is designed as a relatively flush assembly which may be placed over a corner bead 739 applied to finish the joint between the drywall sheeting 738 and the wood framing members 735 .
FIG. 8 shows a fenestration cap 800 attached to a window 870 using a butt joint 895 . The arrangement shown in FIG. 8 is a counterpart to the fenestration cap 500 of FIG. 5 for use with a frameless window system. While the fenestration cap 500 supports the sill of a window in a frameless window system, the fenestration cap 800 may be applied to the jamb of such a window opening to support the sides of the window 870 .
As in the previous figures, the fenestration cap 800 is provided with a plaster key 846 to facilitate the easy application of the plaster 836 , and a drywall channel 845 to facilitate the installation of the drywall sheeting 838 . The fenestration cap 800 is secured to the wood framing members 835 and the plywood sheeting 837 using one or more wood screws 830 . Furthermore, the fenestration cap 800 is provided with a thermal break 810 , which may be supplemented with the creation of a saw cut 896 in the fenestration cap 800 to substantially thermally isolate the interior from the exterior of the finished storefront, preventing heat transmission through the fenestration cap 800 .
FIG. 9 shows a recessed fenestration cap 900 having a built in plaster key 947 which is attached a window pane using a caulked butt joint. The fenestration cap 900 is similar to the fenestration cap 800 of FIG. 8 in that it may be applied to the jamb of a window opening in a frameless window system to support the window therein. However, it differs in that it features a set back similar to that used in the fenestration cap 600 of FIG. 6 , wherein the top and front edges of the plaster key 947 and the top edge of the lip 949 are designed to act as guides to the tradesperson applying the plaster 936 to the assembly.
As in FIG. 6 , the surface created by plastering between the plaster key 947 and the lip 949 will not be completely horizontal. The fenestration cap 900 is designed so that when level, the top edge of the plaster key 947 lies on a slight decline from the horizontal with respect to the top edge of the lip 949 . This encourages water to shed off of this architectural reveal toward the exterior of the storefront. The fenestration cap 900 is also provided with a serrated texture 948 to better anchor the plaster 936 to the fenestration cap 900 .
FIG. 10 is an alternative embodiment of the present invention wherein a sill detail a fenestration cap 1000 shown is anchored to a concrete slab 1001 using a fastener 1002 . The concrete slab 1001 may be part of an overhanging eve. In place on the fenestration cap 1000 are a sill can 1050 , a sill can filler 1055 , and a sill can stop 1060 which, though the top load gaskets 1071 secure the window 1070 .
The gap between the sill can 1050 and the fenestration cap 1000 is sealed with a caulk bead 1052 . As in other embodiments, a gap of set height 1053 is provided as part of the caulk bead 1052 to match industry standard warranty requirements. A water dam 1011 is provided at the interior side of the caulk bead 1052 as a moisture barrier in the event that water is able to infiltrate through to the interior side of the caulk bead 1052 , and to provide a stop for easy installation of the sill can 1050 .
The embodiment of FIG. 10 additionally shows that the fenestration cap 1000 is slightly wedge shaped, having a narrower edge on the exterior side. As such, water will be more inclined to run to the outside of the window 1070 both if it infiltrates between the fenestration cap 1000 and the sill can 1050 , and if it gets into the sill can 1050 itself. In prior art models, if water infiltrated the sill can 1050 for example by flowing between it and the sill can filler 1055 , it would pool within the sill can. Weep holes were sometimes added in the sill can 1050 to aid in drainage, but cannot prevent pooling in the event of an unfavorable alignment of the sill can 1050 itself.
FIG. 11 shows a fenestration cap 1100 according to an alternative frameless embodiment of the present invention wherein the window 1170 is mounted directly on the fenestration cap 1100 using a caulk joint 1195 . As is the previous figures, the fenestration cap 1100 is provided with a plaster key 1146 to facilitate the easy application of the plaster 1136 , and a drywall channel 1145 to facilitate the installation of the drywall sheeting 1138 . The fenestration cap 1100 is secured to the wood framing members 1135 and the plywood sheeting 1137 using one or more wood screws 1130 .
FIG. 12 shows a head detail of a fenestration cap 1200 anchored to an overhang 1201 . The fenestration cap 1200 is of a type which can be attached on a continuous eve or overhang 1201 without need of a flange. In the embodiment shown, the fenestration cap 1200 is attached using the fastener 1202 . On the fenestration cap 1200 is mounted an assembly comprising a sill can 1250 , sill can filler 1255 and sill can stop 1260 . This assembly may be mounted using sheet metal screws 1251 , and seamed using a caulk bead 1252 . A window 1270 may be mounted in this assembly using top load gaskets 1271 . The fenestration cap 1200 may be installed before the sill can 1250 to allow for the completion of work involving the plaster 1236 and drywall sheeting 1238 , the latter of which fits easily into the drywall channel 1245 .
The preceding description has been presented with reference to some embodiments of the invention. Workers skilled in the art and technology to which this invention pertains will appreciate that alterations and changes in the described structure may be practiced without meaningful departing from the principal, spirit and scope of this invention. Accordingly, the foregoing description should not be read as pertaining only to the precise structures and methods described and illustrated in the accompanying drawings, but rather should be read consistent with and as support to the following claims which are to have their fullest and fair scope. For instance, FIG. 10 depicts a fenestration cap that is slightly wedge shaped, and thus parts of the fenestration cap may not be perfectly parallel or perfectly perpendicular in reference to one another. Therefore, as used herein, parallel and perpendicular could mean substantially parallel and substantially perpendicular.
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In an exemplary embodiment, a window sill comprises a structural base having a first side and a second side, a fenestration cap attached to the structural base, a window frame mounted on the fenestration cap and finish elements applied to the structural base and adjacent to the fenestration cap. The window frame may be removed from the fenestration cap without disturbing the finish elements. Alternatively, a method of installing a window in a window opening comprises providing a window opening and preparing the window opening for receiving a fenestration cap, installing a fenestration cap by placement within and attachment to the window opening in a primary step, and installing a window within the window opening by placement within and attachment to the fenestration cap in a secondary step.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to the field of radio communications systems, and more specifically to an inventive method to quickly determine the presence of a multi-carrier signal on a received channel using spectral characteristics of the received signal.
[0002] Multiple carriers are used in the transmission of digital signals to maximize correct reception of those signals in the presence of noise and interference and to maximize the data capacity of the transmission channel. An example of a multiple-carrier system is an orthogonal frequency division multiplexing (OFDM) system, which is used in both cellular telephone systems and in digital radio systems such as AM/FM in-band on-channel (IBOC) systems. Today's broadcast radio systems is comprised of channels that may contain multiple-carrier signals, such as IBOC channels, as well as the traditional analog channels that do not transmit multiple carrier signals, such as AM/FM channels.
[0003] Fast detection or determination of the presence of the multiple-carrier is needed to allow the receiver or the receiver's user to determine whether to continue to receive a channel if the multiple carriers are not present. For example, in an IBOC radio receiver, a particular tuned channel may be transmitting either traditional analog signals (i.e., non-IBOC signals) in which no multiple carriers present or IBOC signals in which multiple carriers are present. The user may prefer to listen only to IBOC channels and so not to continue receiving a channel if it does not transmit IBOC signals.
[0004] Before a digital audio receiver can recover the digital content of a multiple-carrier signal, the receiver must typically “lock” onto the digital signal. “Locking” means that the receiver adaptively configures itself through time, phase, and/or amplitude alignment mechanisms, such as by means of a phase-lock-loop, to receive the multiple-carrier signal in such a way that the digital content of the signal can be recovered. Receivers designed to receive complex digital modulation signals, such as IBOC signals, typically require a significant amount of time to lock onto the multiple carrier signal once the receiver is tuned to a channel where an IBOC signal is present.
[0005] The locking event or the lack of locking can be used as an indicator of the presence of the multiple-carrier signal. However, the long time period that is required for locking to occur, or to determine that no locking has taken place, conflicts with the general requirement for fast detection. Therefore, a different method that quickly detects or determines the presence of multiple-carrier signal components is needed.
SUMMARY OF THE INVENTION
[0006] The present invention describes a method for determining the presence of multiple carrier frequency components in an electrical signal by calculating a value for at least one characteristic of the set of peaks in a defined portion of the frequency spectrum, defining a range of values of the characteristic that would indicate the presence of multiple carrier components, and comparing this calculated characteristic value against the values in the defined range of values. Examples of the type of characteristics of the peaks that may be used include the number of peaks within a defined portion of the frequency spectrum and the average spacing between pairs of peaks. These and other aspects and advantages of the present invention will become apparent upon reading the following detailed description of the invention in combination with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a flowchart depicting the steps of the inventive fast detection method.
[0008] FIG. 2 is a flowchart depicting the steps of the inventive fast detection method using values for peak counts.
[0009] FIG. 3 is a flowchart depicting the steps of the inventive fast detection method using average values for the spacing between pairs of peaks.
DETAILED DESCRIPTION OF THE INVENTION
[0010] The following description of the preferred embodiment of the inventive detection method is not intended to limit the inventive method to this preferred embodiment, but rather to enable any person skilled in the art of radio communications systems to make and use the inventive method.
[0011] Referring now to FIG. 1 , the inventive detection method 10 begins at starting point 20 . In step 30 , frequency bins are created by characterizing spectrally the portion of the spectrum of the received signal that contains the multiple-carrier signal, or some smaller part of that portion, using a spectral resolution that is finer than the frequency spacing of the multiple carriers. This characterization may be performed using any one of many techniques generally known in the art of communication systems, such as, by way of example and not limitation, by Fast Fourier Transform or by a poly-phase filter bank.
[0012] In step 40 , the signal level in each bin is measured using any one of many techniques generally known in the art of communication systems, such as, by way of example and not limitation, an energy or power level detector at each frequency. If the signal being analyzed contains multiple carriers, the characterization of the signal will exhibit a pattern of peaks and valleys. The peaks will be located at the frequencies at or near the location of the multiple carriers, and valleys will be located between these peaks.
[0013] In step 50 , a means of identifying the peaks and valleys is employed. One method to determine the location of peaks and valleys is the “local maximum” method (although an analogous “local minimum” method could also be employed). In the local maximum method, a presumed peak is considered a peak if the frequency characteristic drops on either side of the presumed peak by at least a certain amount, regardless of whether or not the drop is the same on both sides.
[0014] One benefit of the local maximum approach is that it removes the effect of variations in the levels of the individual sub-carrier components due to filtering in the receiver and/or frequency-selective fading on the incoming signal. For example, in the local maximum method, a valley is considered a valley if the frequency characteristic rises on either side of a presumed valley by at least a certain amount, regardless of whether or not the rise is the same on both sides. Although the local maximum method may be used in the preferred embodiment of the inventive method shown in FIG. 1 , any one of many other methods of estimating the location of a local maximum known to those skilled in the art of communications systems could also be used.
[0015] The set of measured levels in the bins resulting from step 40 may exhibit fast variations due to noise that may be present in the signal. This noise may lower the accuracy of identifying the peaks and valleys in identification step 50 . However, this noise may be reduced prior to step 50 by applying a low pass filter to the set of bin levels. The bandwidth of the low pass filter should be set such that the expected patterns of peaks and valleys will pass through the filter but the noise will not.
[0016] In step 60 , the pattern of peaks and valleys is analyzed and evaluated to determine whether a multi-carrier signal is present before the process terminates in step 70 .
[0017] Referring now to FIG. 2 , a method suitable for performing the analysis and assessment of step 60 is described in greater detail. The method begins in step 110 then proceeds to step 120 in which the number of frequency bins, indicative of the spacing between the peaks, is counted. In step 130 an average value for the number of frequency bins between peaks is computed. This computed average value is determined using at least two pairs of adjacent peaks.
[0018] In step 140 , the computed average value is compared to a predetermined range of values for the number of frequency bins between peaks or the spacing. If the computed average value falls within the predetermined range then a multiple-carrier signal component is detected in step 150 before the process ends in step 170 . If the computed average value falls outside of the predetermined range then no multiple-carrier signal component is detected before the process ends in step 170 .
[0019] A standard deviation approach could also be employed to measure the reliability of the computed average value determined in step 130 . A large standard deviation may mean that the computed average value is not a reliable number. The uncertainty or standard deviation of the counts obtained in step 120 can also be used as part of an alternative higher-level strategy to determine the uncertainty of the process outline in FIG. 2 as to whether the pattern of peaks and valleys indicative of a multiple-carrier signal is present or not. For example, if the uncertainty is higher than a certain threshold, the determination result may be that the multiple carrier signal may be present but noisy, and should be rechecked at a later time.
[0020] Referring now to FIG. 3 , a second method suitable for performing the analysis and assessment of step 60 is described in greater detail. This method begins in step 210 then proceeds to step 220 in which the valid peaks are counted within the portion of the frequency spectrum. In step 230 , the number of valid peaks counted in step 220 is compared to a predetermined range of values for the number of valid peaks. If the counted number of valid peaks falls within the predetermined range of values, then a multiple-carrier signal component is detected in step 240 before the process ends in step 270 . If the counted number of valid peaks falls outside of the predetermined range of values for the number of valid peaks, then no multiple-carrier signal component is detected before the process ends in step 270 .
[0021] Under some reception conditions, a portion of the signal spectrum containing the multiple carriers may be impaired by noise and/or interference. In this case, the detection methods outlined above may be applied to smaller parts of the spectrum to detect the multiple carriers but avoid any impairment. For example, in the case of IBOC signals, the spectrum containing the multiple carriers is split between the upper and lower sidebands around the carrier or portions thereof. The detection technique outlined above could be applied to the upper and lower spectrums separately.
[0022] The multiple-carrier spectrum could also be subdivided evenly or unevenly into frequency bands, with the detection methods outlined above applied separately to each band. In each of the approaches outlined above, detection of a multiple carrier signal may be performed by combining the detection results from the individual frequency bands using any one of the various methods for combining detection results that are generally known in the art. One such method would be to require that the multiple carrier signal be detected in a certain minimum number of the subdivided frequency bands.
[0023] One advantage of the inventive methods outline above is that the same processing resources in the receiver that are normally used to fully demodulate the multiple-carrier signal for recovery of its digital content may be used to implement the present inventive fast detection method for multiple carrier component signals. For example, the demodulation processing resources could be configured by a controller to perform the above outlined methods prior to demodulation. If the multiple-carrier component signal is detected, the controller could then re-configure these same processing resources to carry out the locking and demodulation functions. Thus, additional processing resources for the present inventive fast detection method and the associated additional system cost could be avoided.
[0024] The present inventive fast detection method for multiple carrier signal components is not limited to the embodiments illustrated and described; it also covers all equivalent implementations of this method insofar as they do not depart form the spirit of the inventive method. Further, the inventive method is not yet limited to the combination of features as described herein but may be defined by any other combination of all of the individual features disclosed. Any person skilled in the art of radio communications systems will recognize from the previous detailed description and from the figures and claims that modifications could be made to the preferred embodiments of the inventive method without departing from the scope of the inventive method, which is defined by the following claims.
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A method for determining the presence of multiple carrier frequency components in an electrical signal by calculating a value for at least one characteristic of the set of peaks in a defined portion of the frequency spectrum, such as the number of peaks within a defined portion of the frequency spectrum or the average spacing between pairs of peaks, and defining a range of values of the characteristic that would indicate the presence of multiple carrier components, and comparing this calculated characteristic value against the values in the defined range of values.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2012-0119136, filed on Oct. 25, 2012, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference in its entirety.
TECHNICAL FIELD
The present invention relates to a WLAN service method and WLAN system, and more particularly, to a WLAN system using diversity with decreased overhead and MAC/PHY layer communication method thereof.
BACKGROUND
Frequency diversity is one of the characteristics that should be considered in designing wireless communication systems, especially for ones that operate over a wide frequency band such as WiMAX and 3GPP LTE. In addition to spatial and temporal diversities, signals transmitted over a wide frequency band experience independent fluctuations across frequencies. This phenomenon is generally called “frequency selective fading.” Frequency diversity is ignored in conventional WiFi systems because these systems use a channel as a whole. However, adoption of OFDM in 802.11 WLANs triggered recent research interests in harvesting gains from frequency diversity. The importance of frequency diversity research becomes more important than ever as IEEE 802.11 working group (WG) is standardizing the use of wider channels. For example, 802.11n can already use a 40 MHz channel by Phased Coexistence Operation (PCO) and 802.11ac will provide up to a 160 MHz channel. Accordingly, several Wi-Fi protocols exploiting frequency diversity have already been proposed recently in academia.
To harness frequency diversity, a wireless communication system must provide channel quality estimation functionality.
Acquiring channel quality information consumes time and frequency resource that ideally should be used for data transfer. For example, many current wireless systems estimate channel quality using a training sequence (pilot) in a preamble or spend dedicated time only for the channel estimation purpose. Moreover, for N by N Multiple-Input-Multiple-Output (MIMO) systems, N 2 channels have to be estimated resulting in substantial protocol inefficiency. In this case, the high data throughput of a MIMO system cannot be achieved due to the large overhead of channel estimation. In short, there is a trade-off between frequency diversity gains and protocol efficiency.
The research approaches to achieve frequency diversity gains are categorized into two groups; (i) variants of Wi-Fi systems that improve the protocol efficiency and (ii) frequency diversity aware protocols for various wireless networks such as WiMAX, 3GPP LTE, and Wi-Fi networks. However, none of them explore both of the conflicting objectives—i.e., reduction of channel estimation overhead and protocol efficiency—simultaneously. Most previous work emphasizes mainly one side of these since the two objectives are considered as orthogonal to each other (but it is not true as we have discussed above). Also, frequency diversity aware studies are highly theoretical rather than practical, i.e., these researchers solved the channel allocation problem assuming the perfect channel information is given.
SUMMARY
According to the present disclosure, satisfying two conflict objectives, achieving frequency diversity gain and protocol efficiency, boils down to acquisition of channel quality information with a minimum channel estimation cost. In this disclosure, we present a WLAN system we call diversity-aware Wi-Fi (D-Fi), a novel Wi-Fi PHY/MAC protocol that exploits frequency diversity while sustaining protocol efficiency. Specifically, D-Fi collects channel information while resolving channel contentions using an OFDM-based Bloom filter without requiring a dedicated channel estimation mechanism. D-Fi can be combined with other protocols because it is orthogonal to those existing Wi-Fi proposals custom-tailored for improving protocol efficiency.
An exemplary embodiment of the present invention provides a method for providing WLAN service performed by an access point (AP) in a WLAN system including the AP and a plurality of stations (STAs) each of which can associate with the AP, the method comprising: dividing frequency bandwidth of available channel into a plurality of frequency-selective subchannels; receiving, from at least some STAs (first STAs) among the plurality of STAs, CRQ (Contention Resolution reQuest) frame including a signature of the first STAs through at least some of the subchannels, the signature identifying the first STAs; identifying the first STAs using the received CRQ frame; estimating uplink channel quality of the first STAs using the received CRQ frame; allocating subchannels for each of the first STAs; and broadcasting result of subchannel allocation using CRP (Contention Resolution rePly) frame.
It is preferable that the subchannel has a bandwidth equal to or less than minimum coherence bandwidth, or equal to or less than 3 MHz.
The number of the subchannels may be 14.
The signature may be a binary bit sequence of 16 bits, and each of the STAs may receive a unique signature at the time of association with the AP.
The AP may receive synthesized signal of the signatures of the first STAs trying to use the subchannel for each subchannel, and the signature may be modulated on K (K is a natural number) subchannels selected by each of the first STAs according to likelihood of good channel quality.
Each of the first STAs may select the subchannels using the following algorithm 1.
Algorithm 1 Multi channel backoff
for i := requested subchannel i ε C do
if subchannel i is requested & allocated then
Pr(i) ← Pr(i) + α
else if subchannel i is requested & not allocated then
Pr(i) ← Pr(i)/β
end if
end for
Pr
(
i
)
←
Pr
(
i
)
X
K
∑
j
∈
C
Pr
(
j
)
,
∀
i
∈
C
It is preferable that the AP identifies the first STAs using a Bloom filter and the Bloom filter is implemented through subcarrier-level signaling in OFDM system.
The AP may estimate the uplink channel quality by measuring energy of a unique bit, which is transmitted by one STA only, included in the received CRQ frame.
The broadcasting may be broadcasting the CRP frame including data rate information.
The AP may identify the first STAs using Machine Learning (ML) algorithm, preferably, and an ML model used in the ML algorithm may be trained when a STA joins or leaves the AP.
Another exemplary embodiment of the present invention provides a WLAN system comprising: an access point (AP); and a plurality of stations (STAs) each of which can associate with the AP, wherein a channel available in the WLAN system is divided into a plurality of frequency-selective subchannels; at least some STAs (first STAs) among the plurality of STAs transmit a CRQ (Contention Resolution reQuest) frame including a signature of the first STAs through at least some of the subchannels, the signature identifying the first STAs; and the AP identifies the first STAs using the received CRQ frame, estimates uplink channel quality of the first STAs using the received CRQ frame, allocates subchannels for each of the first STAs, and broadcasts result of subchannel allocation using CRP (Contention Resolution rePly) frame.
The first STAs may transmit the CRQ frames simultaneously when the channel is idle for more than DIFS (DCF Inter-Frame Space).
Other features and aspects will be apparent from the following detailed description, the drawings, and the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows MAC (Media Access Control) protocol overview of a WLAN system according to an exemplary embodiment of the present invention.
FIG. 2 is a description for two Bloom filter based operations; inserting elements, i.e., signatures (CRQ) and testing membership (CRQ decoding).
FIG. 3 shows the empirical CDF for the estimation error of a WLAN system according to an exemplary embodiment of the present invention.
FIG. 4 shows that the spectral leakage by the other hash function can only occur at the boundary of the subsequence.
FIG. 5 shows the analysis and simulation results: the false positive and the collision probability of D-Fi and FICA.
FIG. 6 is an algorithm showing the pseudo-code of the multi channel backoff algorithm.
FIG. 7 shows the accuracy for the CRQ decoding with the ML algorithms.
FIG. 8 shows the training time for ML models used for the CRQ decoding.
FIG. 9 depicts the topology used in the experiment according to an exemplary embodiment of the present invention.
FIG. 10 shows the accuracy of the subcarrier-level signal detection.
FIG. 11 is the simulation results: the empirical CDF of the throughput for each scheme.
FIG. 12 is the simulation results which shows Jain's fairness index.
DETAILED DESCRIPTION OF EMBODIMENTS
Hereinafter, exemplary embodiments will be described in detail with reference to the accompanying drawings. Throughout the drawings and the detailed description, unless otherwise described, the same drawing reference numerals will be understood to refer to the same elements, features, and structures. The relative size and depiction of these elements may be exaggerated for clarity, illustration, and convenience. The following detailed description is provided to assist the reader in gaining a comprehensive understanding of the methods, apparatuses, and/or systems described herein. Accordingly, various changes, modifications, and equivalents of the methods, apparatuses, and/or systems described herein will be suggested to those of ordinary skill in the art. Also, descriptions of well-known functions and constructions may be omitted for increased clarity and conciseness.
Now, a WLAN system and PHY/MAC layer communication method thereof according to an exemplary embodiment of the present invention is described with reference to accompanying drawings.
I. Introduction
The D-Fi protocol has the following features.
D-Fi channelizes a Wi-Fi band into several orthogonal subchannels based on the OFDM technique and uses each of them as a channel access unit. This channelized medium access amortizes MAC coordination burdens and hence improves overall MAC protocol efficiency. Moreover, it exploits frequency diversity inherent in a wide band by a frequency-aware subchannel allocation scheme.
D-Fi estimates channel quality while performing contention based channel allocation. To do so, D-Fi adopts a Bloom filter based channel contention mechanism. Specifically, the D-Fi MAC protocol uses RTS/CTS-like Collision Resolution reQuest (CRQ)/Collision Resolution rePly (CRP) frames through a Bloom filter. A CRQ/CRP frame lasts only for a few OFDM symbols. The overhead of D-Fi is much smaller than that of the legacy RTS/CTS frame. Multiple stations (STAs) contend for subchannels simultaneously according to estimated subchannel quality as well as their traffic demands. An AP can estimate the uplink channel quality of the STAs using this synthesized CRQ frame without additional channel estimation overhead. After an AP perform frequency aware subchannel allocation based on the channel estimates then it broadcasts a CRP frame to inform the STAs of the result of channel allocation.
Bloom filter based channel contention incurs the ambiguity problem because of an intrinsic characteristic of a Bloom filter. D-Fi uses two methods to solve the problem. Firstly, an analysis-based multi channel backoff algorithm reduces the occurrence of the ambiguity while allowing DFi STAs to distributively explore/exploit frequency diversity. Next, applying machine learning (ML) algorithms to the D-Fi protocol resolves the ambiguity so that D-Fi can operate the MAC protocol reliably.
We implemented the OFDM-based D-Fi PHY/MAC on a testbed consists of four USRPs/GNUradios. The experiment shows the feasibility and practicality of the D-Fi PHY/MAC protocol. Further, we used detailed trace-driven simulation to evaluate the performance of D-Fi. Our results show that D-Fi has up to 3× and 1.5× better performance in terms of throughput compared to existing 802.11n and FICA (K. Tan, J. Fang, Y. Zhang, S. Chen, L. Shi, J. Zhang, and Y. Zhang. Finegrained Channel Access in Wireless LAN. In ACM SIGCOMM 2010), respectively.
In summary, this disclosure makes the following contributions. (i) We design and implement D-Fi, a Wi-Fi PHY/MAC protocol that exploits frequency diversity while sustaining the MAC efficiency. (ii) We provide a detailed analysis to address the ambiguity problem arisen from the use of a Bloom filter. Based on the analysis we propose a multi channel backoff algorithm that explores/exploits frequency diversity distributively while reducing the occurrence of ambiguity. (iii) We apply ML methods to the D-Fi PHY/MAC protocol and demonstrate the superior performance of ML methods in solving the ambiguity problem arisen in the D-Fi PHY/MAC protocol. (iv) We demonstrate the feasibility of D-Fi with our prototype implementation on the USRP/GNURadio platform and evaluate its performance using the detailed trace-driven simulation.
II. D-FI Design
D-Fi is a CSMA-based Wi-Fi PHY/MAC protocol that performs wireless channel contention and channel quality estimation at the same time. Generally, channel quality estimation incurs overhead because extra estimation time and/or training sequences (pilot) are used for estimation. D-Fi acquires channel information while STAs are performing channel contention and no additional overheads are required. Based on the estimated channel quality, D-Fi exploits frequency diversity. In this section, we detail the design of the D-Fi PHY/MAC.
A. Channelization
Taking a large Fast Fourier Transform (FFT) window size means a long OFDM data symbol in time. Therefore, for the purpose of good protocol efficiency, it is desirable to choose a large FFT window. Although it is possible to choose any large FFT size theoretically, there are several practical concerns that prevent large FFT [4]: (i) Computational complexity increases as an FFT size increases since the theory tells us that the complexity of the N-points FFT (or inverse FFT) is O(N logN). (ii) The frequency separation between subcarriers is imperfect. These limitations are generally caused by mismatched oscillators, Doppler shift, or timing synchronization errors. And these factors eventually lead to lose orthogonality between subcarriers introducing non-negligible inter carrier interference (ICI) in practice. In D-Fi, to deal with such limitations, we choose the FFT size such that an OFDM symbol is 256/512 points in a 20/40 MHz channel (subcarrier bandwidth is about 78.12 KHz.).
Coherence bandwidth is a statistical measure of the range of frequencies over which the channel can be considered “flat”. Recent measurement studies have shown that the minimum coherence bandwidth over the industrial, scientific, and medical (ISM) license-free band (near 2.4/5 GHz) is approximately 3 MHz in indoor environments. Therefore, when a channel access unit (i.e., a subchannel) is narrower than 3 MHz it can be considered as flat within a subchannel and is frequency-selective between subchannels.
These measurement results motivate us to develop D-Fi, a Wi-Fi protocol that exploits frequency-selectivity. We choose 17 contiguous subcarriers to form a subchannel (bandwidth is about 1.4 MHz.). Among 17 subcarriers, 16 subcarriers are used for data transmission and one subcarrier is used as a pilot channel that tracks the subchannel quality while the data is being transferred. There are 14 orthogonal subchannels in a 20 MHz band, and they are frequency-selective one another in typical indoor environments.
B. Protocol Overview
FIG. 1 shows MAC (Media Access Control) protocol overview of a WLAN system according to an exemplary embodiment of the present invention.
D-Fi uses Contention Resolution reQuest (CRQ)/Contention Resolution rePly (CRP) frame exchanges for channel contention as shown in FIG. 1 . Note that a CRQ/CRP frame lasts only for a few OFDM symbols and so its overhead is much smaller than that of the legacy RTS/CTS frame. If the medium is idle for more than distributed interface space (DIFS) STAs may transmit CRQ symbols simultaneously. Each STA selects K subchannels (They are not necessary to be continuous) likely to have good channel quality and modulates his own signature on each selected subchannel. Consequently, multiple CRQs sent from multiple STAs arrive at the AP. These CRQ symbols can be misaligned due to different propagation delay, sensing time (CCA), and RF RxTx switching delay. However the total misalignment has been shown to be tightly bounded [10]. In an OFDM system, as long as the misalignment is less than the cyclic prefix (CP), a receiver can decode misaligned signals [4]. We set the D-Fi CP length such that the maximum alignment is less than CP length.
An AP can extract STAs' uplink channel quality information from CRQ frames. Then the AP allocates subchannels to the STAs based on any channel allocation policy, for example, proportional fairness or throughput-optimum.
To inform STAs of the channel allocation results, the AP broadcasts a CRP frame. This frame conveys the signature of the contention winner and transmission rates for future data transmission.
C. Channel Contention and Estimation
1) Signature:
A signature is a binary bit sequence of 16 bits. A STA receives a unique signature when it joins a Wi-Fi network. The rule for assigning a signature is as follows: First, divide a 16 binary bits sequence into four continuous-bits subsequences. Then choose one bit in each subsequence and mark chosen four bits (one bit from each subsequence) as “1” and the rest as “0”. Therefore, 256 (=44) possible signatures exist. Note that the number of STAs in a WLAN is typically not very large (order of tens and 256 is enough for unique allocation to all STAs).
A signature is carried over one subchannel; one bit over one subcarrier. We use binary amplitude modulation (BAM) to modulate a single bit on each subchannel. Specifically, BAM uses On-Off signaling that maps a binary “0” to zero amplitude and a binary “1” to a random complex number on the unit circle (ej) in a subcarrier. In other words, no signal is transmitted to modulate a binary “0” in a subcarrier and a fixed powered random complex signal is transmitted to modulate a binary “1” in a subcarrier. A receiver can easily detect a BAM symbol by measuring a signal power level on a subcarrier without demodulating an exact symbol.
STAs may join and leave dynamically. At the time of association, an AP allocates a signature to the joining STA. The allocated signatures among 256 possible ones are called “valid”. If a STA is inactive for long time, its signature is taken back and set to be “invalid”.
2) CRQ Frame:
To facilitate simultaneous channel contention and estimation, D-Fi uses the Bloom filter. A subchannel where signatures are transmitted can be considered as a Bloom filter consists of 16 bits. If only one signature is transmitted over a subchannel, then we can easily detect the signature. If two or more signatures collide, the AP uses the Bloom filter technique to resolve signatures. The process of identifying signatures from a Bloom filter is called “CRQ decoding” ( FIG. 2 ).
FIG. 2 is a description for two Bloom filter based operations; inserting elements, i.e., signatures (CRQ) and testing membership (CRQ decoding). These operations are performed in one subchannel (i.e., one Bloom filter). Broadcast of a channel contention result (CRP) is also described at the bottom of the figure.
In CRQ decoding, we should handle two types of ambiguity; the physical and logical errors.
Physical errors.
One bit in a Bloom filter is actually one OFDM subcarrier. A STA will transmit a signal over some selected subcarriers representing its signature. Since the frequency separation between subcarriers is imperfect in practice a subcarrier suffers from so-called “spectral leakage.” A signal spills over adjacent subcarriers. Since subcarrier-level signal detection is implemented by comparing between a signal power level and a threshold, the signal can be falsely detected. We call this event “bitwise false positive (bitwise-FP)” and the event that the signal is falsely missed “bitwise false negative (bitwise-FN)”. Both of the events are the physical errors. Careful and adaptive threshold adjustments can make them negligible. Our software radio implementation (explained in section V) as well as other implementations showed that the physical error rates are quite small.
Logical errors.
An intrinsic characteristic of a Bloom filter is the logical error. During the CRQ decoding process, an AP falsely determines the signatures that are not actually requested. It is generally called “False Positive (FP)” of a Bloom filter. For example, two stations STA 1 and STA 2 , whose signatures are “1000 1000 0010 0001” and “1000 1000 0001 0010”, respectively, request to the same subchannel resulting in a Bloom filter of “1000 1000 0011 0011”. The AP should decode “1000 1000 0011 0011” as a superposition of the signatures of STA 1 and STA 2 . However, due to the inherent ambiguity, it may falsely decode it as “1000 1000 0001 0001” and “1000 1000 0010 0010 as well. Although D-Fi only considers STAs having valid signatures as channel contenders, there still is non-negligible FP rate.
We propose two methods to solve the ambiguity problem; an analysis based multi channel backoff algorithm and machine learning (ML) algorithms. The analysis based multi channel backoff algorithm aims to limit the number of channel requests for one subchannel. On average a STA will request K subchannels at once, and an appropriate value of K is determined by the analysis shown in section III. The multi channel backoff algorithm selects K preferable (i.e., high quality) subchannels in a distributed manner to exploit frequency diversity. On the other hand, ML-based CRQ decoding aims to reduce the probability of logical and physical errors in CRQ decoding (explained in section IV). In short, multi channel backoff prevents the logical errors while ML-based CRQ decoding corrects the physical and logical errors.
3) CRP Frame:
To inform a STA of a channel allocation result, an AP broadcasts a CRP frame. This frame conveys the signature of a contention winner and data rate information for future data transmission for each subchannel. Since there are 256(=2 8 ) signatures, 8 bits are used for a signature and the rest are used for data rate information ( FIG. 2 ).
4) Channel Quality Estimation:
Assume that all stations use the same transmission power and the total transmission energy spreads evenly over each of four bits marked as “1” when sending a CRQ symbol. An AP can guess the channel qualities from the signal strength of unique bits. A unique bit is a bit that is transmitted by one station only. After CRQ decoding, we determine unique bits and use the average energy level of the unique bits belong to a signature as the channel quality ( FIG. 2 ).
We have evaluated the channel estimation performance in terms of accuracy in our implementation. FIG. 3 shows the empirical CDF for the estimation error of our method. As shown in FIG. 3 , the estimation error of our method is less than or equal to 1 dB for most of the cases (90%).
D. Proportional Fairness
Once channel quality estimates are available, an AP can allocate subchannels to STAs by the proportional fairness algorithm. Proportional fairness maximizes the sum of logarithmic throughput over the fixed number (W) of time slots. Let T i [n] be the throughput of a STA i in a time slot n, the throughput of a STA i during W time slots T i (W) [n] is then:
T
i
(
W
)
[
n
]
=
1
W
∑
m
=
n
-
n
0
n
+
W
-
n
0
-
1
T
i
[
m
]
(
1
)
where n 0 is the number of slots look back to the past, and W−n 0 −1 is the number of slots in the future. With the equation (1), our objective function is written as:
max
∑
i
log
T
i
(
W
)
[
n
]
(
2
)
By the Shannon's theorem, the throughput can be further re-written as a function of estimated SNRs. The difference from the original problem is that we apply the proportional fairness algorithm to the reduced problem space since an AP can only estimate the channel quality of the STAs who have made a request. Even with this restriction, in subsection V-B, we will show that D-Fi has close to the optimal performance in terms of exploring/exploiting frequency diversity.
E. Why Bloom Filter?
Basically, a Bloom filter is a space-efficient data structure. Here, the space means the number of subcarriers constructing a subchannel. As we have described above, we cannot use large FFT windows. The price paid for this space-efficiency is probabilistic ambiguity inherent to a Bloom filter: it tells us that the element either definitely is not in the set or may be in the set. The term “may” means that a Bloom filter may generate ambiguity (i.e., false positives). In D-Fi, resolution of the ambiguity is particularly important because it estimates the channel quality based on the unique bits in signatures. Unfortunately, it is impossible to eliminate false positives completely and hence we turn our attention to find a method to mitigate the false positive probability. As we will see afterwards, machine learning algorithms (MLs) are good solutions to this problem.
III. Analysis
In this section, we analyze the false positive probability and the collision probability of the contention mechanism in D-Fi. Based on the analysis we propose a multi channel backoff method that enables a STA to explore/exploit frequency diversity distributively. It also reduces the false positive probability of the Bloom filter based contention mechanism.
We assume a WLAN consists of N STAs and C subchannels. As a Bloom filter is used for each subchannel C Bloom filters exist. A Bloom filter consists of m binary bits (i.e., subcarriers)
r ( = N × K C )
and h hash functions (Each bit of a signature is chosen by each hash function). A STA can request for K subchannels each time it contends for a channel. On average, STAs will select a certain subchannel. In other words, on average, r elements (signatures) will be inserted into a Bloom filter. Given that hash functions are uniform, the probability that a certain bit is selected by one of h hash functions is h/m.
Let us derive the probability that a subcarrier is set to be “1” taking into account the spectral leakage. An OFDM system suffers from high spectral sidelobes, and consequently, a subcarrier may accidentally be set to “1” because of the leakage of power from subcarriers nearby. Assume that the only adjacent subcarriers cause power leakage. Let P leak be the probability of the spectral leakage. Then the probability that a certain bit is set to “1” because of the spectral leakage is
2
hP
leak
m
.
Remind that each of our hash functions selects one bit from each of the non-overlapping subsequences (each subsequence is m/h bits long). The probability that an inside bit—a bit not adjoining to the subsequence boundary—is set to “1” is given as:
h
m
+
2
hP
leak
m
(
3
)
While consecutive inside bits cannot be selected by two hash functions at the same time, two boundary bits can be set to “1” by two hash functions ( FIG. 4 ). Therefore we have to subtract the probability of the event that two hash functions simultaneously set the bits at the boundary as “1” from the equation (3):
h
m
+
2
hP
leak
m
-
(
h
m
)
2
P
leak
(
1
+
P
leak
)
(
4
)
Combining equation (3) and equation (4), the probability that a certain bit is set to “1” is:
P
positive
1
=
2
(
h
m
+
2
hP
leak
m
-
(
h
m
)
2
P
leak
(
1
+
P
leak
)
)
m
h
+
(
m
h
-
2
)
(
h
m
+
2
hP
leak
m
)
m
h
(
5
)
Then the probability that a certain bit is set to “0” is 1−P positive 1 .
Now we extend to the case of multiple requests onto a subchannel. If there are r requests to a subchannel, the probability that a certain bit is set to “0” is P negative r = − (1−P positive 1 ) r , and the probability that a certain bit is set to “1” is − P positive r =1−(1−P positive 1 ) r . Now consider a STA that does not contend for the subchannel. Even if the STA does not participate in contention, each of its h signature bits has non-negative probability of being “1”. The probability that all h bits are “1”, which would cause an AP to erroneously claim that a STA has requested for the subchannel, is given as:
P falsepositive D-Fi =( P positive r ) h (6)
For the collision probability of D-Fi, it is zero because an AP allocates a subchannel to exactly one STA.
For the comparison purpose, we also analyze the false positive and collision probabilities of the FICA contention mechanism. In FICA, a STA transmits a request signal over one randomly chosen subcarrier within a subchannel. An AP selects one active subcarrier and all the STAs who have sent the signal on that subcarrier are allowed to use the subchannel for the next data transmission. In addition, even if FICA does not suffer from logical false positives, it may wrongly select inactive subcarriers due to the spectral leakage. Therefore, the probability of the false positive in FICA is:
P
falsepositive
FICA
=
P
(
A
bit
is
set
to
''
1
''
w
/
spectral
leakage
)
-
P
(
A
bit
is
set
to
''
1
''
w
/
o
spectral
leakage
)
=
(
1
-
(
1
-
(
1
m
+
2
P
leak
m
)
)
r
)
-
(
1
-
(
1
-
1
m
)
r
)
(
7
)
Since a collision occurs only when two or more STAs send their request signals on the same subcarrier, the collision probability in FICA is:
P
collision
FICA
=
1
-
(
1
-
1
m
)
r
-
1
(
8
)
A. Remarks
To validate our analysis, we have performed simple simulations. FIG. 5 shows the analysis and simulation results: the false positive and the collision probability of D-Fi and FICA. We have used 0.1 for the probability of the spectral leakage, P leak . As anticipated, the false positive rate is significant when the number of requests for a subchannel is large. The D-Fi's signature based contention mechanism performs better than FICA's when the number of requests is less than 2.6; its collision probability and false positive probability are smaller than those of FICA. Even so, it is important to control the number of requests for a subchannel. In order to make the number of requests for a subchannel operate within an appropriate range, we propose a multi channel backoff method. Our multi-channel backoff method enables a STA to explore frequency diversity distributively while controlling the number of requests to a subchannel.
B. Multi Channel Backoff
We propose a multi-channel backoff method that distributively controls the number of subchannels a STA requests. Each STA maintains a vector, [Pr(1), Pr(2), . . . , Pr(C)] where Pr(i) is how likely a STA requests for a channel i. Initially all Pr(i) are set to be K/C. Based on the results of contention, we adjust Pr(·) according to the additive increase/multiplicative decrease (AIMD) manner. After hearing a CRP frame, a STA knows whether it is selected to use a subchannel or not. For each selected subchannel i, the STA increases the value of Pr(i) by. And for each non-selected subchannel i, the STA decreases the value of Pr(i) by multiplying it with 1/β. Afterwards Pr(·) is normalized in order that their sum is to be K.
FIG. 6 is an algorithm showing the pseudo-code of the multi channel backoff algorithm.
On average, a STA requests K subchannels. Obviously, the optimal value of K depends on the number of active STAs (N) in a network. An AP estimates the number of active STAs in the network [20] and periodically broadcasts an appropriate
K ( = r × C N )
value. We adjust r such that the false positive probability is not large (e.g., 10%) based on the analysis shown in section III.
One might argue that this multi-channel backoff mechanism cannot accommodate many STAs due to the high false positive probabilities. However, as we will see in the section IV, applying machine learning algorithms further eliminates the false positive probabilities and this allows D-Fi to accommodate many STAs (tens of STAs).
IV. Enhancement: Machine Learning
The multi-channel backoff controls to distribute requests over subchannels. However D-Fi still suffers from nonnegligible false positives. We apply machine learning (ML) methods to further reduce the false positive probabilities.
To apply an ML method to the CRQ decoding process, we collect the dataset consisting of per-subcarrier RSSI readings. In our experiment, we assume that the maximum number of requests to a subchannel is three. We refer to a single set of 16 per-subcarrier RSSI readings as an instance. Since we know the STAs transmitting a CRQ frame in advance we can put a label (i.e., a list of the STAs transmitting a CRQ frame) on each instance. We can use this labeled set of instances to establish the ground truth. Now, we apply a supervised ML method to this set. Specifically, we train an ML model using this set of labeled instances and evaluate the trained ML model with the ground truth. ML models are evaluated with the crossvalidation method provided by WEKA (WEKA tool. http://www.cs.waikato.ac.nz/ml/weka/).
To visualize the CRQ decoding performance with the ML methods, in FIG. 7 we plot the accuracy of various ML algorithms. The applied algorithms are Naive Bayes, Naive Bayesian tree, J48 (C4.5) decision tree, and support vector machine (SVM). Naive Bayes and Naive Bayesian tree are generally known as simple and fast algorithms. And J48 tree and SVM are highly accurate although they are the results obtained from the area of an Internet traffic classification research. As shown in FIG. 7 , all ML algorithms significantly outperform the direct CRQ decoding method (i.e., the method using the Bloom filter only) when the number of training instances is greater than 200. With sufficient training, ML algorithms correct the CRQ decoding errors almost completely (99.9% accuracy). FIG. 8 shows the time required to train an ML model. The Naive Bayes algorithm, generally known as the simplest one, requires only tens of microseconds to be trained due to its low complexity. Moreover, an AP will take hundreds of milliseconds to collect 200 instances which are revealed to be sufficient to train a robust ML model. We next discuss several issues arisen when we apply ML methods to a real WLAN.
A. Getting The Set of Labeled Instances in a Real WLAN
To establish ground truth in a real WLAN, an AP has no choice but to label an instance through the direct CRQ decoding process. Then the false positives may happen and a subchannel can be assigned to a STA who actually does not request the subchannel. However the STA will not use the subchannel for the data transmission and the AP can infer the occurrence of a false positive and correct the label. Although it is hard for an AP to get the complete set of the labeled instances in a real WLAN, we believe that this corrected set of the instances will suffice to perform CRQ decoding robustly.
B. When an AP should train ML models?
To train a ML model, an AP needs a set consisting of at least 200 labeled instances, and this set must be evenly distributed over all possible labels. Note that our multi channel backoff algorithm tries to distribute requests evenly over all subchannels. Once trained, if no significant channel fluctuations exist, an ML model produces an accurate CRQ decoding output. We should re-train the ML model when a training set is outdated.
V. Performance Evaluation
A. Implementation
1) D-Fi Prototype and Experiment Setup:
We implemented the D-Fi OFDM-based PHY/MAC on a small testbed of 4 USRPs and GNU Software Define Radio (SDR). We adopt a simple Binary Amplitude Modulation (BAM) to modulate each bit of a signature used for a CRQ/CRP frame. In order to minimize the false positive of the subcarrierlevel signal detection, the threshold used for the signal power level comparison is adaptively configured. Our experiment is conducted within a laboratory to show the feasibility of the DFi PHY/MAC protocol in a typical indoor wireless scenario.
We depict the topology used in our experiment in FIG. 9 . In FIG. 9 , we have chosen four positions randomly, and let one node serve as an AP and the other three nodes be STAs associated with the AP. A rich set of the TX powers provided by the SDR is used, resulting in the 10 dB difference between the min and max received signal strengths.
2) Results:
FIG. 10 shows the feasibility of the OFDM subcarrier-level signaling. Since we have used three STAs for transmitting a CRQ symbol, multiple CRQ symbols combine at a receiver. The sum SNR of this synthesized CRQ symbol is plotted along the x-axis. We call the case that the signal strength difference among the individual CRQ symbols is smaller than 5 dB “similar case”, and otherwise “different case”. In the whole range of our experiment setups, the DFi's subcarrier-level signaling performs reliably. Occasional bitwise-FP and bitwise-FN may still happen, however, as we have shown in section IV, D-Fi successfully handles such occurrences with the ML algorithms. When this signature-level signal detection is applied to the CRQ decoding process, the accuracy of about 92% is achieved without the ML algorithms because of the logical errors. Applying the ML methods, however, the CRQ decoding process almost completely eliminates the logical errors and achieves the accuracy of about 99.9%.
We next show the accuracy of our channel estimation method. As shown in FIG. 3 , for most of the cases (90%), the estimation error is less than or equal to 1 dB. These two results show that the D-Fi's channel contention and estimation mechanisms are practically feasible in typical indoor environments where a WLAN operates.
B. Trace-Driven Simulation
1) Simulation Setup:
The above D-Fi prototype on the USRP is suitable for demonstrating the feasibility of the Bloom filter based channel contention and estimation method, but not the diversity exploration/exploitation performance of D-Fi. Since an USRP relies on software to process a signal, it experiences difficulty in processing a wide-band (20 MHz) signal. Additionally, the supported data rate is not as high as that in hardware radios at a current development stage of an USRP. Therefore, we resort to trace-driven simulations to assess the diversity performance of D-Fi.
To conduct high fidelity emulation of real world setting, we have used the 802.11n data traces provided by the authors Harnessing Frequency Diversity in Multicarrier Wireless Networks. In ACM MobiCom 2011 (A. Bhartia, Y. C. Chen, S. Rallapalli, and L. Qiu). The traces are obtained from commodity Intel Wi-Fi Link 5300 NIC and its modified driver. The traces contain per-subcarrier (30 subcarriers for 20 MHz) RSSI readings for both the 24 mobile and 30 static diverse links. With the 54 diverse links, we have set up to 50 nodes in our simulations.
We compare the diversity exploration/exploitation performance of 802.11n, FICA, Carrier-by-Carrier in turn algorithm (C-by-C), FARA, D-Fi, and the throughput optimal unit. For a fair comparison, we have modified Cby-C and FARA to use a subchannel as an access basis. For diversity-aware schemes such as C-by-C and FARA, we consider the same amount of the MAC protocol overhead with D-Fi to compare the performance due to the diversity exploitation capabilities. Multi channel backoff parameters for D-Fi (i.e., α and β) have been fine-tuned to assess the best performance of D-Fi.
2) Results:
We first show the D-Fi's overall throughput against the other schemes. FIG. 10 presents the empirical cumulative distribution function (ECDF) of the throughput for each scheme. The D-Fi's throughput gains over legacy 802.11n and FICA are 3× and 1.5×, respectively. Because the 802.11n scheme does not channelize a 20 MHz band and uses random access, it neither reduces the MAC overhead nor exploits the diversity. FICA, which uses the channelized random access, reduces the MAC overhead but fails to exploit the diversity. Now, let us compare the D-Fi's diversity exploration/exploitation performance with the other diversity-aware schemes in terms of throughput. Even though the proposed multi channel backoff algorithm requests only a subset of all the subchannels, the D-Fi's diversity exploitation/exploration performance is equivalent to those of the other diversity-aware schemes as shown in FIG. 11 .
We next show the D-Fi's fairness performance. Since DFi allocates a subchannel based on the proportional fairness algorithm, it is expected to be fair as in random access schemes like 802.11n or FICA. To verify that, we compute Jain's fairness index with the throughput obtained by each STA. FIG. 12 presents the fairness index with all the schemes described above. It clearly shows that D-Fi offers high throughput while maintaining fairness comparable to random access schemes like 802.11n and FICA
A number of exemplary embodiments have been described above. Nevertheless, it will be understood that various modifications may be made. For example, suitable results may be achieved if the described techniques are performed in a different order and/or if components in a described system, architecture, device, or circuit are combined in a different manner and/or replaced or supplemented by other components or their equivalents. Accordingly, other implementations are within the scope of the following claims.
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Provided is a method for WLAN service performed by an access point (AP) in a WLAN system including the AP and a plurality of stations (STAs) each of which can associate with the AP, the method comprising: dividing frequency bandwidth of available channel into a plurality of frequency-selective subchannels; receiving, from at least some STAs (first STAs) among the plurality of STAs, CRQ (Contention Resolution reQuest) frame including a signature of the first STAs through at least some of the subchannels, the signature identifying the first STAs; identifying the first STAs using the received CRQ frame; estimating uplink channel quality of the first STAs using the received CRQ frame; allocating subchannels for each of the first STAs; and broadcasting result of subchannel allocation using CRP (Contention Resolution rePly) frame.
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BACKGROUND
[0001] Unit dose packaging is an attractive packaging format for certain pharmaceutical applications because it is convenient, yet sturdy enough to be opened and closed numerous times until the course of medication is completed, and also enables the user to track the consumption of doses according to the prescribed schedule. Examples of such packaging are described in U.S. Pat. No. 6,047,829 (Johnstone), which is commonly assigned with this application.
[0002] The Johnstone patent relates to a unit dose paperboard package that includes an outer paperboard sleeve, an inner paperboard slide card that is lockably retained within the sleeve. The sleeve includes a plurality of side panels operatively connected to each other such that one of said plurality of side panels includes a first inner slide card releasing means, and another of said side panels includes a second inner slide card releasing means, such that the inner slide card retaining and releasing means are located substantially adjacent to said unit dose dispensing means.
[0003] An improvement over that described and claimed in U.S. Pat. No. 6,047,829 is contained in another commonly assigned patent (U.S. Pat. No. 6,412,636). In this patent the package is rendered less susceptible to unintentional opening and has improved structural stability. Child resistance is a feature particularly desired for pharmaceutical packaging, and is mandated by the Poison Prevention Packaging Act of conductive 1970 .
[0004] In addition to child resistance it is also desirable that the unit dose packaging system be senior friendly to permit easy withdrawal of the package contents with minimum manipulation. Such a withdrawal means should be easy to use even if the patients manual dexterity or strength is reduced.
[0005] The aforesaid patents permit the user to track consumption of medication doses (e.g., pills) by visually inspecting the packaging. However, significantly more data can be obtained pertaining to the consumption of unit doses if a reusable electronics component that automatically tracked and transmitted dosing events was able to be removably integrated with the packaging.
SUMMARY
[0006] One embodiment of the disclosure describes a unit dose paperboard package insert. The unit dose package insert includes a paperboard blank comprised of a bottom panel and a top panel. The bottom panel includes one or more areas of weakness outlined by perforations. The bottom panel further includes an electrical trace element having at least first and second ends positioned away from the areas of weakness wherein the electrical trace element intersects the one or more areas of weakness such that when an area of weakness is compromised the electrical trace element is broken for that area of weakness. The top panel includes one or more unit dose cut out areas and an electronics seating hub component cut out area. The unit dose package insert also includes a blister pack comprised of one or more sealed unit doses positionable atop the bottom panel such that the unit doses are substantially above the unit dose cut out areas. There is also an electronics seating hub component adapted to mechanically receive a removable, reusable electronics component wherein the electronics seating hub component is positioned proximate to the termination of the electrical trace element ends. The top panel substantially covers and is adhered to the bottom panel to secure the blister packs and electronics seating hub component securely between the top and bottom panel such that the sealed unit doses protrude through the unit dose cut out areas and the electronics seating hub component protrudes through the electronics seating hub component cut out area.
[0007] The blank can further include a crease that defines a boundary between the top panel and the bottom panel such that folding the blank along the crease positions the top panel substantially covering the bottom panel aligning the cut out areas of the top panel with the areas of weakness of the bottom panel. A pair of additional creases can also be included in which the space in between the creases defines an end panel when the unit dose package insert is folded back over itself along each crease.
[0008] In one embodiment, the electronics seating hub component comprises a housing including first and second pairs of opposing walls. One wall of the first pair of opposing walls includes at least one opening at the base of the wall that is adapted to receive a tab that is attached to an electronics component. The opposite wall of the first pair of opposing walls includes a cut out area to facilitate insertion and removal of the electronics component within the electronics seating hub component. One wall of the second pair of opposing walls includes a detent adapted to receive a corresponding inverted detent that is attached to an electronics component such that the electronics component remains seated in place upon lining up the detent and inverted detent.
[0009] In another embodiment, the electronics seating hub component comprises a pair of opposed rigid side members, each including a dovetail slot extending substantially the length of each side member. There is also rigid cross member including one or more electrical contacts that are electrically coupled with the electrical trace element ends. An electronics component having a corresponding dovetail slot can be slidably seated with the electronics seating hub component.
[0010] In another embodiment, the disclosure describes a reusable electronics component that can be electrically coupled with a disposable unit dose package to collect and disseminate data pertaining to the expression of unit doses. The reusable electronics component includes a seating mechanism adapted to fit into an electronics seating hub component, a microcontroller, an RF module coupled with the microcontroller for sending and receiving data wirelessly, an electrical trace contact interface coupled with the microcontroller for electrically coupling the reusable electronics component with electrical traces present on the disposable unit dose package, and a software application coupled with the microcontroller for detecting when a unit dose has been expelled from the disposable unit dose package. The reusable electronics component can further include a display for displaying data, an indicator light for providing a visual status indication, a speaker for providing an audible status indication, a power jack for recharging an internal power source of the electronics component, and a data port for providing a wired data output mechanism.
[0011] In yet another embodiment of the disclosure, a method of assembling a unit dose package insert is described. A blank comprised of a top panel and a bottom panel, wherein the top panel and a bottom panel include one or more creases, cut outs, and perforations required to accommodate a blister pack and an electronics seating hub component is formed. Electrical traces are applied to the blank in a desired pattern so as to ensure each unit dose has a portion of the electrical trace associated therewith. The blister pack is adhered to the bottom panel of the blank such that each unit dose is substantially over a perforated area. The electronics seating hub component is also adhered to the bottom panel such that electrical trace terminations are coupled with corresponding electrical trace contacts in the electronics seating hub component. The top panel is then sealed to the bottom panel thereby encasing the blister pack and the electronics seating hub component firmly and immovably between the top and bottom panels of the unit dose package insert. The electrical traces can be comprised of conductive ink that is printed onto the blank.
[0012] In another embodiment of the disclosure, a unit dose package system is described. The unit dose package system includes a slide card insert comprised of a blank that includes a bottom panel and a top panel. The bottom panel includes one or more areas of weakness outlined by perforations. The bottom panel further includes an electrical trace element having at least first and second ends positioned away from the areas of weakness wherein the electrical trace element intersects the one or more areas of weakness such that when an area of weakness is compromised the electrical trace element is broken for that area of weakness. The top panel includes one or more unit dose cut out areas and an electronics seating hub component cut out area. The unit dose package insert also includes a blister pack comprised of one or more sealed unit doses positionable atop the bottom panel such that the unit doses are substantially above the unit dose cut out areas. There is also an electronics seating hub component adapted to mechanically receive a removable, reusable electronics component wherein the electronics seating hub component is positioned proximate to the termination of the electrical trace element ends. The top panel substantially covers and is adhered to the bottom panel to secure the blister packs and electronics seating hub component securely between the top and bottom panel such that the sealed unit doses protrude through the unit dose cut out areas and the electronics seating hub component protrudes through the electronics seating hub component cut out area. The unit dose package system further includes a reusable electronics component mechanically and electrically coupled with the electronics seating hub component to create a complete electrical circuit between each unit dose and the reusable electronics component. A cover adapted to receive the slide card insert such that the slide card insert is lockably and slidably engaged within the cover is also included.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates a unit dose packaging system according to one embodiment of the disclosure including an internal slide card and outer sleeve with child resistant button release means.
[0014] FIGS. 2 a and 2 b illustrate views of the slide card.
[0015] FIG. 3 is an illustration of an electronics component that can be removably coupled with a slide card according to one embodiment of the disclosure.
[0016] FIG. 4 is a block diagram illustrating components of an electronic component like that illustrated in FIG. 3 .
[0017] FIG. 5 illustrates one embodiment of an electronics seating hub and an electronics component.
[0018] FIG. 6 illustrates another embodiment of an electronics seating hub and an electronics component.
[0019] FIG. 7 is an exploded view of the various layers and components that comprise a finished slide card according to an embodiment of the disclosure.
[0020] FIG. 8 is a data flow diagram that describes a process for assembling a slide card according to an embodiment of the disclosure.
[0021] FIG. 9 is a perspective view of a first embodiment of a unit dose package in which a seating hub is not permanently incorporated into the package.
[0022] FIG. 10 a is another perspective view of the embodiment shown in FIG. 9 , illustrating the connection of an electronic component to the unit dose package using a temporary mounting hub.
[0023] FIG. 10 b is a partial, side, schematic view of the process of connecting an electronic component to the paneling of the unit dose package, using a temporary mounting hub in the manner provided in FIG. 10 a.
[0024] FIG. 11 is a perspective view of a variation of the embodiment illustrated in FIG. 9 , in that no slotting is provided in the paneling for attachment of an electronic component via a seating hub.
[0025] FIG. 12 is another perspective view of the variation shown in FIG. 11 , illustrating the connection of an electronic component to the unit dose package using a hinged slide-mount.
[0026] FIGS. 13 a - 13 b are schematic front, side, and back views, respectively, of the blister pack employed in the embodiment illustrated in FIGS. 9-12 .
[0027] FIG. 14 is a perspective view of a second embodiment of a unit dose package in which a seating hub is not permanently incorporated into the package.
[0028] FIG. 15 is another perspective view of the embodiment shown in FIG. 14 , illustrating the connection of an electronic component to the unit dose package using a temporary mounting hub.
[0029] FIG. 16 is a perspective view of a variation of the embodiment illustrated in FIG. 14 , in that no slotting is provided in the paneling for attachment of an electronic component via a seating hub.
[0030] FIG. 17 is another perspective view of the variation shown in FIG. 16 , illustrating the connection of an electronic component to the unit dose package using a hinged slide-mount.
[0031] FIG. 18 is a perspective view of a third embodiment of a unit dose package in which a seating hub is not permanently incorporated into the package.
[0032] FIG. 19 is another perspective view of the embodiment shown in FIG. 14 , illustrating the connection of an electronic component to the unit dose package using a temporary mounting hub.
[0033] FIG. 20 is a perspective view of a variation of the embodiment illustrated in FIG. 18 , in that no slotting is provided in the paneling for attachment of an electronic component via a seating hub.
[0034] FIG. 21 is another perspective view of the variation shown in FIG. 20 , illustrating the connection of an electronic component to the unit dose package using a hinged slide-mount.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0035] Referring to FIG. 1 , an embodiment of the unit dose package comprises a slide card 20 , which can be releasably, lockably engaged with an outer sleeve 10 . The outer sleeve 10 is comprised of a top panel 11 and a bottom panel 12 , which are foldably connected by side panels 13 and 14 , and an end panel 15 , which secures one end opening of the package.
[0036] The top panel 11 can include a release mechanism 16 , which is formed by a series of connected cuts in the sleeve substrate made by conventional techniques. The cut edges form a flexible tab that can be depressed to exert pressure on one or more layers of substrate underlying top panel 11 to release a locking mechanism 38 of slide card 20 that engages a reciprocal locking mechanism 39 of the outer sleeve 10 and allow the slide card 20 to be withdrawn sufficiently to expose one or more blisters 23 that have been associated with slide card 20 .
[0037] Top panel 11 can further include a notch 17 that provides a finger hold to facilitate withdrawal of slide card 20 . A corresponding notch (not shown) having similar dimensions as notch 17 is positioned parallel to but offset from notch 17 in the edge of the bottom panel. Notch 17 is shown positioned close to the center of the edge of top panel 11 while its corresponding notch on the opposite side panel is positioned off center such that there is incomplete overlap with notch 17 . The position of these notches along the outer edges of the sleeve 10 and their placement in relation to each other may be varied depending on the overall dimensions of the package.
[0038] Slide card 20 can be folded along creases to form an end panel 22 and also define a second area 21 that can be utilized for additional blister packaging. An electronics component 25 is shown seated within an electronics seating hub component 24 . The electronics component 25 when seated in electronics seating hub component 24 have a height dimension that is very close to the height of end panel 22 . This is so that when the slide card 20 is fully inserted in outer sleeve 10 , the end panel 22 cannot be collapsed. This provides an additional measure of child resistance to the packaging. In addition, a protruding element 45 is placed such that when the slide card 20 is folded over onto itself to create opposing top and bottom panels, the protruding element 45 on the top panel will be proximate to the electronics component 25 /electronics seating hub component 24 on the bottom panel in a manner that prevents the top panel from sliding out further enhancing the child resistant aspect of the packaging.
[0039] Referring to FIGS. 2A and 2B , a slide card 20 is shown in an isometric view. As just described, the slide card 20 includes an electronics seating hub component 24 that can be positioned proximate to one or more electrical trace ends (not shown) so as to enable the contacts 28 (see, e.g., FIG. 5 ) of the electronics component 25 to operatively connect or to the one or more electrical trace ends. Dashed lines define creases for an end panel 22 and a locking mechanism 38 . The slide card 20 can be folded along the creases to create the end panel 22 and a locking mechanisms 38 such that when the slide card 20 is folded and inserted into the outer sleeve 10 , a packaging solution is created that allows the slide card 20 to be coupled with the outer sleeve 10 in a slidable and lockable manner. It is noted that the protruding element is not shown in FIGS. 2A and 2B , but can of course be present.
[0040] When folded, the slide card 20 forms two opposed panels each capable of containing blister packs 23 . In FIG. 2A , the electronics seating hub component 24 is shown on what could be considered the lower panel of the slide card 20 while in FIG. 2B , the electronics seating hub component 24 is shown on what could be considered the upper panel of the slide card 20 . Thus, the electronics seating hub component 24 can be situated strategically on the slide card 20 and is not necessarily restricted to a single location.
[0041] Also shown within the electronics seating hub component 24 is a set of electrical trace contacts 32 . These contacts terminate a corresponding set of electrical traces (not shown) that can be pre-printed on the slide card to correspond with each unit dose of the blister packs 23 . When an electronics component 25 is operatively seated within the electronics seating hub component 24 , a corresponding set of contacts 28 (see, FIG. 5 for an example embodiment) operatively engages the trace contacts to complete an electronics circuit. It should be noted that the placement and number of electrical trace contacts 32 within an electronics seating hub component 24 can be a design choice that is best adapted to a given configuration.
[0042] In practical use of a packaging system, a user can simply remove and re-use an electrical component 25 each time a new slide card 20 of unit doses is received. As an additional benefit, the height dimension of the electrical component 25 adds additional structural support to a folded slide card when seated.
[0043] Referring to FIG. 3 , an example electronics component 25 is illustrated from an exterior perspective. In addition to internal electrical components, the electronics component 25 can include one or more of a display 50 , a set of LED lights 51 , 52 , 53 , a speaker 54 , a power jack 55 , and a data port 56 . Depending on the hardware and software capabilities of the electronics component 25 , a display can be utilized to illustrate the current date/time, the date/time of the last recorded dose, and the date/time of the next scheduled dose. This information can be pre-programmed by the user via a device that can be coupled either wirelessly or via data port 56 to the software within the electronics component 25 . In addition, one or more LED lights 51 , 52 , 53 can be color coded to indicate the current status of the next unit dose. For instance, a green LED 51 could indicate that a user is current with his medication. A yellow LED 52 could indicate that the user is within an hour of the next scheduled unit dose, and a red LED 53 could indicate that the user is past due on his next schedule dose. A speaker 54 could beep to give the user an audible status indicator. For instance, one beep could indicate that the next scheduled dose is within minutes while 3 beeps could indicate that the next scheduled dose is past due. The beeps can be repeated for a predetermined cyclical period.
[0044] The electronics component 25 can be powered by removable or re-chargeable batteries. If re-chargeable, a power jack 55 can allow an external source to re-charge the internal batteries when a power cable is inserted into the power jack 55 . A data port can accept a data cable that would allow a wired transfer of data between the electronics component 25 and another device. This could be in addition to or in lieu of a wireless transmission mechanism. The data port can be a USB cable for instance but may also be adapted for other data formats as well.
[0045] Referring to FIG. 4 , a block diagram of the internal components of an example electronics component 25 is illustrated. A microcontroller 60 coordinates the activities of the remaining components. A pin trace contact interface 63 provides the mechanism to complete circuit(s) individually between the rest of the electronics component 25 and a plurality of blister packs wherein each blister pack can be individually associated with an electrical trace such that rupturing a blister pack will also break the electrical trace associated with the blister pack. Such an event can create a detectable change in electrical potential throughout the entire circuit that indicates the dispensing of a unit dose. There is an assumption that the unit dose is then ingested by a user as prescribed.
[0046] The electronics component 25 can further comprise one or more of an RF module 61 and associated antenna 62 , one or more batteries 64 , a display 50 , a speaker 54 , LED indicator lights 51 - 53 , a power jack 55 , a data port 56 , and software applications with associated memory 65 .
[0047] The software applications and associated memory 65 can be programmed to respond variously to the detection of a rupture blister package. The event can be recorded and date/time stamped as data and packed into a message format suitable for wireless transmission over the RF module 61 . The RF module 61 can include cellular protocols such as GSM or CDMA, or can be limited to more short range communication protocols such as Bluetooth, WiFI, or WiMax. Data can be received and/or sent between the electronics component 25 and one or more external devices utilizing the RF module 61 and a corresponding appropriate network. Or, the data can be sent out via the data port 56 which can be a USB cable or other suitable cable/data format pairing.
[0048] As described earlier, the microcontroller 60 can include a clock element that knows the current date/time and, in conjunction with the software application(s) 65 that has been programmed with a dosage schedule, provides visual and/or audible alerts and reminders to the user via the LED indicators 51 - 53 or the speaker 54 .
[0049] FIG. 5 illustrates one embodiment of an electronics seating hub and an electronics component. In this example, the electronics component 25 includes one or more tabs 26 that are somewhat hook shaped. One or more detents 27 can also be included on either side of the electronics component 25 to help keep it in place when mechanically coupled with the electronics seating hub component 24 . Also shown are a series of electrical trace contacts 28 . The electronics seating hub component 24 is comprised of a housing 29 having a corresponding number of inverted detents 31 on the interior surface that are positioned to correspond with detents 27 when the electronics component 25 is mechanically coupled with the electronics seating hub component 24 . The housing 29 further comprises electrical trace contacts 32 and one or more openings 30 that are adapted to receive the one or more tabs 26 such that the tabs 26 , when properly manipulated will fit through the openings 30 and seat the electronics component 25 securely in the electronics seating hub component 24 . To help achieve this, the housing 29 can include a cut out area 40 on the housing wall opposite the wall electronics component when inserting and removing it into the electronics seating hub component 24 .
[0050] In operation, the electronics component 25 is tilted so that the tabs 26 can fit through the openings 30 of the electronics seating hub component 24 . The electronics component 25 can then be pivoted or rocked downward until the detents 27 and inverted detents 31 engage one another. This will also bring contacts 28 and contacts 32 into an operatively electrically coupled relationship and complete the circuitry contained on the slide card 20 and within the electronics component 25 .
[0051] It should be noted that the orientation and placement of the contacts 28 , 32 , tabs 26 , openings 30 , cut out areas 40 and detents 27 , 31 described above can be design choices and are not limited to only the configuration shown.
[0052] FIG. 6 illustrates another embodiment of an electronics seating hub and an electronics component. In this embodiment, the electronics seating hub component 24 is comprised of a rigid member 33 having opposing side members 41 , 42 connected by an end member 43 . The side members 41 , 42 include a dovetail 34 slot extending substantially the length of the side members 41 , 42 . A plurality of electrical trace contacts 35 can be disposed on the interior surface of the end member 43 .
[0053] The electrical component 25 includes a portion having a matching dovetail 36 pattern and electrical contacts 37 such that the electrical component can be slidably inserted into the electronics seating hub component 24 by aligning the matching dovetail portions. Upon full insertion of the electronics component 25 into the electronics seating hub component 24 , contacts 35 and 37 will contact one another to create an electrically coupled relationship.
[0054] The coupling between the electronics seating hub component 24 and the electronics component 25 can be configured in other ways in addition to those described above. The embodiments described herein are not limited to merely the configurations described with reference to FIGS. 5 and 6 .
[0055] FIG. 7 is an exploded view of the various layers and components that comprise a slide card according to an embodiment of the disclosure. The slide card 20 starts as a reinforced blank that has been designed to receive one or more blister packs 79 comprised of individual unit doses 23 . The slide card 20 generally comprises a bottom panel 71 and a top panel 72 . The top panel 72 is designed to be folded over and sealed on top of the bottom panel 71 . Alternatively, the top 72 and bottom 71 panels can be separate from one another wherein the top panel 72 is positioned over the bottom panel 71 rather than folded into place.
[0056] The bottom panel includes areas of weakness defined by perforations 74 such that sufficient force downward will cause the perforated area to tear leaving an opening in the bottom panel 71 capable of passing a unit dose. An electrical ink trace element 73 is applied to the bottom panel 71 such that each perforated area includes part of the electrical trace element 73 . The electrical trace element 73 terminates in an area reserved for an electrical seating hub component 24 . In addition, creases 77 allow for the slide card to be folded into another spatial dimension once the top panel 72 has been folded over the bottom panel 71 . There is space 78 reserved on the panel for additional traces and blister packs as desired.
[0057] The top panel includes first cut out areas 75 for each individual unit dose 23 of blister pack 79 . A second cut out area 76 is designed to allow the electrical seating hub component 24 to protrude from the slide card 20 once assembled. A third cut out area 46 is designed to allow protruding element 45 to protrude from the slide card 20 once assembled.
[0058] A locking mechanism 38 can also be included to provide enhanced child resistant functionality. The locking mechanism 38 is adapted to engage a first reciprocal catch 39 that is within the outer sleeve 10 shown in FIG. 1 . To release the slide card locking mechanism 38 , a user would depress the release mechanism 16 shown in FIG. 1 .
[0059] Protruding element 45 also provides enhanced child resistant functionality in that it encounters electronics seating hub component 24 and electronics component 25 when a user tries to remove the top panel of the slide card 20 . This action is prevented because the protruding element can not be pulled over the electronics seating hub component 24 and electronics component 25 .
[0060] The illustrated electrical traces 73 can be applied directly on the slide card 20 , in a manner well known by those skilled in the art. The electrical traces 73 can be printed on the slide card 20 using conventional printing or lithography methods such as but not limited to screen or off-set methods. The inks used in the printing method to form the circuitry are conductive inks, selected based on the performance needs of the individual circuits. Conductive inks typically include conductive metals such as but not limited to copper or silver. The ink used to form the illustrated electrical traces 73 can be a carbon-based conductive ink readily understood by those skilled in the art.
[0061] The electronics component 25 is designed to be reusable with respect to multiple unit dose slide card inserts. Thus, the actual electronics component is not shipped with the unit dose slide card insert originally. Rather, a user is responsible for inserting the electronics component 25 into the electronics seating hub component 24 when receiving the unit dose packaging system. However, since the electronics component 25 itself aids in enhancing the child resistant aspect of the packaging, the original packaging can have a dummy electronics component already seated in the electronics seating hub component 24 . When a user receives the unit dose packaging system containing the dummy electronics component, he simply removes the dummy component and inserts the real electronics component 25 .
[0062] FIG. 8 is a data flow diagram that describes a process for assembling a slide card such as that illustrated in FIG. 7 according to an embodiment of the disclosure. The steps do not necessarily occur in chronological order. At 81 , electrical traces are printed on the blank in the desired pattern so as to ensure each unit dose has a portion of the electrical trace associated therewith. At 82 , the blank is then manipulated to contain all the creases, cut outs, and perforations required to accommodate the blister pack(s) and electronics seating hub component. At 83 , the blister pack(s) are adhered to the bottom panel of the blank such that each unit dose is substantially over a perforated area. At 84 , the electronics seating hub component is then adhered to the bottom panel such that the electrical trace terminations of the printed conductive ink are mated to corresponding electrical trace contacts in the electronics seating hub component. At 85 , the blank is then folded over and sealed according to the creases thereby encasing the blister pack(s) and electronics seating hub component firmly and immovably between the top and bottom panels of the slide card.
[0063] As an alternative process for assembling a slide card, a blister pack and electronics seating hub component may be placed on the top panel, with the blister cavities and electronics seating hub component protruding through apertures in the top panel. These components may be adhered to the top card. The bottom panel would be folded over and the entire structure sealed at one time.
[0064] Further embodiments are disclosed as unit dose packages 100 ( FIGS. 9-13 ), 200 ( FIGS. 14-17 ), and 300 ( FIGS. 18-21 ). The disclosed unit dose packages 100 , 200 , and 300 have like-named components that are similar in structure and function, unless expressly indicated to the contrary. Further, the unit dose packages 100 , 200 , and 300 may incorporate features (e.g., a sleeve and/or child-proofing) associated with other above-described embodiments, and such combinations of elements are deemed to be within the scope hereof.
[0065] The disclosed unit dose package 100 may include a paneling component 102 , a blister pack 104 , and an electrical trace element 106 . As per this embodiment, the electrical trace element 106 may be particularly associated with the blister pack 104 , as will be detailed later.
[0066] The paneling component 102 may include at least a first (e.g., bottom) panel 108 , through which a unit dose of medicine is ultimately expressed, and may yet further include a second (e.g., top) panel 110 . Where both are employed, the top panel 110 may substantially cover and be adhered (e.g., via adhesive/glue or an intermediate tape) to the bottom panel 108 so as to secure the blister pack 104 therebetween. The bottom panel 108 and top panel 110 may be separate or integral. For example, the bottom and top panel 108 , 110 may be part of a unitary paneling component 102 , connected by a first panel fold 112 . Further, the paneling component 102 can be made, for example, of paperboard, plastic, etc., and, if separately produced, the bottom and top panels 108 , 110 need not be made of the same material. The bottom panel 108 may, in one wallet card embodiment, define a first bottom panel section 108 a and a second bottom panel section 110 a , and the top panel 110 may, in a like manner, define a first top panel section 110 a and a second top panel section 110 b . A wallet fold 113 may integrally link the first bottom panel section 108 a and the second bottom panel section 110 a , as well as the first top panel section 110 a and the second top panel section 110 b . The wallet fold 113 may have a width, for example, that accommodates for the unit doses carried by the wallet card. As a whole, such a wallet card arrangement may provide, e.g., additional space for instructional and/or promotional information to be printed and/or further mechanical protection for the unit doses carried thereby.
[0067] The bottom and top panels 108 , 110 are designed to facilitate the expressing of unit doses (not expressly shown) from a given blister pack 104 . In one embodiment, the bottom panel 108 may be provided with at least one area of panel weakness 114 (defined, for example, by at least one nick or perforation and/or a reduced thickness) to promote easy punch-out at such locations for unit dose delivery. In a corresponding manner, the top panel 110 may include at least one unit dose cut out or opening 116 to accommodate therethrough protruding unit doses carried by a given blister pack 104 . The number of areas of panel weakness 114 and dose cut outs 116 may, for example, be chosen to match the number of unit doses that the given unit dose package 100 is intended to supply.
[0068] The blister pack 104 , as best seen in FIGS. 13 a - 13 c , may include a blister substrate 138 and at least one unit dose site 140 (i.e., a carrier location for a given unit dose of medicine). Further, as a feature of the embodiment of FIGS. 9-12 , the blister substrate 138 may act as the carrier of the electrical trace element 106 . The electrical trace element 106 defines at least first and second trace ends 142 . In this embodiment, the electrical trace element 106 , including the trace ends 142 thereof, may be deposited or otherwise coated on the blister substrate 138 , either directly or on an intermediate coating.
[0069] As is the case with each of unit dose package embodiments, the at least first and second trace ends 142 may extend away from the at least one area of panel weakness 114 and may be proximate to and exposed through an electronics receiving region 118 (as seen, e.g., in FIG. 10 a ). By such placement of the at least first and second trace ends 142 , a connection between the electrical trace element 106 and the electronic component 120 may be made. Further, for a situation in which the electrical trace element 106 may be formed on the back of the blister substrate 138 , the surface upon which the electrical trace element 106 should not be a conductor (e.g., metal), as might otherwise be the case for a blister substrate 138 . Thus, the blister substrate 138 could be made of a non-conductive material (e.g., paperboard, plastic, etc.) and/or coated with a non-conductive layer, thereby providing a non-conductive surface upon which the electrical trace element 106 could then be deposited.
[0070] In addition to the unit dose cut outs 116 , other through holes may be created in paneling 102 . In this embodiment, an electronics receiving region 118 may, for example, be in the form of an opening. Such an opening may be cut, punched, or otherwise formed through the bottom panel 108 . The receiving region 118 may, further, be adapted mechanically receive an electronics component 120 and may, particularly, be configured for exposing the electrical trace element 106 for electrical connection with the electronics component 120 .
[0071] FIGS. 10 a and 10 b show the unit dose package in a sealed arrangement. One exemplary manner for attaching the electronics component 120 to a unit dose package 100 may readily be seen. This example may include at least one mounting opening 122 within the paneling component 102 . For example, the at least one mounting opening 122 may take the form of an opposed pair of C-shaped slots, extending through both the bottom and top panels 108 , 110 . A mounting hub 124 , a reusable version of which is shown, may be adapted to connect to the electronics component 120 and the paneling component 102 , via the at least one mounting opening 122 , with a hub base 126 , at least one hub projection 128 , and at least one hub slot 130 ; and at least one extended projection/tab 132 and at least one detent projection/tab 134 directly protruding, respectively, from opposed sides of the electronics component 120 . Each hub projection 128 may extend directly from and essentially perpendicularly to the hub base 126 . So that each hub projection 128 may be received through a corresponding mounting opening 122 as part of the attachment process, the number of hub projections 128 may be the same or less than the number of mounting openings 122 , and the configuration (e.g., size, shape, positioning) of the hub projections 128 and the corresponding mounting openings 122 should facilitate insertion (e.g., a slide fit) of the former into the latter. The mechanical placement tolerance associated with the mounting openings 122 and those similar to them in other disclosed embodiments may be controlled to help ensure a link between the electronics component 120 and the trace element 106 . For example, the mechanical placement tolerance could be controlled to 0.5 mm.
[0072] Further, each given extended tab 132 may be inserted through a respective hub slot 130 for providing a stable connection between the electronics component 120 and the mounting hub 124 . Meanwhile, each detent tab 134 may generally be shorter than a given extended tab 132 and rounded and/or angled faces. Because of the configuration of such detent tabs 134 , a given detent tab 134 may readily be snap-fit into a corresponding hub slot 130 . That snap fit therebetween, along with the connection between a given extended tab 132 and a corresponding hub slot 130 , can enable a steady yet releasable linkage of the electronics component 120 to a unit dose package 100 , via the mounting hub 124 . It is further understood that the mounting hub 124 could instead be pre-assembled with or built into the paneling component 102 .
[0073] The process of attaching the electronics component 120 to a unit dose package 100 in the manner of FIGS. 10 a and 10 b may be, for example, be achieved through a multiple step procedure. Each hub projection 128 may first be inserted through a corresponding mounting opening 122 to a point where the hub base 126 abuts the paneling component 102 . Upon such positioning, the at least one extended tab 132 associated with the electronics component 120 may be introduced at an angle into a respective hub slot 130 . Thereupon, the electronics component 120 may be pivoted downwardly, relative to the free/unconnected side thereof (see FIG. 10 b ), until the at least one detent tab 134 locks into place in a respective hub slot 130 .
[0074] Another potential means of attaching the electronics component 120 to a unit dose package 100 is illustrated in the variation shown in FIGS. 11 and 12 . As per that variation, a slide clip 136 may, for example, be used to connect an electronics component 120 to a paneling component 102 . While the slide clip 136 may be shown to be a pivotable connector (e.g., a spring-loaded pivot), it may, for example, be a simple slide clip construction, e.g., similar to a paper clip or a spring clip used on a pencil/pen. A slide clip 136 should be able to generate sufficient force between the electronics component 120 and the electrical trace element 106 to ensure a consistent electrical connection therebetween, or such force would need to be provided via another means (e.g., adhesive or mechanical connector). As a by-product of using the slide clip 136 , as can be seen in FIG. 11 , no mounting openings 122 would necessarily have to be provided in the panel component 102 .
[0075] Yet other potential means of attaching the electronics component 120 to a unit dose package 100 are possible. As broadly suggested by the variation illustrated in FIGS. 9 , 10 a , and 10 b , one of the electronics component 120 and the paneling component 102 could be provided with a first alignment mechanism and the other provided with a second co-acting alignment mechanism. For example, the first alignment mechanism could be, e.g., a projection/tab/protrusion, and the other thereof could be provided with a corresponding slot. As further possibilities, the first and second alignment mechanisms could be a hook-and-loop (e.g., Velcro) combination or any sort of snap-fit combination. It should be also understood that the first and/or second alignment mechanisms need not be an integral part of the electronics component 120 and/or the paneling component 102 , so long as that given alignment mechanism is able to produce the desired result. The temporary mounting hub 124 is one such an example of a non-integral alignment mechanism.
[0076] The disclosed unit dose package 200 may include a paneling component 202 , a blister pack 204 , and an electrical trace element 206 . The primary difference between the unit dose packages 100 and 200 is the manner in which the electrical trace element 206 is incorporated into the unit dose package 200 . More particularly, in the embodiment associated with unit dose package 200 , the electrical trace element 206 may be carried separately (e.g., not deposited on the blister pack 204 ). The description of the disclosed unit dose package 200 , as such, focuses on those details related to the mounting/positioning of the electrical trace element 206 and modifications associated with such placement, as the remaining features are similar to those otherwise associated with the unit dose package 100 .
[0077] The features distinguishing the unit dose package 200 from the unit dose package 100 are best seen in FIGS. 14 and 16 . Instead of potentially being carried on the blister pack 204 , the electrical trace element 106 is deposited, wired, or otherwise incorporated into a trace element carrier 208 . The trace element carrier 208 may have a non-conductive surface upon which the electrical trace element 106 is provided or another mechanism (e.g., an insulating coating) by which portions of the electrical trace element 206 may be electrically isolated from one another.
[0078] For example, the trace element carrier 208 may, for example, be an adhesive tape (e.g., single- or double-sided); a paperboard, plastic, or other insulating substrate; or a dielectric-coated metal foil. Alternatively, the substrate material need not be limited to such, so long as the portions of the electrical trace element 206 may be electrically isolated from one another (e.g., via selective coating). As suggested by the potential use of an adhesive tape for the trace element carrier 208 , it is to be understood that one of ordinary skill in the art may choose use any various adhesive and/or mechanical fastening means to ensure the desired position of trace element carrier 208 and, thereby, the electrical trace element 206 relative to the paneling component 202 and/or the blister pack 204 . It is to be understood that, in a manner similar to a given electrical trace element 206 , the trace element carrier 208 may be constructed (e.g., material, thickness, etc.) in a manner that facilitates the expression of a given unit dose from the unit dose package 200 yet still is strong enough to withstand production, to avoid accidental dispersal of medicine, and/or, potentially, to be folded (as per FIGS. 15 , 17 ).
[0079] The paneling component 202 may include at least a first/bottom panel 210 , through which a given unit dose is ultimately expressed, and, optionally, a second/top panel 212 . Where both are employed, as is the case illustrated ( FIGS. 14-17 ), the top panel 212 may substantially cover and be adhered (e.g., via adhesive/glue or an intermediate tape) to the bottom panel 210 so as to secure the blister pack 204 therebetween. The bottom panel 210 may be provided with at least one area of panel weakness 214 (defined, for example, by a perforation or reduced thickness) to promote easy punch-out at such locations for unit dose delivery. In a corresponding manner, the top panel 212 may include at least one unit dose cut outs or openings 216 to accommodate therethrough protruding unit doses carried by a given blister pack 204 . As such, the trace element carrier 208 may thereby be located between the bottom panel 210 and the blister pack 204 in a manner to position the electrical trace element 206 relative to the at least one area of panel weakness 214 to allow ready delivery of medicine. That is, when a given dose of medication (not specifically shown) is expressed out of the unit dose package 200 , the electrical trace element 206 and the corresponding region of the trace element carrier 208 are broken, along with the respective area of panel weakness 214 .
[0080] An electronics receiving region/opening 218 may be formed through the bottom panel 210 to permit mechanical receipt of an electronic/electronics component 220 . In a manner quite similar to that shown in FIGS. 9 , 10 a , and 10 b , one potential manner of receiving the electronics component 220 is shown in FIGS. 14 and 15 , employing at least one mounting opening 222 in the paneling component 202 and a separate mounting hub 224 , a reusable form of which is illustrated. Another variation, paralleling that of FIGS. 11 and 12 , is shown in FIGS. 16 and 17 , in which a slide clip 226 is used to hold the electronics component 220 in place on the paneling component 202 . It is, however, to be understood that other mechanisms, such as those discussed above with the unit dose package 100 , may be used to mount the electronics component 220 . For example, the trace element carrier 208 may have the mounting hub 224 preassembled therewith and/or built in thereto. Other known hub-to-electronic component connections could be used in relation to the mounting hub 224 and the electronics component 220 , e.g., pin-and-socket or USB-type. The particular type of connection used may, in part, be chosen based on the number of uses expected (i.e., certain connector types may offer greater protection of contact points during transitioning).
[0081] In particular, the electrical trace element 206 may have at least first and second trace ends 228 that are exposed via the electronics receiving region 218 , and such at least first and second trace ends 228 may thereby form an electrical connection with the mounted electronics component 220 . Such trace ends 228 may, potentially, be located anywhere on the trace element carrier 208 , so long as such placement facilitates connection thereof with a given electronics component 220 . Further, such trace ends 228 may, for example, be directed away from any areas of the electrical trace element 206 that might be subject to breakage in the normal course of use of the unit dose package 200 .
[0082] Finally, with respect to the unit dose package 200 , the blister pack 204 may include, for example, a blister substrate 230 and at least one dosage site 232 (i.e., location where a given unit dose of medicine stored/carried). It is noted that, since the blister pack 204 need not carry the electrical trace element 206 as per the case of the unit dose package 100 , any blister pack construction known in the art could potentially be employed as part of this embodiment.
[0083] The disclosed unit dose package 300 ( FIGS. 18-21 ) may, for example, include a paneling component 302 , a blister pack 304 , and an electrical trace element 306 . The primary difference between the disclosed unit dose package 300 and the other two unit dose packages 100 and 200 is the manner in which the electrical trace element 306 is incorporated into the unit dose package 300 . More particularly, in the embodiment associated with unit dose package 300 , the electrical trace element 206 may be carried (e.g., coated or deposited) on the paneling component 302 . The description of the disclosed unit dose package 300 , as such, focuses on those details related to the mounting/positioning of the electrical trace element 306 and modifications associated with such placement, as the remaining features are similar to those otherwise associated with the unit dose packages 100 , 200 .
[0084] The features distinguishing the unit dose package 300 from the unit dose packages 100 , 200 are best seen in FIGS. 18 and 20 . Instead of potentially being carried on the blister pack 304 or on a separate element (e.g., a trace element carrier), the electrical trace element 306 is deposited, wired, coated, or otherwise incorporated into and/or on paneling component 302 . In particular, the paneling component 302 may include at least a first/bottom panel 308 , through which a unit dose is ultimately expressed, and, optionally, a second/top panel 310 . In this embodiment, the electrical trace element 306 is deposited on the bottom panel 308 .
[0085] Where both panels 308 , 310 are employed, as is the case illustrated ( FIGS. 18-21 ), the top panel 310 may substantially cover and be adhered (e.g., via adhesive/glue or an intermediate tape) to the bottom panel 308 so as to secure the blister pack 304 therebetween. The bottom panel 308 may be provided with at least one area of panel weakness 312 (defined, for example, by a perforation or reduced thickness) to promote easy punch-out at such locations for unit dose delivery. In a corresponding manner, the top panel 310 may include at least one unit dose cut outs or openings 314 to accommodate therethrough protruding unit doses carried by a given blister pack 304 . The electrical trace element 306 is positioned relative to the at least one area of panel weakness 312 so that, when a given dose of medication (not specifically shown) is expressed out of the unit dose package 300 , a given section of the electrical trace element 306 is broken, along with the respective area of panel weakness 312 .
[0086] An electronics receiving region/opening 316 may be formed, e.g., through the bottom panel 308 to permit mechanical receipt of an electronic/electronics component 318 . In a manner quite similar to that shown in FIGS. 9 , 10 a , and 10 b , one potential manner of receiving the electronics component 318 is shown in FIGS. 14 and 15 , employing at least one mounting opening 320 in the paneling component 302 and a separate temporary mounting hub 322 . Another variation, paralleling that of FIGS. 11 and 12 , is shown in FIGS. 16 and 17 , in which a slide clip 324 is used to hold the electronics component 220 in place on the paneling component 202 . It is, however, to be understood that other mechanisms, such as those discussed above with the unit dose package 100 , may be used to mount and align the electronics component 318 .
[0087] Further, the electrical trace element 306 may have at least first and second trace ends 326 that are exposed via the electronics receiving region 316 , and such at least first and second trace ends 326 may thereby form an electrical connection with the mounted electronics component 318 . Such trace ends 326 may, potentially, be located anywhere on the bottom panel 308 , so long as such placement facilitates connection thereof with a given electronics component 318 . Further, such trace ends 326 may, for example, be directed away from any areas of the electrical trace element 306 that might be subject to breakage in the normal course of use of the unit dose package 300 . Yet, additionally, it is to be understood that, for example, the trace ends 326 may be located on an opposite half (not labeled) of the bottom panel 308 than the main portion of the electrical trace element 306 , thereby allowing one page of an insert or slide card to be dedicated to connection with an electronics component 318 and the other one or more pages be used for unit dose dispersal.
[0088] Furthermore, with respect to the unit dose package 300 , the blister pack 304 may include, for example, a blister substrate 328 and at least one dosage site 330 (i.e., location where a given unit dose of medicine stored/carried). It is noted that, since the blister pack 304 need not carry the electrical trace element 306 as per the case of the unit dose package 100 , any blister pack construction known in the art could potentially be employed as part of this embodiment.
[0089] Other embodiments and variations associated with the disclosed unit dose packages 100 , 200 , 300 may be possible. For one, any number of pages/sheets of unit doses, as practical, could be provided. Additionally, it is to be understood that each such unit dose packages 100 , 200 , 300 could be used as a stand-alone package (e.g., wallet dispenser) or as a slidable insert in the manner disclosed elsewhere in this application (e.g., insertable into a sleeve). Yet further, one of the ordinary skill in the art may choose to extend the trace ends onto the opposite one of the top and bottom panels and/or to relocate the position of the electronics receiving region, so long as that combination permits connection between the trace ends and the electronics component. More simply, it is further contemplated that the electrical trace element and/or the trace ends thereof might be associated with the top panel and that the electronics receiving cut out be formed in the bottom panel.
[0090] It is believed that the present disclosure includes many other embodiments that may not be herein described in detail, but would nonetheless be appreciated by those skilled in the art from the disclosures made. Accordingly, this disclosure should not be read as being limited only to the foregoing examples or only to the designated preferred embodiments.
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Described herein is an apparatus and method for attaching a removable and reusable electronics component to a to a slide card that can be preprinted with electrical traces for the purpose of collecting data on pill expression. A removable and reusable electronics component can be coupled with a slide card incorporating preprinted electrical traces, using a hub like plastic seating component attached to and through the slide card.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for engagement with a rotatable support wheel of a vehicle for propelling the apparatus ahead of the vehicle in the direction of travel thereof. More particularly, the present invention relates to a snowplow blade or the like having a pair of spaced-apart rollers extending from the rear wall thereof for rotatable engagement with forward peripheral portions of the respective front wheels of the vehicle to allow the front wheels to propel the snowplow blade ahead of the vehicle.
2. Description of the Prior Art
The prior art discloses numerous mechanisms for attaching a snowplow blade or the like to the front of a vehicle such as an automobile or a pickup truck. Some of the known prior art devices provide means for connecting the snowplow blade to the front bumper of the vehicle. Such mechanisms present a problem because typical vehicular bumpers are not sturdy enough for such use and may become damaged thereby.
Other prior art devices avoid using the bumper of the vehicle for thrust purposes and instead provide means for coupling directly to the frame of the vehicle. Such devices, however, tend to be mechanically complex and difficult to install, typically requiring the installer to work under the vehicle to effect the connections with the vehicle frame. This can be especially uncomfortable in cold weather and with snow on the ground. Known prior art devices also tend to be heavy, cumbersome, and bulky for storage.
Accordingly, the prior art points out the need for a lightweight, vehicular attachment system for a snowplow or the like which avoids stress on the bumper of a vehicle, avoids the necessity for complicated, time consuming, and inconvenient connections with the frame of the vehicle, and folds compactly for storage.
SUMMARY OF THE INVENTION
The problems outlined above are solved by the vehicular attachment system in accordance with the present invention. That is to say, the invention hereof provides for a lightweight, compact system for coupling a working implement such as a snowplow blade or the like to a vehicle and which avoids potentially damaging stress on the bumper of the vehicle and cumbersome connections to the vehicle frame.
The preferred apparatus includes a working implement such as a snowplow blade or the like and an engagement means coupled with the implement for operative engagement with the forward peripheral portions of the front wheels of the vehicle. The preferred engagement means includes a pair of horizontally disposed rollers coupled respectively to the rear wall of the implement by extended mounting structures which present the rollers for engagement with the forward peripheral portion of the wheels so that when the vehicle wheels move forwardly, they impart corresponding rotation to the rollers and thereby impart corresponding movement to propel the apparatus forwardly.
Advantageously, the mounting structures space the implement forward of the front bumper of the vehicle in order to avoid any potential damage to the bumper. Elastomeric straps are also provided which extend between the blade and the bumper and/or frame of the vehicle in order to hold the rollers engaged with the wheels. The mounting structures also includes respective height wheels which can be adjusted to present the rollers at the proper height for engagement with the peripheral portion of the front wheels of the vehicle. Other preferred aspects will become apparent from the description herein.
In use, the forward wheels of the vehicle provide all of the thrust necessary to move the working implement forward and the rotatable nature of the rollers in engagement with the peripheral portion of the wheels prevents the front wheels from riding up over the rollers.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a rear perspective view of the preferred apparatus;
FIG. 2 is a side elevational view of the apparatus engaged with the front of a vehicle;
FIG. 3 is a front elevational view of the apparatus engaged with the vehicle of FIG. 2; and
FIG. 4 is a side elevational view of the apparatus in its folded storage position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawing figures, preferred apparatus 10 includes working implement 12 and engagement means 14.
Working implement 12 can be in the form of any structure to be propelled by and ahead of a vehicle. For example, working implement 12 can be a wheeled cart, for hauling materials such as soil, sod, fireplace logs, or the like. In the preferred embodiment herein, however, working implement 12 is configured as a snowplow blade.
Implement 12 includes flat, rectangular structural body 16 preferably composed of fiberglass, synthetic resin material, or hardwood. These compositions are preferred over metal because of their relatively light weight, although metal could certainly be used as a matter of design choice.
Working implement 12 presents a forward face 18 (FIGS. 2, 3, and 4) and a rearward face 20. Forward face 18 includes handle 22 centrally located adjacent the upper edge thereof and a pair of spaced-apart elastomeric bumper straps 24 coupled to forward face 18 by means of conventional "S" hooks and eye-bolts. The ends of straps 24 also include conventional "S" hooks.
Rearward face 20 includes a pair of spaced-apart, elastomeric, frame straps 26 coupled to rearward face 20 about midway between the upper and lower edges the purpose of which is explained hereinbelow. Rearward face 20 also includes a pair of spaced-apart upright guide posts 28 conventionally coupled to rearward face 20 at opposed ends thereof and extending upwardly beyond the upper edge for visually aiding the operator of the vehicle propelling the apparatus 10 inasmuch as structural body 16 may not be visible over the hood of the vehicle.
Working implement 12 also includes angleiron wear piece 30 conventionally bolted to body 16 along the lower edge thereof as shown in the drawing figures. Wear piece 30 is replaceable if it wears out due to sliding contact with the pathway of the vehicle.
Engagement means 14 includes a pair of spaced-apart mounting structures 32 and a corresponding pair of engagement rollers 34.
Each mounting structure 32 includes a pair of spaced-apart mounting brackets 36, hinge rod 38 threaded at each end, a pair of spaced-apart extension arms 40, support plate 42, a pair of spaced-apart height wheel support brackets 44, height wheel 46, and adjustment arm assembly 48. Components 36-48 are preferably composed of steel.
Spaced-apart, L-shaped mounting brackets 36 are conventionally bolted to rearward face 20 with one leg of each extending rearwardly from rearward face 20. Additional appropriately spaced bracket mounting holes 50 are defined in structural body 16 to allow left-right adjustment of mounting structure 32 to match the front wheel spacing of the vehicle used to propel apparatus 10.
The inboard ends of extension legs 40 are located adjacent the inboard sides of the rearwardly extending legs of mounting brackets 36. Hinge rod 38 extends through appropriately defined holes in brackets 36 and in extension legs 40 in order to hingedly couple engagement means 14 to working implement 12. Conventional nuts threadably secure each end of hinge rod 38.
Extension legs 40 each include tubular base member 52, cylindrical extension member 54 slidably received in member 52, locking pin 56, and extension roller 58.
Tubular base member 52 includes locking hole 60 defined near the outboard end therethrough which is designed to register with a series of similarly defined locking holes (not shown) defined near the inboard end of tubular base member 52. The slidable nature of extension member 54 within base member 52 allows telescoping adjustment of extension legs 40. The length adjustment of legs 40 can be locked by inserting locking pin 56 through locking hole 60 and through a corresponding registered hole in extension member 54.
In the alternative, the locking arrangement using pin 56 can be replaced by an assembly wherein a nut is welded to base member 52 with a locking bolt threaded therethrough and through a corresponding hole in member 52 to tightly engage member 54 to lock in place.
Extension legs 40 also include a respective pair of guide rollers 58 rotatably coupled to the outboard ends thereof. Each guide roller 62 presents an axis of rotation which is flared outwardly at about 10-degrees relative to the axis of the corresponding extension leg 40, the purpose of which will be explained hereinbelow. Guide rollers 62 are preferably coated with non-scuffing rubber or synthetic resin material.
Rectangular support plate 42 is conventionally welded or bolted to the lower surface of the corresponding tubular base members 52 and defines the spacing between legs 40. Spaced-apart height wheel support brackets 44 are conventionally welded or bolted to the underside of support plate 42 and rotatably mount height wheel 46 therebetween. The downwardly extending leg of each height wheel support bracket 44 includes three vertically spaced-apart holes 64 defined therein which allow the height wheel 46 to be adjusted in order to adjust the height of mounting bracket 36.
Adjustment arm assembly 48 includes bracket 66, notched adjustment arm 68, and U-clamp 70.
L-shaped bracket 66 is conventionally bolted to rearward face 20 with one leg thereof extending rearwardly. An additional series of bracket holes 72 are defined in structural body 16 in correspondence with bracket mounting holes 50 so that bracket 62 can be appropriately positioned when mounting brackets 36 are shifted left or right.
Adjustment arm 68 has one end conventionally bolted to the rearwardly extending leg of bracket 66 and the other end thereof positioned within U-clamp 70 on the outboard side of extension member 54. U-clamp 70 clamps the notched end of adjustment arm 68 to extension member 54. Notches 74 defined in adjustment arm 68 aid in preventing hinged movement of mounting structure 32 when apparatus 10 is in use. However, if apparatus 10 strikes an obstruction during use, clamp 70 allows arm 68 to slip and thereby prevent damage to the various components of apparatus 10. If a locking bolt is used in place of locking pin 56 as described above, the locking bolt will also allow member 54 to slip relative to member 52 to prevent damage to apparatus 10.
Clamp 10, in the alternative, can be welded adjacent the outboard end of member 52 as a matter of design choice and convenience.
Cylindrical engagement rollers 34 are rotatably coupled between a respective pair of extension legs 40 making up each mounting structure 32 adjacent the inboard end of guide rollers 62. Rollers 34 are preferably coated with non-scuffing rubber or synthetic resin.
FIG. 2 is a side elevational view illustrating the use of apparatus 10 in connection with vehicle 76 which includes a pair of front wheels 78 (only one of which is shown) and an overhanging section including front bumper 80. To use apparatus 10, it must be initially adjusted for the particular wheel spacing, wheel size, and overhang of vehicle 76. Apparatus 10 is first placed in front of vehicle 76 with mounting structures 32 extending rearwardly toward front wheels 78 and with rearward face 20 spaced preferably about three inches in front of bumper 80.
The left-right spacing of mounting structures 32 is then adjusted to match the spacing of wheels 78 by selecting the appropriate mounting holes 50 and 72. With pin 56 removed and U-clamp 70 loosened, cylindrical extension members 54 are then shifted rearwardly until engagement rollers 34 contact the forward peripheral portions of front wheels 78. Pin 56 is then reinserted through hole 60 and the registered holes of members 54 to lock the adjusted length of extension legs 40. U-clamp 70 is then tightened to prevent hingeable movement of mounting brackets 36 relative to working implement 12.
Next, the height of engagement rollers is adjusted if needed so that rollers 34 engage the proper location on the forward peripheral portion of front wheels 78. With reference to the radii of wheels 78, this location is between horizontal and 45-degrees below horizontal. With this location, front wheels 78 can exert a force component on rollers 34 which is primary horizontal but which also includes a downward force component sufficient to prevent front wheels 78 from riding under engagement rollers 34. That is to say, if engagement rollers 34 ride too high on front wheels 78, working implement 12 will have a tendency to tip forwardly. Conversely, if engagement rollers 34 ride too low, the downward force component will put excessive strain on height wheel 46 thereby shortening its life. Preferably, engagement rollers should be located between 10 and 30 degrees below horizontal relative to the axis of rotation of front wheel 78.
After height wheel 46 has been properly adjusted by selecting the appropriate adjustment hole 64, frame straps 26 are then hooked to the frame of the vehicle at a convenient location. Many vehicles include eye-bolts located behind the front bumper used for loading and unloading the vehicle from ships. Frame straps 26 are intended to conveniently hook to these eye-bolts (not shown). Frame straps 26 help maintain engagement rollers 34 in contact with the front peripheral portion of front wheel 78 when the vehicle is turning or backing up.
Finally, bumper straps 24 are extended over the top of working implement 12 and then downwardly along rearward face 20 to hook to the lower edge of front bumper 80. Bumper straps 24 help keep wear piece 30 in contact with the pathway of the vehicle for effective snowplowing or the like and also aid in maintaining rollers 34 in contact with front wheel 78.
With apparatus 10 engaged with vehicle 76 as described above, the forward peripheral portions of wheels 78 exert forward force on engagement rollers 34 to propel apparatus 10 ahead of vehicle 76. The forward peripheral portions of wheels 78 also exert a downward force component on rollers 34 along with straps 24, 26 to keep height wheels 46 engaged with the vehicle pathway and thereby prevent forward tipping of implement 12. The rotation of wheels 78 also induce corresponding rotation of rollers 34 to prevent any traction therebetween and to prevent wheels 78 from riding over rollers 34.
Extension rollers 58 help keep mounting brackets 36 centered on the respective front wheels 78. The flared, rotatable, and non-scuffing nature of the rubber or synthetic resin coating on rollers 58 avoid any potential damage to the tire sidewalls or wheel covers of wheels 78.
The structure of apparatus 10 spaces working implement 12 forward of bumper 80 and thereby prevents any damage thereto.
FIG. 3 presents a front elevational view of apparatus 10 operably engaged with vehicle 76. Depending on the size of vehicle 76, the operator thereof may not be able to view working implement 12 over the vehicle's hood. Guide posts 28 extending upwardly from the outboard edges of implement 12 provide the operator of vehicle 76 with a guide as to the position of implement 12 during use.
FIG. 4 illustrates apparatus 10 in a storage position. To place apparatus 10 in the storage position, clamps 70 are loosened and mounting structures 42 rotated about hinge rod 38 until extension legs 40 contact rearward face 20 of implement 12. Straps 24 and 26 are then wrapped around mounting structures 32 to hold them in the storage position.
The lightweight nature of apparatus 10 allows it to be easily carried by handle 22 and stored, for example, by using handle 22 to hang apparatus 10 from a hook on the wall of a garage. Apparatus 10 can be placed in the storage position as illustrated in FIG. 4, without changing any of the various adjustments. Re-engagement with vehicle 76 requires only that mounting structures 32 be rotated down to the original position, clamps 70 tightened, and straps 24 and 26 reconnected.
The present invention contemplates many variations in design of the preferred apparatus 10. For example, as discussed above, working implement 12 can be any structure which is desired to be propelled ahead vehicle 76. For example, working implement 10 can be blades of different configurations and can even be a wheeled cart as a matter of design choice. Additionally, the use of the present invention is not limited to the forward portion of the vehicle, but could also be used for the rear of the vehicle for use when the vehicle is moving rearwardly. As a further example, the present invention also encompasses an embodiment in which the vehicle has only one front wheel in which case only one, centrally located, mounting structure would be required.
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An apparatus for engagement with a vehicle is provided which allows a rotatable support wheel of the vehicle to propel the apparatus ahead of the vehicle in the direction the travel thereof. The preferred apparatus includes a snowplow blade or the like, a pair of spaced-apart mounting structures extending rearwardly from the blade, and a pair of horizontally disposed, transverse rollers rotatably coupled with respective mounting structures for engaging a forward peripheral of the front wheel of the vehicle, and elastomeric straps for holding the rollers engaged with the vehicle wheels. In use, forward motion of the vehicle wheels cause the forward peripheral portion of the wheels to engage the respective rollers and propel the apparatus forward for plowing snow or the like.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from German Patent Application Serial No. 10 2006 048 429.0 filed on Oct. 12, 2006, entitled “Energieabsorptionsvorrichtung, insbesondere für nichtaxiale Belastung” (Energy Absorption Device, In Particular For Non-Axial Loads), the disclosure of which is incorporated herein by reference for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates to an energy absorption device, and more particularly to an energy absorption device which may be situated between a support structure of a vehicle and a bumper to absorb energy by deformation.
BACKGROUND OF THE INVENTION
[0003] Energy absorption devices are used for the purpose of absorbing as much energy as possible in the event of an accident, before the vehicle body of the vehicle plastically deforms. In less severe accidents, the energy absorption capability of an energy absorption device may be sufficient to entirely avoid plastic deformation of the vehicle body. The repair costs remain low in this way, because only the bumper and the energy absorption device have to be replaced.
[0004] For good energy absorption, it is optimal if the energy absorption devices are implemented as an extension of longitudinal girders of an underbody of the vehicle and the bumper, in particular its crossbeam, is located horizontally at the height of the energy absorption devices. The forces are thus introduced linearly into the energy absorption device, by which its entire length may be used well for the deformation, i.e., absorbing energy.
[0005] The vehicle manufacturers have made efforts to bring as many vehicle variants as possible onto the market. To keep the costs as low as possible, the various vehicle variants are constructed on one underbody. If sports utility vehicles or SUVs are constructed on a passenger automobile underbody, the underbody is higher than in the passenger automobile. According to the legal requirements, however, the bumper, in particular its crossbeam, must be located at the height which normally corresponds to a passenger automobile bumper. This means that a Vertical offset between the bumper, in particular its crossbeam, and longitudinal girders of the underbody is to be bridged.
[0006] One possibility is to implement the energy absorption device, as up to this point, as a longitudinal extension of the longitudinal girder of the underbody, but provide a bumper with a cross member which extends over the entire vertical area and is implemented as solid. In this way, the forces may be introduced into the energy absorption device well and absorbed thereby.
[0007] Employing energy absorption devices according to the species and bridging the offset between the bumper, possibly a cross member thereof, and the longitudinal girder of the underbody, using them is also known. More compact and lighter bumpers, in particular more compact and lighter crossbeams may thus be used, which saves weight. However, tests have shown that accident forces are not conducted linearly enough through these energy absorption devices, which results in poor energy absorption.
SUMMARY OF THE INVENTION
[0008] The present invention is based on the object of improving an energy absorption device according to the species in the simplest possible way so that energy may be dissipated well, but nonetheless forces are introduced diagonally into the energy absorption device.
[0009] The object is achieved according to the invention by an energy absorption device having the features of Claim 1 .
[0010] The auxiliary profile stabilizes the main profile of the energy absorption device and particularly counteracts an undesired buckling of the energy absorption device. In this way, the energy absorption device remains stable for the absorption and transmission of forces in spite of forces being introduced diagonally or even transversely. This means that in spite of the diagonally introduced forces, good efficiency of the energy absorption is achieved. In particular in the event of an offset between support structure and bumper, compact and light bumpers are usable. If bumpers are implemented having crossbeams, the crossbeam may be implemented as light and compact.
[0011] If the bumper is situated offset to the support structure and the energy absorption device bridges the offset, the auxiliary profile may advantageously stabilize a cross-sectional section of the main profile, which is situated in front in the offset direction. A cross-sectional section of the main profile, which is especially endangered by buckling, is stabilized in this way.
[0012] The cross-sectional section may preferably be a lower cross-sectional section of the main profile in relation to the vehicle. Pivoting of the bumper downward in the event of an accident is thus counteracted and the forces are absorbed well.
[0013] The auxiliary profile may preferably stabilize an approximately horizontal lateral cross-sectional section of the main profile in relation to the vehicle. A cross-sectional section of the main profile is thus stabilized, which is situated in front in the direction of a transverse component of an accident force, i.e., a cross-sectional section of the main profile which is endangered by buckling by the transverse component of the accident force is stabilized. Energy may thus be absorbed efficiently even in the event of a diagonal frontal impact using the energy absorption device.
[0014] The lateral cross-sectional section may especially favorably be an outer cross-sectional section in relation to a longitudinal central direction of the vehicle. This has an especially good stabilizing effect in the event of accident forces which displace the bumper in the cited outward direction.
[0015] The auxiliary profile may especially advantageously have an essentially arched cross-section. This provides it with good rigidity against undesired buckling.
[0016] The cross-section of the auxiliary profile may especially favorably implement an essentially convex contour with an area of the cross-section of the main profile. The auxiliary profile and the area of the cross-section of the main profile thus have good rigidity against buckling and supplement one another mutually.
[0017] The cross-section of the auxiliary profile may advantageously have chamfers. The chamfers have a stabilizing effect against undesired buckling.
[0018] The auxiliary profile may preferably be situated in the interior of the main profile. The energy absorption device may thus be implemented in a space-saving way and nonetheless has good stability and good energy absorption capability.
[0019] The auxiliary profile may preferably taper in the direction toward the support structure of the vehicle. The energy absorption device is thus more strongly stabilized on the side of the bumper against undesired buckling in the offset direction than on the side of the support structure of the vehicle.
[0020] The height of the cross-section of the auxiliary profile may especially advantageously decrease in the direction toward the support structure of the vehicle. In this way, the auxiliary profile has a greater stabilizing effect against undesired buckling in the direction of its height on the side of the bumper than on the side of the support structure of the vehicle.
[0021] The auxiliary profile may advantageously taper in the direction toward the bumper. In this way, the energy absorption device is more strongly stabilized against undesired buckling in the direction of the transverse component of the accident force on the side of the support structure than on the side of the bumper.
[0022] The height of the cross-section of the auxiliary profile may preferably decrease in the direction toward the bumper. The auxiliary profile thus has a greater stabilizing effect against undesired buckling in the direction of its height on the side of the support structure than on the side of the bumper.
[0023] If the bumper is situated offset to the support structure and the energy absorption device bridges the offset, the auxiliary profile may especially favorably have an inclination in relation to a longitudinal direction of the support structure, which is opposite to the direction of the offset. The forces introduced from the bumper may thus be conducted through the energy absorption device having a stronger component parallel to the longitudinal direction of the support structure in spite of the offset.
[0024] If the bumper is situated offset to the support structure and the energy absorption device bridges the offset, the auxiliary profile may preferably have a profile back which is inclined opposite to the direction of the offset in relation to the longitudinal direction of the support structure. In this way, forces may be conducted at an angle through the profile back and at least partially compensate for the angularity of forces which are conducted through the main profile. The sum of the forces conducted through the energy absorption device thus approaches the longitudinal direction of the support structure better in its direction.
[0025] The auxiliary profile may especially advantageously be laterally inclined horizontally in relation to a longitudinal direction of the support structure. The auxiliary profile is thus inclined corresponding to a transverse component of an accident force to be expected and has an especially good stabilizing effect against undesired buckling in relation to the transverse component.
[0026] The auxiliary profile may especially favorably have a profile back which is laterally inclined horizontally in relation to a longitudinal direction of the support structure. In this way, the profile back is inclined corresponding to a transverse component of an accident force to be expected and applies a good stabilization component against undesired buckling in relation to the transverse component.
[0027] At least two auxiliary profiles running at a distance to one another may advantageously be provided. The energy absorption device is stabilized even better against undesired buckling using a plurality of auxiliary profiles. Due to the distance between the auxiliary profiles, they may deform without obstruction.
[0028] The auxiliary profile may especially preferably be fastened to the main profile over a greater length in an area on the support structure side than in an area on the bumper side. The shorter fastening length in the area on the bumper side makes a deformation of the auxiliary profile and the main profile easier here. The greater fastening length in the area on the support structure side increases the resistances of the auxiliary profile and the main profile to deformation here. The force applied to the support structure may be kept at an essentially constant level.
[0029] A transition area may preferably be provided, in which the auxiliary profile is fastened to the main profile over a shorter length than in the area on the support structure side and over a greater length than in the area on the bumper side. In the transition area, the auxiliary profile and the main profile have a moderate resistance against deformation viewed overall, compared to the areas on the support structure and bumper sides. This contributes well to keeping the force applied to the support structure at a constant level.
[0030] The auxiliary profile may advantageously be fastened to the main profile over approximately 30% to 45% of its length in the area on the support structure side, preferably over approximately 40% of its length. In this way, the auxiliary profile and the main profile have an increased resistance to deformation in a good area, i.e., a good area which first deforms at higher forces.
[0031] The auxiliary profile may especially preferably be fastened to the main profile over approximately 3% to 10% of its length, preferably over approximately 5% of its length, in the area on the bumper side. The auxiliary profile and the main profile thus have a good area in which the resistance to deformation is lower, i.e., which already absorbs energy at lower forces, because auxiliary profile and main profile may fold freely in a good area.
[0032] The auxiliary profile may advantageously be fastened to the main profile over approximately 5% to 15% of its length, preferably over approximately 10% of its length, in the transition area. The auxiliary profile and the main profile thus have a good area of moderate resistance to deformation viewed overall, i.e., a good area in which energy is only absorbed at a later point in time.
[0033] The auxiliary profile may favorably have a greater material strength on the support structure side than on the bumper side. The auxiliary profile has a higher resistance to deformation on the support structure side than on the bumper side.
[0034] The auxiliary profile may preferably have at least two material parts of different material thicknesses. The auxiliary profile thus has a different resistance to deformation in each material part.
[0035] The auxiliary profile may advantageously have a material part which has a material thickness varied by rolling. The provision of the areas of different material thicknesses may thus be performed for many workpieces in an efficient process.
[0036] The material of the auxiliary profile may advantageously have a higher strength on the support structure side than on the bumper side. The auxiliary profile thus has a lower resistance on the bumper side than on the support structure side.
[0037] The auxiliary profile may especially expediently have at least one longitudinal bead extending in its longitudinal direction, preferably in the area proximal to the support structure. In the area of the longitudinal bead, the auxiliary profile has a higher resistance to deformation in its longitudinal direction.
[0038] The auxiliary profile may especially preferably have at least one transverse bead extending transversely to its longitudinal direction, preferably in the area close to the bumper. The auxiliary profile may be folded more easily in its longitudinal direction in the area of the transverse bead. The transverse bead defines an area for intentional folding deformation, the energy absorption device as a whole remaining stabilized against undesired buckling.
[0039] If the bumper is situated offset to the support structure and the energy absorption device bridges the offset, a first cross-sectional section of the main profile which is situated in front in the offset direction may preferably have a higher deformation resistance than a second cross-sectional section of the main profile which is situated behind the first cross-sectional section in the offset direction. In this way, a cross-sectional section of the main profile, which is endangered by buckling by the structural offset, is stabilized.
[0040] A first cross-sectional section of the main profile which is located on a first horizontal side of the energy absorption device in relation to the vehicle may advantageously have a higher deformation resistance than a second cross-sectional section of the main profile which is located on the second horizontal side of the energy absorption device in relation to the vehicle. The anterior cross-sectional section of the main profile in the direction of a transverse component of an accident force is thus stabilized against undesired buckling.
[0041] The first cross-sectional section may preferably have a greater material thickness than the second cross-sectional section. The first cross-sectional section thus has a higher resistance to deformation than a second cross-sectional section.
[0042] The material of the first cross-sectional section may preferably have a greater material thickness than the second cross-sectional section. The first cross-sectional section thus has a higher resistance to deformation than the second cross-sectional section.
[0043] The material of the first cross-sectional section may advantageously have a higher strength than the material of the second cross-sectional section. The second cross-sectional section thus has a lower resistance to deformation than the first cross-sectional section.
[0044] More chamfers may advantageously be provided on the first cross-sectional section than on the second cross-sectional section. The first cross-sectional section thus has a higher resistance to deformation than the second cross-sectional section.
[0045] The main profile in the intermediate profile may especially preferably be produced from sheet-metal-type material and/or sheet-metal-type profiles. The energy absorption device may thus be implemented having low weight and a high level of design freedom.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] An embodiment of the invention is shown in the drawing and described hereafter. In the figures:
[0047] FIG. 1 shows a perspective view of energy absorption devices of a first embodiment of the invention between a crossbeam of a bumper and support structures of a vehicle,
[0048] FIG. 2 shows a perspective illustration of one of the energy absorption devices according to the invention from FIG. 1 ,
[0049] FIG. 3 shows a perspective illustration of a part of the energy absorption device from FIG. 2 ,
[0050] FIG. 4 shows a schematic sectional view of the energy absorption device between the bumper and one of the support structures according to the first embodiment,
[0051] FIG. 5 shows a schematic sectional illustration having alternative orientations of an auxiliary profile of the energy absorption device,
[0052] FIG. 6 essentially shows a top view of the part of the energy absorption device from FIG. 3 ,
[0053] FIG. 7 shows, partially and individually, two cross-sectional views of a main profile and an auxiliary profile of the energy absorption device,
[0054] FIG. 8 shows a side view of the energy absorption device according to FIG. 1 ,
[0055] FIG. 9 shows a sectional view of the energy absorption device along a line IX-IX in FIG. 8 ,
[0056] FIG. 10 shows a sectional view of the energy absorption device along a line X-X in FIG. 8 ,
[0057] FIG. 11 shows a force-distance diagram of the energy absorption device,
[0058] FIG. 12 shows a perspective view of energy absorption devices of a second embodiment of the invention between a crossbeam of a bumper and support structures of a vehicle,
[0059] FIG. 13 shows a perspective illustration of one of the energy absorption devices according to the invention from FIG. 12 ,
[0060] FIG. 14 shows a perspective illustration of a part of the energy absorption device from FIG. 13 ,
[0061] FIG. 15 shows a cross-sectional view of the energy absorption device from FIG. 13 ,
[0062] FIG. 16 shows a cross-sectional view of an alternative design of the cross-sectional profile of the energy absorption device,
[0063] FIG. 17 shows a partial frontal view of the configuration from FIG. 12 ,
[0064] FIG. 18 shows a schematic sectional view of the energy absorption device between the bumper and one of the support structures along a line XVIII-XVIII in FIG. 17 , and
[0065] FIG. 19 shows a schematic sectional view of the energy absorption device between the bumper and one of the support structures along a line XIX-XIX in FIG. 17 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0066] Identical reference numerals are used for similar elements in the following description.
[0067] FIGS. 1 through 11 relate to a first embodiment of the invention.
[0068] FIG. 1 partially shows a vehicle body configuration of a vehicle. The vehicle body configuration has support structures 4 , 5 , energy absorption devices according to the invention attached thereto, and a bumper, of which only a crossbeam 3 is shown, however. The energy absorption devices are constructed symmetrically to one another and are each situated between the bumper, i.e., crossbeam 3 , and the particular support structure. The crossbeam 3 connects the two energy absorption devices 1 , 2 . The support structures 4 , 5 are each longitudinal girders of an underbody or platform of the vehicle in the present embodiment.
[0069] The bumper, i.e., the crossbeam 3 , is situated offset to the particular support structure. The particular energy absorption device bridges the offset between the crossbeam 3 and the particular support structure 4 , 5 . The energy absorption devices are fastened, preferably removably, to the relevant support structure 4 , 5 via a particular flange 6 , 7 .
[0070] In this embodiment, the offset is vertical. A horizontal offset is additionally or alternatively possible.
[0071] The left energy absorption device 1 in FIG. 1 is shown in a perspective view in FIG. 2 . It has a deformable main profile 8 , like a hollow body in cross-section, which carries the bumper via the crossbeam 3 . The main profile may have a closed or open structure like a hollow body.
[0072] The main profile 8 has a first cross-sectional section 9 and a second cross-sectional section 10 . The first cross-sectional section 9 is situated in front in the offset direction 11 and the second cross-sectional section is situated behind the first cross-sectional section 9 in the offset direction 11 . In this embodiment of the invention, the first cross-sectional section 9 is a lower cross-sectional section in relation to the vehicle and the second cross-sectional section 10 is an upper cross-sectional section.
[0073] The cross-sectional sections are shell-type components in this embodiment of the invention, which are connected to one another by joining, e.g., welding, and have a shared inner chamber. However, it is also possible to implement the main profile part in one piece.
[0074] The energy absorption device has at least one deformable auxiliary profile 12 provided in the cross-section of the main profile 8 . The auxiliary profile 12 may be situated inside or outside the main profile 8 . It extends in the longitudinal direction of the main profile and stabilizes it against undesired buckling. Thus, in spite of the offset between support structure and crossbeam, accident forces acting essentially parallel to the longitudinal direction of the sport structure may be well accommodated, absorbed, and relayed in the direction toward the support structure, the energy absorption capability of the energy absorption device 1 being able to be exploited well. The auxiliary profile is implemented as shell-like.
[0075] The two cross-sectional sections 9 , 10 and the auxiliary profile 12 are produced from sheet-metal-type, reshaped material and/or sheet-metal-type profiles, which were possibly reshaped further.
[0076] The auxiliary profile 12 may be situated on the first and/or second cross-sectional section 9 , 10 . In the present embodiment of the invention, it is attached on the first cross-sectional section 9 and stabilizes it against undesired buckling.
[0077] As shown in FIGS. 2 and 3 , the auxiliary profile has an essentially arched cross-section, which is implemented as approximately U-shaped or C-shaped in this embodiment of the invention. The cross-section of the auxiliary profile 12 has chamfers 59 , by which it is additionally stabilized against undesired buckling.
[0078] The auxiliary profile 12 forms an essentially convex contour with an area of the cross-section of one of the first and second cross-sectional sections 9 , 10 , in this embodiment with an area of the cross-section of the first cross-sectional section 9 . The rigidities of the first cross-sectional section 9 and auxiliary profile 12 thus supplement one another well.
[0079] It is equally possible to attach the auxiliary profile 12 having reversed arched cross-section on the first cross-sectional section. The rigidities of the auxiliary profile and the first cross-sectional section 9 also supplement one another mutually here.
[0080] The intermediate profile 12 extends essentially over the entire length of the first cross-sectional section 9 . As may be seen from FIGS. 2 and 3 , the auxiliary profile 12 is situated inclined in relation to the main profile 8 . An end 51 of the intermediate profile 12 on the bumper side is situated approximately centrally in the main profile 8 . An end 52 of the intermediate profile 12 on the support structure side is situated in front in the main profile 8 in relation to the offset direction 11 . The end 51 on the bumper side is situated in the area of a profile opening 16 of the first cross-sectional section 9 , i.e., in a rear area of the first cross-sectional section 9 in relation to the offset direction 11 . The end 52 on the support structure side is situated in the area of a profile floor 17 of the first cross-sectional section 9 , i.e., in front in the offset direction.
[0081] The auxiliary profile 12 extends continuously between the end 51 on the bumper side and the end 52 on the support structure side. A discontinuous course, e.g., an interrupted course, is also possible, however.
[0082] As may also be seen from FIG. 4 , the auxiliary profile 12 has an inclination which is opposite to the offset direction 11 in relation to a longitudinal direction of the support structure 4 . A longitudinal center line 18 of the auxiliary profile 12 runs in the direction toward the crossbeam 3 in relation to a longitudinal center line 19 of the support structure 4 , i.e., it encloses a corresponding angle therewith in relation to the offset direction 11 . The longitudinal center line 18 of the intermediate profile 12 runs away from a center line 20 of the crossbeam 3 in the direction toward the crossbeam 3 and encloses a corresponding angle therewith in relation to the offset direction 11 .
[0083] However, it is also possible to orient the intermediate shell 12 parallel to the longitudinal direction of the support structure and/or the crossbeam, i.e., to provide the longitudinal center line 18 of the auxiliary profile running parallel to the longitudinal center line 19 of the support structure and/or the center line 20 of the crossbeam 3 . This is illustrated in FIG. 5 with the aid of a longitudinal center line 218 for the auxiliary profile.
[0084] The auxiliary profile may just as well be situated with a greater inclination in relation to the longitudinal direction of the support structure 4 . This is illustrated in FIG. 5 with the aid of a longitudinal center line 118 for the auxiliary profile.
[0085] Reference is again made to FIG. 4 . The auxiliary profile 12 has a profile back 21 . The profile back 21 is also inclined opposite to the offset direction 11 in relation to the longitudinal direction of the support structure 4 . It runs in the direction toward the crossbeam 3 in relation to the longitudinal center line 19 of the support structure 4 . It runs more strongly inclined than the longitudinal center line 18 of the auxiliary profile 12 .
[0086] The auxiliary profile 12 has lateral edges 53 , 54 , one of which is shown in FIG. 4 and which are situated leading in the offset direction 11 . The lateral edge 54 shown runs approximately parallel in relation to the offset direction to the longitudinal center line of the support structure 4 and the center line 20 of the crossbeam 3 .
[0087] The auxiliary profile 12 tapers in the direction toward the support structure 4 . The height of the cross-section of the auxiliary profile 12 decreases in the direction toward the support structure 4 , as may be seen from FIG. 4 . The width of the auxiliary profile 12 also decreases, as shown in FIG. 6 .
[0088] It is also possible that the auxiliary profile essentially maintains its width and/or height over its length. In addition, it is possible that the width and/or height of the auxiliary profile increases in the direction toward the support structure 4 .
[0089] Welded bonds 55 , 56 , 57 , 58 , using which the second cross-sectional section 10 , the intermediate profile 12 , and the first cross-sectional section 9 are fastened to the crossbeam 3 , are also shown in FIG. 4 . Furthermore, it may be seen from FIG. 4 that the intermediate profile 12 extends in the direction toward the support structure 4 up into an area of the flange 6 . The auxiliary profile 12 is welded on the flange 6 or is supported freely thereon, as shown in FIG. 4 .
[0090] Reference is made to FIG. 6 . The auxiliary profile 12 is fastened on the main profile 8 , i.e., on the first cross-sectional section 9 , over a greater length on the support structure side than on the bumper side. In this embodiment of the invention, a transition area 15 is also provided between the area 14 on the support structure side and the area 13 on the bumper side of the auxiliary profile 12 , in which the auxiliary profile 12 is fastened on the main profile 8 over a shorter length than in the area 14 on the support structure side and over a greater length than in the area 13 on the bumper side.
[0091] With this design of the fastenings, the auxiliary profile 12 folds successively from the crossbeam 3 up to the support structure 4 . The force level applied to the support structure 4 remains essentially constant.
[0092] Because the auxiliary profile 12 is fastened at least on the main profile 8 , i.e., on the first cross-sectional section 9 , in the area 13 on the bumper side, it may fold most freely here in the event of a deformation. The deformation resistance is thus lowest in relation to the fastening here. In the area 14 on the support structure side, the deformation resistance is highest in relation to the fastening, because the auxiliary profile 12 is fixed on the main profile over the largest area here. In the transition area 15 , the deformation resistance in regard to the fastening is between that of the area 14 on the support structure side and that of the area 13 on the bumper side.
[0093] Welded bonds 22 , using which the auxiliary profile 12 is fastened on the main profile 8 , i.e., on the first cross-sectional section 9 , over 30% to 45% of its length, preferably over approximately 40% of its length, are provided on both sides on the support structure side. The auxiliary profile is fastened over approximately 3% to 10% of its length, e.g., over 5 to 20 mm, on the main profile 8 , i.e., on the first cross-sectional profile 9 , preferably over approximately 5% of its length, e.g., over 10 mm, as shown in FIG. 6 , using welded bonds 23 provided on both sides on the bumper side.
[0094] Central welded bonds 24 , 24 are provided on both sides between the welded bonds 22 , 22 on the support structure side and the welded bonds 23 , 23 on the bumper side, using which the auxiliary profile is attached on the main profile 8 over approximately 5% to 15% of its length, e.g., over 15 to 30 mm, preferably over approximately 10% of its length, e.g., over 20 mm, as shown in FIG. 6 .
[0095] The fastenings, i.e., the welded bonds 22 , 22 ; 23 , 23 ; 24 , 24 may be implemented continuously or interrupted, e.g., as spot welds.
[0096] The fastenings, i.e., the welded bonds 22 , 22 ; 23 , 23 ; 24 , 24 , extend essentially in the longitudinal direction of the auxiliary profile 12 . Good folding is thus achieved and this contributes to a uniform level of the force applied to the support structure. The folds run essentially transversely to the longitudinal direction of the auxiliary profile 12 .
[0097] An interval 25 , 25 , which extends over approximately 5% to 15% of the length of the intermediate profile 12 , e.g., over 15 to 30 mm, preferably over approximately 10% of its length, e.g., over 20 mm, is provided between the welded bonds 22 , 22 on the support structure side and the central welded bonds 24 , 24 in each case. An interval 26 , 26 , which extends over approximately 30% to 45% of the length of the auxiliary profile 12 , preferably over approximately 30% to 40% of the length, is provided between the welded bonds 23 , 23 on the bumper side and the central welded bonds 24 , 24 in each case, as shown in FIG. 6 . The left interval 26 shown in FIG. 6 is shorter than the right interval in this figure.
[0098] It is possible to provide still further intervals and/or welded bonds.
[0099] An interval is also provided between the welded bonds 23 , 23 on the bumper side and a terminal edge 27 of the auxiliary profile 12 on the bumper side, as shown in the figure. The welded bonds 22 , 22 on the support structure side extend up to a terminal edge 28 of the intermediate profile 12 on the support structure side.
[0100] In the area of the cited intervals, the intermediate profile may fold freely upon deformation in relation to the first cross-sectional section 9 .
[0101] Upon the selection of the length of the fastenings, i.e., welded bonds, and the intervals, the total length of the energy absorption device, the cross-section of the energy absorption device, the material thickness, the strength of the material, and the forces to be transmitted are taken into consideration.
[0102] Multiple auxiliary profiles may be provided in an energy absorption device according to the invention. They are preferably situated at intervals from one another to be able to deform independently from one another. In spite of the interval, the auxiliary profiles may be fastened jointly to the main profile, for example, welded jointly to the main profile and having lateral edges situated one above another.
[0103] The auxiliary profile 12 may have a greater material thickness on the support structure side than on the bumper side. The greater material thickness on the support structure side provides the auxiliary profile 12 with a greater resistance to deformation here than on the bumper side. The auxiliary profile 12 may be constructed from at least two material parts of different material thicknesses. The material parts may be welded together.
[0104] It is also possible to implement the auxiliary profile 12 having a material part which has a material thickness varied by rolling. The material thickness may vary fluidly, by which the resistance against deformation changes fluidly. The material thickness may be varied flexibly upon rolling, in particular in regard to the position of specific material thicknesses.
[0105] The material of the auxiliary profile 12 may have a higher strength on the support structure side than on the bumper side. This is a further possibility for implementing the auxiliary profile 12 having a higher strength against deformation on the support structure side.
[0106] The cited different material thicknesses and strengths of the material may be implemented by employing so-called tailored blanks, whether they are welded or rolled.
[0107] As shown in FIG. 7 , the auxiliary profile 12 has a longitudinal bead 29 , which is implemented in an area 14 on the support structure side and extends approximately in the longitudinal direction. The longitudinal bead 29 is shaped into the profile back 21 and implemented as depressed in the direction toward an inner chamber of the auxiliary profile 12 . It increases the deformation resistance of the auxiliary profile 12 against a deformation in its longitudinal direction.
[0108] In the area 13 on the bumper side, the auxiliary profile 12 has two transverse beads 30 , 31 extending approximately transversely to its longitudinal direction. The transverse beads 30 , 31 are implemented as depressed in the direction toward the inner chamber of the auxiliary profile 12 . Three or four transverse beads may also be provided.
[0109] In the transition area 15 , the auxiliary profile 12 has a transverse bead 32 extending approximately transversely to its longitudinal direction, which is implemented as raised away from the inner chamber in this embodiment. The interval of this transverse bead 32 to its adjacent transverse bead 30 in the area 13 on the bumper side is greater in this embodiment of the invention than the interval of the transverse beads 30 , 31 in the area on the bumper side to one another.
[0110] The transverse beads 30 , 31 , 32 decrease the deformation resistance of the auxiliary profile 12 against a deformation in its longitudinal direction. They encourage a desired unfolding of the auxiliary profile 12 .
[0111] Using the measures described above, which may also be applied partially or individually, the auxiliary profile is implemented having lower deformation resistance in the direction toward the bumper than in the direction toward the support structure. These measures may also be applied to the first cross-sectional section 9 and/or the second cross-sectional section 10 of the main profile 8 , and also partially or individually. The first cross-sectional section 9 and/or the second cross-sectional section 10 may also have a greater material thickness on the support structure side than on the bumper side, have a material of higher strength on the support structure side than on the bumper side, have at least one longitudinal bead, and/or have at least one transverse bead, as described for the auxiliary profile 12 .
[0112] The first cross-sectional section 9 and the second cross-sectional section 10 are shown having beads in FIG. 7 for exemplary purposes. The first cross-sectional section 9 has transverse beads extending approximately transversely to its longitudinal direction in an area which approximately corresponds to the transition area 15 of the auxiliary profile 12 . A first transverse bead 33 is shaped into the profile floor 17 of the first cross-sectional section 9 and implemented as raised toward the interior of the first cross-sectional section 9 in this embodiment. A second transverse bead 35 is shaped into a side wall 34 of the first cross-sectional section 9 adjacent thereto, which is also implemented as raised in this embodiment toward the interior of the first cross-sectional section 9 .
[0113] The first cross-sectional section 9 has a bead extending approximately transversely or diagonally to its longitudinal direction on an end 36 on the bumper side, which runs essentially parallel to the terminal edge 38 of the end 36 on the bumper side. This bead is implemented as depressed away from the interior of the first cross-sectional section 9 in this embodiment.
[0114] In an area which corresponds to the area 14 of the auxiliary profile 12 on the support structure side, the first cross-sectional section 9 has a longitudinal bead 39 implemented in its profile floor 17 and extending in the longitudinal direction. The longitudinal bead is implemented as raised toward the interior of the first cross-sectional section 9 in this embodiment.
[0115] The second cross-sectional section 10 has a first transverse bead 41 in its profile back 40 , implemented as corresponding to the first transverse bead 33 of the first cross-sectional section 9 , which is implemented as raised in the direction toward an interior of the second cross-sectional section 10 in this embodiment. Adjacent to this first transverse bead 41 , a second transverse bead 43 is shaped into a side wall 42 of the first cross-sectional section 10 corresponding to the second transverse bead 35 of the first cross-sectional section 9 .
[0116] Starting from the first transverse bead 41 of the second cross-sectional section 10 , the profile of the profile back 40 passes into a third cross-sectional bead 44 bulging in the opposite direction to the first transverse bead. The longitudinal position at which the first transverse bead 41 passes into the third transverse bead 44 corresponds in this embodiment of the invention to the longitudinal position of the second transverse bead 43 implemented in the side wall 42 .
[0117] A bead 46 running diagonally or approximately transversely to the longitudinal direction of the second cross-sectional section 10 is implemented in the profile back 40 of the second cross-sectional section 10 on an end 45 on the bumper side. This bead 46 is depressed in the direction toward the interior of the second cross-sectional section 10 in this embodiment and is located in an area close to the third transverse bead 44 of the second cross-sectional section 10 , as shown in FIG. 7 .
[0118] The direction in which the relevant desired folding is implemented is determined by the direction of the arching of the transverse beads.
[0119] Measures have been described above, using which the intermediate profile and/or the first cross-sectional section and/or the second cross-sectional section are implemented having a lower deformation resistance on the bumper side than on the support structure side. These measures each contribute to the force, which is exerted on the support structure 4 during the deformation of the energy absorption device according to the invention, remaining essentially constant.
[0120] It is also possible to provide the lower deformation resistance on the support structure side and the higher deformation resistance on the bumper side.
[0121] An asymmetry exists between the deformation resistance of the first cross-sectional section and that of the second cross-sectional section. The first cross-sectional section 9 of the main profile is implemented overall having a higher deformation resistance, in particular against undesired buckling, than a second cross-sectional section 10 . For example, in contrast to the second cross-sectional section 10 , it has the longitudinal bead 29 . It may also have a greater material thickness and/or material of greater strength than the second cross-sectional section 10 and/or have more chamfers.
[0122] Cross-sectional views of the energy absorption device along lines IX-IX and X-X of the side view of FIG. 8 are shown in FIGS. 9 and 10 . The greater material thickness of the first cross-sectional section 9 in relation to the second cross-sectional section 10 is schematically illustrated therein.
[0123] As shown in FIGS. 9 and 10 , the cross-sectional shapes of the first and second cross-sectional sections are fundamentally different. The cross-sectional profile of the first cross-sectional section 9 has more chamfers 47 than the second cross-sectional profile, although both cross-sectional profiles have an essentially U-shaped or C-shaped cross-section. In the present exemplary embodiment, the first cross-sectional section 9 has six chamfers 47 and the second cross-sectional section 10 has four chamfers 48 , i.e., the first cross-sectional section 9 is more rigid in this regard than the second cross-sectional section 10 .
[0124] A force-distance diagram of the energy absorption device 1 according to the invention is shown in FIG. 11 . An ideal curve 50 is plotted by linear, bold lines adjacent to the graphs 49 which show the measurement result. The ideal curve 50 corresponds to 100% energy absorption efficiency. As may be inferred from the illustration, an energy absorption efficiency of approximately 90% is achieved using the energy absorption device 1 according to the invention, i.e., the energy absorption device absorbs non-axial loads with good efficiency. The force applied to the support structure 4 remains essentially at equal level.
[0125] In the embodiment described above, the bumper 3 is offset to the support structure 4 , 5 of the vehicle and the energy absorption device 1 , 2 bridges the offset 11 . However, it is also possible to use the present invention in an energy absorption device which extends essentially in the longitudinal direction of the support structure 4 , 5 of the vehicle. A lateral cross-sectional section of the main profile is stabilized using an auxiliary profile. In this way, accident forces acting at an angle to the longitudinal axis of the vehicle and/or to the longitudinal direction of the support structure may be absorbed with good efficiency by the energy absorption device. For example, this is well possible for an angularity of approximately 0 to 40°, in particular up to 30°. In spite of the angularity of the forces, the energy absorption device remains stable for the absorption and transmission of forces.
[0126] The second embodiment of the invention is shown in FIGS. 12 to 19 . The essential differences to the first embodiment of the invention are explained hereafter.
[0127] In the second embodiment of the invention, the energy absorption devices 301 , 302 are provided extending essentially in the longitudinal direction of the support structures 4 , 5 , i.e., longitudinal girders. The energy absorption devices 301 , 302 are thus implemented as an extension of the support structures 4 , 5 .
[0128] The energy absorption devices 301 , 302 are constructed essentially symmetrically to one another. Therefore, only the left absorption device 301 in FIG. 12 is described hereafter.
[0129] As may be seen from FIGS. 12 and 13 , the energy absorption device 301 has two cross-sectional sections 309 , 310 , which are situated laterally approximately horizontally in relation to the vehicle. The first cross-sectional section 309 , i.e., the left cross-sectional section in FIG. 13 , is situated on the outside in relation to a longitudinal central direction 361 of the vehicle. The second cross-sectional section 310 , i.e., the right cross-sectional section in FIG. 13 , is situated on the inside in relation to the longitudinal central direction 361 .
[0130] An accident force 366 acting at an angle to the longitudinal central direction 361 , which is composed of a transverse component 364 and a longitudinal component 365 , is illustrated in FIG. 12 .
[0131] In the second embodiment of the invention, the first cross-sectional section 309 is stabilized against an undesired buckling by the transverse component 364 of the accident force 366 with the aid of an auxiliary profile 312 shown in FIG. 13 . The cross-sectional section of the energy absorption device which is anterior in the direction of the transverse component 364 of the accident force 366 is thus stabilized.
[0132] In other words, the cross-sectional section situated in front in the offset direction is stabilized by the auxiliary profile. In the second embodiment of the invention, the offset is reflected in the transverse component 364 of the accident force 366 , while in contrast a structural offset is provided in the first embodiment of the invention.
[0133] It may be seen from FIGS. 13 and 14 how the auxiliary profile 312 is implemented and situated in the main profile 308 formed from first cross-sectional section 309 and second cross-sectional section 310 . The auxiliary profile 312 runs, viewed in the longitudinal direction of the energy absorption device 301 , at an angle to the first cross-sectional section 309 , i.e., laterally inclined horizontally in relation to the longitudinal direction of the support structure 4 . The lateral edges 353 , 354 of the auxiliary profile 312 run at a greater angle in relation to the profile back 367 of the first cross-sectional section 309 than a profile back 321 of the auxiliary profile 312 . The interval between the profile back 367 of the first cross-sectional section 309 and the auxiliary profile 312 , in particular its profile back 321 , increases in the direction of the support structure 4 . The auxiliary profile 312 and its profile back 321 are thus laterally inclined horizontally in relation to the vehicle in the direction of the transverse component 364 of the expected accident force 366 .
[0134] The cross-section of the energy absorption device, as it is implemented approximately in the area of its longitudinal center, is shown in FIG. 15 . The auxiliary profile 312 forms an essentially concave-convex contour with the first cross-sectional section 309 . As may be seen from FIG. 16 , it is also possible that the auxiliary profile 312 implements an essentially convex contour with the first cross-sectional section 309 .
[0135] The measures described for the first embodiment of the invention for designing the deformation resistance and/or the deformation behavior of the energy absorption device and/or its elements are similarly applicable in the second embodiment of the invention. Thus, for example, in the second embodiment of the invention, the first cross-sectional section 309 also has a higher deformation resistance than the second cross-sectional section 310 . The anterior cross-sectional section in the direction of the transverse component 364 of the accident force 366 is thus already stabilized against undesired buckling in addition to the reinforcement by the auxiliary profile 312 .
[0136] As in the first embodiment of the invention, the first cross-sectional section 309 has more chamfers than the second cross-sectional section 310 . In this embodiment of the invention, the first cross-sectional section 309 has four chamfers 347 , while in contrast the second cross-sectional section 310 has two chamfers 348 . In contrast to the first embodiment of the invention, the chamfers of the first cross-sectional section 309 run significantly away from one another in the direction of the support structure 304 , as shown in FIG. 13 .
[0137] A schematic sectional view of the energy absorption device 301 along a line XVIII-XVIII in FIG. 17 is shown in FIG. 18 , the course of the sectional faces being illustrated. As may be seen from FIG. 18 , the energy absorption device tapers toward the bumper, i.e., the crossbeam 3 , in the vertical direction.
[0138] FIG. 19 is a sectional view of the energy absorption device 301 along a line XIX-XIX in FIG. 17 , the course of the sectional faces being illustrated. As shown in FIG. 19 , the energy absorption device 301 essentially maintains its horizontal width in the direction toward the bumper, i.e., toward the crossbeam 3 .
[0139] In the second embodiment of the invention, the first cross-sectional section and the auxiliary profile 312 are provided horizontally on the exterior. It is also possible to provide the first cross-sectional section 309 and/or the auxiliary profile 312 horizontally on the interior. The energy absorption device may thus be stabilized in particular against undesired buckling as a result of accident forces, in which the transverse component is directed opposite to the transverse component 364 shown in FIG. 12 .
[0140] Similarly good energy absorption efficiency as in the first embodiment, i.e., similarly good efficiency as shown in FIG. 11 , is achieved using the energy absorption device of the second embodiment of the invention.
[0141] In addition, it is possible to combine the designs of the first and second embodiments with one another. I.e., in the event of a structural offset between support structure and crossbeam of the bumper, stabilization may additionally be provided against buckling as a result of accident forces acting at an angle to the vehicle.
[0142] The energy absorption devices according to the invention are also usable with bumpers without crossbeams.
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The invention relates to an energy absorption device which can be arranged to absorb energy by deformation between a support structure of a vehicle and a damper, the energy absorption device carrying a deformable main profile which has a hollow body-type cross-section. The aim of the invention is to improve an energy absorption device of the aforementioned type in such a manner that the energy can be well carried off even if the forces produced by an accident impact the energy absorption device at an angle. For this purpose, a deformable supplementary profile is provided on the cross-section of the main profile.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of pending U.S. Provisional Patent Application No. 60/883,535 entitled “Two-Part Epoxy Non-Skid Coating for a Deck or Floor” filed on Jan. 5, 2007, which is hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to non-skid coatings, and more specifically to lightweight, low abrasive and low heavy metal content non-skid coatings suitable for floors and decks.
[0003] Non-skid coatings for ship decks should be durable, environmentally friendly and light-weight while still having sufficient anti-slippage properties. For naval ships, particularly aircraft carriers, multiple non-skid coatings may be used. For example, an aircraft carrier may use an “L Composition” non-skid coatings in the landing areas of flight decks and a general non-skid “G Composition” for all other areas. The landing area deck coatings must have non-abrasive aggregate in order to avoid abrading the arresting cables. Typically, flight deck coatings comprise a two-part reactive resin (including, but not limited to, epoxy resins), fillers, additives, thixotropes, etc. with an aluminum granule/aggregate filler. However, the current coatings still are heavier than desired, contain high amounts of specific heavy metals and do not provide enhanced anti-slip properties.
BRIEF SUMMARY OF THE INVENTION
[0004] In one embodiment, the invention is a composition for non-skid coatings, the composition comprising a two-part reactive resin (including, but not limited to, epoxy resins), fillers, additives, thixotropes, etc. and an aggregate/granule filler comprising particles of a thermoset and/or thermoplastic resin. In other embodiments, the thermoset resin is a special type of polycarbonate resin. Generally, the inventive composition is characterized by having lower heavy metal content than a composition having a similar loading of a filler comprising aluminum based particles and in having a density that is about 15 to about 30 percent less than a composition having a similar loading of a filler comprising aluminum or aluminum oxide based particles.
DETAILED DESCRIPTION OF THE INVENTION
[0005] The epoxy resin (other thermoset two part reactive resins can also be used in whole or to modify the epoxy) used in the practice of this invention may vary and includes conventional, commercially available epoxy resins. Two or more epoxy resins may be employed in combination. In general, known epoxy resins that are currently used for navy ship deck applications can be used. As described in U.S. Pat. No. 7,037,958, incorporated herein by reference, such epoxy resins can be glycidated resins, cycloaliphhatic resins, epoxidized oils, and so forth. The glycidated resins are frequently the reaction product of a glycidyl ether, such as epichlorohydrin, and a bisphenol compound such as bisphenol A; C 4 -C. 28 alkyl glycidyl ethers; C 2 -C. 28 alkyl- and alkenyl-glycidyl esters; C 1 -C. 28 alkyl-, mono- and poly-phenol glycidyl ethers; polyglycidyl ethers of pyrocatechol, resorcinol, hydroquinone, 4,4′-dihydroxydiphenyl methane (or bisphenol F or Novalac), 4,4′-dihydroxy-3,3′-dimethyldiphenyl methane, 4,4′-dihydroxydiphenyl dimethyl methane (or bisphenol A), 4,4′-dihydroxydiphenyl methyl methane, 4,4′-dihydroxydiphenyl cyclohexane, 4,4′-dihydroxy-3,3′-dimethyldiphenyl propane, 4,4′-dihydroxydiphenyl suflone, and tris (4-hydroxyphynyl)methane; polyglycidyl ethers of the chlorination and bromination products of the above-mentioned diphenols; polyglycidyl ethers of novolacs; polyglycidyl ethers of diphenols obtained by esterifying ethers of diphenols obtained by esterifying salts of an aromatic hydrocarboxylic acid with a dihaloalkane or dihalogen dialkyl ether; polyglycidyl ethers of polyphenols obtained by condensing phenols and long-chain halogen paraffins containing at least two halogen atoms; N,N′-diglycidyl-aniline; N,N′-dimethyl-N,N′-diglycidyl-4,4′-diaminodiphenyl methane; N,N,N′,N′-tetraglycidyl-4,4′-diaminodiphenyl methane; N,N′-diglycidyl-4-aminophenyl glycidyl ether; N,N,N′,N′-tetraglycidyl-1,3-propylene bis-4-aminobenzoate; phenol novolac epoxy resin; cresol novolac epoxy resin; and combinations thereof. Representative non-limiting examples of epoxy resins useful in this invention include bis-4,4′-(1-methylethylidene) phenol diglycidyl ether and (chloromethyl) oxirane Bisphenol A diglycidyl ether. Commercially available epoxy resins that can be used in the practice of this invention include, but are not limited to, Araldite GY6010, DER 331, Epalloy 1500, Epalloy 1501, GZ7071PM75 and Epon 828. Generally any conventional epoxy resin or hydrogenated epoxy resin with an epoxide equivalent weight of between 100 and 750 eew.
[0006] The non-skid coating is made by incorporating aggregate material into the epoxy coating. The aggregates usable for this invention can comprise thermoset and/or thermoplastic polymer resins used alone, blended or in combination with other low abrasive aggregates. Such resins include, but are not limited to, polycarbonates, such as allyl diglycol carbonate, ABS, methylmethacrylate as well cured epoxies, polyurethanes, acrylics, polyesters, and the like. The aggregate material is ground, milled or crushed to the desired particle size for a particular end use. A particularly convenient source for the thermoset polycarbonate aggregate material is crushed lenses from used eyeglasses. Typical particles sizes are in the 150 micron to 1600 micron range and can incorporate any ratio or blend of these particles sizes to optimize application and coefficient of friction characteristics.
[0007] Additionally, the aggregate can comprise plant-based aggregates. Such plant-based aggregates can be, for example, ground up nut shells, including, but not limited to, walnuts, Korean pine nuts, coconuts, etc. The plant-based aggregates can comprise up to 100% plant-based material or may be combined with aggregates/granules made from silica-free geological materials. Preferably the geological minerals have a Moh's hardness value from about 3 to about 7. Suitable examples of geological minerals include, but are not limited to, nephaline syenite and amorphous glass silicates.
[0008] The polymer aggregate can be used as 100% of the aggregate or may be partially or totally replaced with plant-based aggregate. As such, the aggregate comprises between 0-100% polymer aggregate and 0-100% plant-based aggregate, with the percentage of the polymer aggregate and the plant based aggregate summing to 100%.
[0009] The aggregate can be mixed into either, the resin or hardener or both, of the two epoxy components prior to blending the components together to begin the epoxy cure.
[0010] Numerous benefits can be achieved by using the inventive non-skid coating in place of existing non-skid coatings. First, the coatings weigh 15 to 30% less, on an equal volume basis, than current G or L compositions using aluminum or aluminum oxides. Second, the inventive coatings contain significantly reduced levels of heavy metal contamination. This benefit is particularly important due to the ever more restrictive EPA guidelines when the non-skids are removed from the decks and disposed in landfills. These metals include, but are not limited to, the following examples of reduced total metals content over the prior art.
[0000]
Typical Alumiinum
Typical Polymer
Containing Non-Skid
Containing Non-Skid
Total Metals Content
Total Metals Content
Chromium VI
0.0005%
0.00013%
Antimony
0.006%
0.000047%
Arsenic
0.0087%
0.00024%
Beryllium
0.00188%
0.000021%
Cadmium
0.00095%
ND %
Chromium and/or
<0.005%
ND %
Chromium III
Cobalt
<0.001%
0.00044%
Copper
0.0182%
0.0048%
Lead
0.015%
0.00006%
Molybdenum
0.0033%
0.000033%
Mercury
<0.0001%
<0.0001%
Nickel
0.0365%
0.00015%
Selenium
<0.001%
ND %
Silver
0.01%
ND %
Thallium
<0.001%
ND %
Zinc
0.0052%
0.00026%
[0011] Third, the anti-slip properties of the inventive coatings are better because the aggregate particles tend to be angular compared to the generally smooth or spherical particles of aluminum aggregates. Typical improvements in anti-slip coefficient of friction properties are measured using the guidelines of MIL-PRF-24667B for 50 cycles and 500 cycles of the arresting cable are:
[0000]
Typical Aluminum
Typical Polymer
Non skid
Grit Non-Skid
50 Cycles
500 cycles
50 Cycles
500 Cycles
DRY
1.03
0.95
1.20
1.80
WET
0.96
0.92
1.20
1.50
OILY
0.93
0.86
1.10
1.20
[0012] The inventive coatings have been blind tested on carrier fight decks. These tests demonstrated that the inventive coatings have sufficient durability and anti-slip properties, while also being sufficiently nonabrasive to the arresting cables to comply with the requirements for such applications.
[0013] The inventive coatings can be used in any situation where non-skid decks and flooring are required and low-coating weight is desired. Examples include floors in wet environments such as decks and steps on water-going vessels including boats, barges and ships, aircraft carrier flight decks, etc.
[0014] In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms 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.
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An non-skid coating comprising a two-part epoxy and a filler comprising particles of a thermoset resin provides a durable, low-weight, low-abrasive coating for decks and floors, especially for aircraft carrier flight decks. The coating has the further advantage of having lower heavy metal content than current aluminum-based, non-skid coatings.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to Japanese Patent Application No. 2013-069182, filed on Mar. 28, 2013, the content of which is hereby incorporated by reference.
BACKGROUND
[0002] The present disclosure relates to a sewing machine.
[0003] A sewing machine is known that causes a cutting needle attached to a needle bar to automatically rotate. The sewing machine includes a rotation mechanism, which is provided on the cutting needle attached to the needle bar, and a presser bar. The presser bar includes a concave portion that is indented toward an axial line of the presser bar. The rotation mechanism includes a plurality of convex portions that are arranged at equal intervals along the direction of rotation of the cutting needle and that protrude in a direction in which they become separated from the cutting needle. The cutting needle and the plurality of convex portions rotate integrally. The rotation mechanism includes a rotation locking member that locks the rotation of the cutting needle. The rotation locking member locks one of the plurality of convex portions in a position in which it can engage with the concave portion.
[0004] When the sewing machine causes the cutting needle to rotate, the needle bar is lowered in a position in which one of the plurality of convex portions is in a position in which it can engage with the concave portion. After that, the sewing machine moves the needle bar in the horizontal direction. The convex portion that engages with the concave portion rotates around the axial line of the needle bar along with the movement of the needle bar. By this rotation, the sewing machine can automatically cause the cutting needle to rotate.
SUMMARY
[0005] However, with the above-described sewing machine, in an operation to cut a work cloth using the cutting needle by moving the needle bar up and down, it is necessary that the convex portion does not come into contact with the concave portion and a specific gap is provided between the convex portion and the concave portion. As a result, there is a possibility that the cutting needle may not rotate smoothly even if the needle bar is moved in the horizontal direction, due to variations in the dimensions of the above-described members and variations arising in the assembly of each of the members.
[0006] Various embodiments of the general principles described herein provide a sewing machine that each enable rotating a cutting needle stably and automatically.
[0007] Various embodiments herein provide a sewing machine that includes a needle bar driving mechanism, an embroidery frame movement mechanism, a cutting needle rotation mechanism, a processor, and a memory. The needle bar driving mechanism is configured to move a needle bar in a first direction. The embroidery frame movement mechanism is configured to receive an embroidery frame, and is configured to move the embroidery frame along a second direction crossing the first direction. The embroidery frame comprises a protruding portion that protrudes outward from the embroidery frame. The cutting needle rotation mechanism comprises a cutting needle, a cam member, and a support mechanism. The cam member has a fixed cutting needle and comprises a plurality of cams arranged along the first direction and rotatable around the first direction. Each of the plurality of cams comprises a surface portion. The surface portion comprises a width along the first direction and is arranged in different positions along the first direction. The support mechanism is configured to support the cam member on the needle bar rotatably. The memory is configured to store computer-readable instructions that cause the sewing machine to set a height of the needle bar to a specific position from a plurality of positions, each of the plurality of positions representing that each of the plurality of cams is able to contact with the protruding portion, instruct the needle bar driving mechanism to move the needle bar to the specific position, and instruct the embroidery frame movement mechanism to move the embroidery frame along the second direction to a predetermined position where the protruding portion is able to contact with one of the plurality of cams.
[0008] Embodiments also provide a sewing machine that includes a needle bar driving mechanism, an embroidery frame movement mechanism, a cutting needle rotation mechanism, a processor, and a memory. The needle bar driving mechanism is configured to move a needle bar in a first direction. The embroidery frame movement mechanism is configured to receive an embroidery frame and is configured to move the embroidery frame along a second direction and a third direction crossing the first direction. The embroidery frame comprises a plurality of protruding portions. Each of the plurality of the protruding portions is disposed on the embroidery frame along the third direction. Each of the plurality of the protruding portions protrudes outward from the embroidery frame. The cutting needle rotation mechanism comprises a cutting needle, a cam member, and a support mechanism. The cam member has a fixed cutting needle and comprises a plurality of cams arranged along the first direction and rotatable around the first direction. Each of the plurality of cams comprises a surface portion that comprises a width along the first direction and arranged in different positions along the first direction. The support mechanism is configured to support the cam member on the needle bar rotatably. The memory is configured to store computer-readable instruction that causes the sewing machine to instruct the embroidery frame movement mechanism to move the embroidery frame along the second direction and the third direction to a specific position where one of the plurality of protruding portions is able to contact with one of the plurality of cams.
[0009] Embodiments also provide a sewing machine that a needle bar driving mechanism, a cutting needle rotation mechanism, an embroidery frame movement mechanism, a processor, and a memory. The needle bar driving mechanism is configured to move a needle bar in a first direction. The cutting needle rotation mechanism comprises a cutting needle, a base member, and a support member. The base member comprises a protruding member that protrudes along a particular direction to be separated from the needle bar. The support member is configured to support the base member on the needle bar rotatably. The embroidery frame movement mechanism is configured to receive an embroidery frame and is configured to move the embroidery frame along a second direction crossing the first direction. The embroidery frame comprises a plurality of guide portions. Each of the plurality of guide portions is configured to engage with the protruding member. The memory is configured to store computer-readable instructions that cause the sewing machine to set a specific position of the embroidery frame to a predetermined position from a plurality of positions, each of the plurality of positions representing that each of the plurality of guide portions is able to engage with the protruding member, instruct the embroidery frame movement mechanism to move the embroidery frame to the specific position, and instruct the needle bar driving mechanism to move the needle bar in the first direction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] Embodiments will be described below in detail with reference to the accompanying drawings in which:
[0011] FIG. 1 is an example of a perspective view of a sewing machine 1 ;
[0012] FIG. 2 is an example of an enlarged perspective view of the vicinity of a cutting needle rotation mechanism 50 ;
[0013] FIG. 3 is an example of an enlarged right side view of the vicinity of the cutting needle rotation mechanism 50 ;
[0014] FIG. 4 is an example of a perspective view of the cutting needle rotation mechanism 50 ;
[0015] FIG. 5 is an example of an exploded perspective view of the cutting needle rotation mechanism 50 ;
[0016] FIG. 6 is an example of a block diagram showing an electrical configuration of the sewing machine 1 ;
[0017] FIG. 7 is an example of a data configuration diagram of outwork pattern data 100 ;
[0018] FIG. 8 is an example of a data configuration diagram of cam number data 210 ;
[0019] FIG. 9 is an example of a data configuration diagram of drive shaft stop angle data 220 ;
[0020] FIG. 10 is an example of a data configuration diagram of rotation difference amount data 230 ;
[0021] FIG. 11 is an example of a flowchart of cutwork execution processing;
[0022] FIG. 12 is an example of a flowchart of first cutting needle rotation processing;
[0023] FIG. 13 is an example of a perspective view of a contact portion 322 causing a cam 512 to rotate;
[0024] FIG. 14 is an example of a perspective view showing a modified example of an embroidery frame 9 ;
[0025] FIG. 15 is an example of a perspective view of a sewing machine 2 ;
[0026] FIG. 16 is an example of a perspective view of a cutting needle rotation mechanism 60 ;
[0027] FIG. 17 is an example of a plan view of a support portion 700 ;
[0028] FIG. 18 is an example of a perspective view of a guide portion 712 ;
[0029] FIG. 19 is an example of a data configuration diagram of guide portion number data 300 ;
[0030] FIG. 20 is an example of a flowchart of second cutting needle rotation processing; and
[0031] FIG. 21 is an example of a perspective view of a case in which a protruding portion 621 is guided by the guide portion 712 .
DETAILED DESCRIPTION
[0032] Hereinafter, a sewing machine 1 according to a first embodiment of the present disclosure will be explained with reference to the drawings. The sewing machine 1 performs sewing or cut work on a work cloth (not shown in the drawings). The cut work is an operation to form a pattern on the work cloth by cutting out specific areas of the work cloth.
[0033] The configuration of the sewing machine 1 will be explained with reference to FIG. 1 to FIG. 3 . The lower right side, the upper left side, the lower left side, the upper right side, the upper side and the lower side in FIG. 1 correspond, respectively, to the front side, the rear side, the left side, the right side, the upper side and the lower side of the sewing machine 1 . Further, the left-right direction of the sewing machine 1 is an X direction and the front-rear direction of the sewing machine 1 is a Y direction.
[0034] As shown in FIG. 1 , the sewing machine 1 is provided with a bed portion 7 , a pillar 12 , an arm portion 13 and a head portion 14 . The bed portion 7 is a base of the sewing machine 1 and extends in the left-right direction. An embroidery frame movement mechanism 30 , which will be described later, can be detachably mounted on the bed portion 7 . The pillar 12 is provided extending upward from the right end portion of the bed portion 7 . The arm portion 13 extends to the left from the top end portion of the pillar 12 . The head portion 14 is provided on the leading left end of the arm portion 13 . A needle plate 5 is disposed on the top surface of the bed portion 7 . A feed dog (not shown in the drawings), a movement mechanism 85 (refer to FIG. 6 ), a movement motor 80 (refer to FIG. 6 ) and a shuttle mechanism (not shown in the drawings) are provided inside the bed portion 7 below the needle plate 5 . The feed dog moves the work cloth that is placed on the top of the bed portion 7 by a predetermined amount. The movement mechanism 85 drives the feed dog. The movement motor 80 is a pulse motor that drives the movement mechanism 85 . The shuttle mechanism is a mechanism that is structured to form stitches in a sewing workpiece, by moving in concert with a sewing needle, when the sewing needle (not shown in the drawings) is attached to the lower end of the needle bar 6 (which will be described later).
[0035] A vertically long rectangular liquid crystal display 15 is provided on the front surface of the pillar 12 . The liquid crystal display 15 displays images of various items, such as a plurality of types of sewing patterns or cutwork patterns, names of commands to execute various functions, and various messages etc. A transparent touch panel 26 (refer to FIG. 6 ) is provided on the front surface of the liquid crystal display 15 . A user can select or input a desired sewing pattern, a desired cutwork patter or a command to be executed by touching a portion on the touch panel 26 that corresponds to an item displayed on the liquid crystal display 15 , using a finger or a dedicated touch pen.
[0036] The structure of the arm portion 13 will be explained. Operation switches 35 , which include a sewing start switch etc., are provided on the lower portion of the front surface of the arm portion 13 . An opening/closing cover 16 is provided on the upper portion of the arm portion 13 . FIG. 1 shows a state in which the opening/closing cover 16 is closed. The opening/closing cover 16 is axially supported by a rotating shaft (not shown in the drawings) that extends in the left-right direction. The rotating shaft is provided on the upper rear end portion of the arm portion 13 . A thread storage portion (not shown in the drawings) housing a thread spool (not shown in the drawings) that supplies an upper thread (not shown in the drawings) is provided underneath the opening/closing cover 16 , that is, inside the arm portion 13 . The upper thread that extends from the thread spool is supplied to a sewing needle that is not shown in the drawings, via a threading portion that includes a tensioner, a thread take-up spring and a thread take-up lever etc (that are not shown in the drawings). The tensioner is provided on the head portion 14 and adjusts the thread tension. The thread take-up lever is driven to move reciprocatingly in the up-down direction and pulls up the upper thread. A sewing needle (not shown in the drawings) or a cutting needle rotation mechanism 50 can be selectively attached to the lower end of the needle bar 6 (refer to FIG. 3 ) that is provided on the lower portion of the head portion 14 . The sewing needle is attached when the sewing machine 1 performs the sewing operation, and the cutting needle rotation mechanism 50 is attached when the sewing machine 1 performs outwork. The needle bar 6 is driven to move in the up-down direction by a needle bar up-and-down movement mechanism 84 (refer to FIG. 6 ) that is provided inside the head portion 14 . The needle bar up-and-down movement mechanism 84 is driven by a drive shaft 72 (refer to FIG. 6 ) that is rotated by a sewing machine motor 79 (refer to FIG. 6 ). When the drive shaft 72 makes one rotation, the needle bar 6 moves reciprocatingly once in the up-down direction. In other words, the rotation angle of the drive shaft 72 and the position (height) of the needle bar 6 in the up-down direction correspond to each other, and the position of the needle bar 6 in the up-down direction can be determined by detecting the rotation angle of the drive shaft 72 . Further, due to a needle bar swinging mechanism 86 (refer to FIG. 6 ) that is provided inside the head portion 14 , the needle bar 6 can swing in a direction that is orthogonal to a direction (the front-rear direction) in which the work cloth is fed by the feed dog (not shown in the drawings). The needle bar swinging mechanism 86 is driven by a swinging motor 81 (refer to FIG. 6 ).
[0037] As shown in FIG. 2 and FIG. 3 , the cutting needle rotation mechanism 50 is detachably attached to the lower end of the needle bar 6 . The cutting needle rotation mechanism 50 rotatably supports a cutting needle 8 that extends in the up-down direction. When the cutting needle rotation mechanism 50 is attached to the needle bar 6 , the needle bar 6 moves to a position that is highest in a movement range of the needle bar 6 in the up-down direction (hereinafter also referred to as a top needle position). When the cutting needle 8 is used to perform cutwork, a blade portion 89 of the cutting needle 8 is moved from the top side to the bottom side of the work cloth (not shown in the drawings) and forms a specific cut in the work cloth that depends on the orientation of the blade portion 89 . The cutting needle rotation mechanism 50 will be explained in more detail later.
[0038] A presser bar 17 (refer to FIG. 3 ) is provided to the rear of the needle bar 6 . A presser mechanism 90 (refer to FIG. 6 ) that is provided inside the head portion 14 is driven by a presser motor 99 (refer to FIG. 6 ), and the presser bar 17 is thus moved up and down. A presser holder 18 is attached to the lower end of the presser bar 17 . A presser foot 19 , which presses the work cloth, is detachably mounted on the presser holder 18 .
[0039] As shown in FIG. 1 , the embroidery frame movement mechanism 30 includes a main body case 21 that has a flat top surface and a movable case 48 that is disposed on the top side of the main body case 21 . A slit 101 that extends in the left-right direction is provided in a central portion, in the front-rear direction, of the top surface of the main body case 21 . A slit 102 that extends in the left-right direction is provided in the top portion of the front surface of the main body case 21 .
[0040] The movable case 48 has a cuboid shape that is longer in the front-rear direction. The movable case 48 is provided internally with a frame holder (not shown in the drawings), a Y axis movement mechanism 93 (refer to FIG. 6 ) and a Y axis motor 83 (refer to FIG. 6 ). A part of the frame holder is exposed from the movable case 48 and an embroidery frame 9 can be detachably mounted on the frame holder. The embroidery frame 9 holds the work cloth. The work cloth held by the embroidery frame 9 is placed on the top of the bed portion 7 and below the needle bar 6 (refer to FIG. 3 ) and the presser foot 19 (refer to FIG. 2 ). The embroidery frame 9 will be explained in more detail later. The Y axis movement mechanism 93 is a mechanism that moves the frame holder in the front-rear direction (the Y direction). The embroidery frame 9 that holds the work cloth moves in the front-rear direction by the frame holder being moved in the front-rear direction. The Y axis motor 83 drives the Y axis movement mechanism 93 .
[0041] The main body case 21 is provided internally with an X axis movement mechanism 92 (refer to FIG. 6 ) and an X axis motor 82 (refer to FIG. 6 ). The X axis movement mechanism 92 moves the movable case 48 in the left-right direction (the X direction). A support portion (not shown in the drawings) that supports the movable case 48 passes through each of the slits 101 and 102 and is coupled to the X axis movement mechanism 92 . The embroidery frame 9 that holds the work cloth moves in the left-right direction by the movable case 48 being moved in the left-right direction. The X axis motor 82 drives the X axis movement mechanism 92 .
[0042] The structure of the cutting needle rotation mechanism 50 will be explained with reference to FIG. 4 and FIG. 5 . As shown in FIG. 4 , the cutting needle rotation mechanism 50 includes a support mechanism 40 , a cam member 51 and the cutting needle 8 . The support mechanism 40 is attached to the lower end of the needle bar 6 (refer to FIG. 3 ). The support mechanism 40 supports the cam member 51 such that the cam member 51 can rotate around the axial line of the needle bar 6 . Further, the upper end of the cutting needle 8 is fixed to the lower end of the cam member 51 . The axial line of the cutting needle 8 is aligned with the axial line of the needle bar 6 (refer to FIG. 3 ).
[0043] As shown in FIG. 5 , the support mechanism 40 includes a support member 41 , a rotation member 43 and a plate spring 44 . The support member 41 is formed of a synthetic resin material and is a substantially cylindrical shape that extends in the up-down direction. The axial line of the support member 41 is aligned with the axial line of the cutting needle 8 . The support member 41 includes a first support portion 411 and a second support portion 412 . The second support portion 412 extends downward from the lower end of the first support portion 411 . The outer diameter of the second support portion 412 is smaller than the outer diameter of the first support portion 411 . The first support portion 411 has a spindle 413 , engagement receiving portions 414 and a groove portion 415 . The spindle 413 is a shaft that extends upward from a central portion of the upper end surface of the first support portion 411 . The spindle 413 is a metal shaft and is fixed to the first support portion 411 such that the spindle 413 cannot rotate. The axial line of the spindle 413 is aligned with the axial line of the support member 41 . The upper end of the spindle 413 is attached to the needle bar 6 (refer to FIG. 3 ). A flat surface portion 417 is formed on the spindle 413 and the spindle 413 is attached to the needle bar 6 such that the flat surface portion 417 is parallel to a specific direction (the left-right direction in FIG. 5 ). With the above-described structure, the cutting needle rotation mechanism 50 is attached to the needle bar 6 with a specific orientation. The engagement receiving portions 414 are circular holes that are provided in an outer peripheral portion of the first support portion 411 . The eight engagement receiving portions 414 are arranged every 45 degrees in a plan view, in the circumferential direction of the outer peripheral portion. The groove portion 415 is formed along the outer peripheral portion of the first support portion 411 and is a groove portion that joins the mutually adjacent engagement receiving portions 414 . The second support portion 412 has a concave portion 416 . The concave portion 416 is formed on the top end of the second support portion 412 , in the circumferential direction of an outer peripheral portion.
[0044] The rotation member 43 is made of a synthetic resin and is a substantially cylindrical shape that extends in the up-down direction. The axial line of the rotation member 43 is aligned with the axial line of the support member 41 . An insertion hole 433 is formed in the upper end of the rotation member 43 . The insertion hole 433 is a hole that is substantially circular in a plan view and that extends downward from the top end surface of the rotation member 43 . The inner diameter of the insertion hole 433 is slightly larger than the outer diameter of the second support portion 412 . The second support portion 412 is inserted into the insertion hole 433 . The insertion hole 433 is surrounded by an outer peripheral portion 435 of the rotation member 43 . Four cut-out portions, which are cut out from the top toward the bottom, are arranged on the top end of the outer peripheral portion 435 , each of the cut-out portions being arranged at equal intervals along the circumferential direction of the outer peripheral portion 435 . The top end of the outer peripheral portion 435 is divided up by the four cut-out portions and each of the divided portions has a convex portion 432 that protrudes toward the inner side. The top end of the outer peripheral portion 435 can be elastically deformed in the radial direction. Each of the convex portions 432 fits with the concave portion 416 . The inner dimension of each of the four convex portions 432 is slightly smaller than the outer diameter of the lower end of the second support portion 412 , and slightly larger than the outer diameter of the outer peripheral portion of the portion of the second support portion 412 on which the concave portion 416 is formed. Here, when the rotation member 43 is assembled on the support member 41 , the second support portion 412 is inserted into the insertion hole 433 . At the time of insertion, the top end of the outer peripheral portion 435 deforms elastically and spreads to the outer side, and the convex portions 432 pass the lower portion of the second support portion 412 . After that, when a position is reached in which each of the convex portions 432 fits with the concave portion 416 , the divided portions of the top end of the outer peripheral portion 435 that were elastically deformed each return to their original shape. As described above, the movement of the rotation member 43 in the up-down direction is locked by the so-called snap fit of the convex portions 432 in the concave portion 416 , and the rotation member 43 is then able to rotate around the axial line. With the above-described structure, the rotation member 43 is rotatably supported by the support member 41 .
[0045] The plate spring 44 is a thin plate-shaped elastic member having a rectangular shape that is long in the up-down direction. A hole 441 is formed on the lower side (a base end side) of the plate spring 44 . The hole 441 is aligned with the position of a screw hole 434 that is formed in the rotation member 43 , and the plate spring 44 is fixed to the rotation member 43 by being fixed by a screw 45 . An engagement portion 442 is formed on the upper side (a leading end side) of the plate spring 44 . The engagement portion 442 is a convex portion that protrudes from the leading end of the plate spring 44 toward the axial line of the rotation member 43 (to the rear in FIG. 5 ). The engagement portion 442 engages with one of the eight engagement receiving portions 414 .
[0046] The plate spring 44 imparts an urging force in a direction in which the engagement portion 442 engages with the engagement receiving portion 414 (a direction toward the axial line of the support member 41 ). As a result, the rotation of the rotation member 43 (to which the plate spring 44 is fixed) around its axial line is locked with respect to the support member 41 .
[0047] The cam member 51 is a member that extends downward from a central portion of the lower end surface of the rotation member 43 . The cam member 51 rotates integrally with the rotation member 43 . The axial line of the cam member 51 is aligned with the axial line of the rotation member 43 . The cam member 51 has cams 511 to 514 and a shaft hole (not shown in the drawings).
[0048] Each of the cams 511 to 514 is substantially elliptical in a plan view, each having a width in the up-down direction and each having mutually the same shape. The cams 511 to 514 are formed integrally such that they overlap with one another in the up-down direction. The centers of the cams 511 to 514 are all positioned on the axial line of the cam member 51 .
[0049] In a rotation direction that is centered on the axial line of the cam member 51 , the longitudinal direction of each of the cams 511 to 514 is displaced by 45 degrees, in a plan view, with respect to the mutually adjacent cam. When the left-right direction is taken as reference and the counter-clockwise direction is taken as a positive direction in the plan view, all the angles in the longitudinal direction of each of the cams 511 to 514 (hereinafter referred to as the “longitudinal direction angle”) are different. In FIG. 4 and FIG. 5 , the longitudinal direction angle of the cam 511 is 90 degrees, the longitudinal direction angle of the cam 512 is 135 degrees, the longitudinal direction angle of the cam 513 is zero degrees and the longitudinal direction angle of the cam 514 is 45 degrees. The cams 511 to 514 rotate integrally. In first cutting needle rotation processing that will be described later, the cams 511 to 514 rotate in the clockwise direction in the plan view and the longitudinal direction angle of each of the cams 511 to 514 thus changes every 45 degrees.
[0050] The cam 511 is provided with a contact receiving portion 611 . Similarly, the cam 512 is provided with a contact receiving portion 612 , the cam 513 is provided with a contact receiving portion 613 and the cam 514 is provided with a contact receiving portion 614 . Each of the contact receiving portions 611 to 614 is formed of a pair of side wall portions that are symmetric with respect to the axial line of each of the cams 511 to 514 . Each of the contact receiving portions 611 to 614 extends in the longitudinal direction of each of the cams 511 to 514 . That is, the longitudinal direction of each of the contact receiving portions 611 to 614 is displaced by 45 degrees with respect to the adjacent one of the contact receiving portions 611 to 614 , in the rotational direction around the axial line of the cam member 51 . As will be described later, a contact portion 322 that is provided on the embroidery frame 9 comes into contact with one of the contact receiving portions 611 to 614 .
[0051] The shaft hole (not shown in the drawings) is formed in a substantially D shape in a bottom view and extends upward from the bottom end surface of the cam member 51 . As will be described later, the top end of the cutting needle 8 is inserted into the shaft hole. A screw hole 544 is provided in the lower end of the outer peripheral wall of the cam member 51 and communicates with the shaft hole.
[0052] The cutting needle 8 extends in the up-down direction and the lower end of the cutting needle 8 has the blade portion 89 that cuts out the work cloth. The blade portion 89 has a width in a direction that is orthogonal to the axial line of the cutting needle 8 . The upper end of the cutting needle 8 has a substantially D shape in a plan view and is provided with a flat surface portion 95 that extends in parallel with the axial direction. The upper end of the cutting needle 8 is inserted into the shaft hole of the cam member 51 and is fixed to the cam member 51 in a state in which the flat surface portion 95 is pressed by the leading end of a screw 20 that is screwed into the screw hole 544 . With the above-described structure, the cutting needle 8 rotates integrally with the cam member 51 . The direction in which the blade portion 89 extends (hereinafter referred to as the width direction) is a specific direction (the left-right direction in FIG. 5 ).
[0053] Next, the embroidery frame 9 will be explained with reference to FIG. 1 and FIG. 2 . The embroidery frame 9 has a known structure and is provided with an outer frame, an inner frame and an adjusting screw that is provided on the outer frame in order to adjust the size of the embroidery frame 9 . However, for convenience of explanation in the present embodiment, the inner frame and the adjusting screw are not illustrated in the drawings and only the outer frame is illustrated. The embroidery frame 9 is formed as a ring that is substantially rectangular in a plan view. On the embroidery frame 9 , a protruding portion 320 that protrudes upward is provided on a central portion, in the front-rear direction, of a right side portion of an outer frame 91 . The protruding portion 320 includes a support portion 321 and a contact portion 322 . The support portion 321 protrudes upward from the top surface of the central portion of the outer frame 91 . The contact portion 322 is a substantially rectangular plate shape that is longer in the left-right direction in a plan view, and extends to the right from the top end of the support portion 321 . The support portion 321 supports the contact portion 322 . The width of the contact portion 322 in the up-down direction is substantially the same as the width of each of the cams 511 to 514 in the up-down direction.
[0054] When the first cutting needle rotation processing that will be described later is performed, a CPU 151 (refer to FIG. 6 ) moves the embroidery frame 9 such that the contact portion 322 of the embroidery frame 9 comes into contact with and presses the cam member 51 . When the contact portion 322 comes into contact with and presses the cam member 51 , the cam member 51 rotates by 45 degrees. As a result of the above-mentioned processing, the width direction of the blade portion 89 of the cutting needle 8 also extends in the direction in which the cam member 51 has rotated by 45 degrees. Further, before the cutwork operation is started, the embroidery frame 9 is in a position in which the contact portion 322 is separated to the left from the cam member 51 . Hereinafter, this position is referred to as a withdrawn position.
[0055] An electrical configuration of the sewing machine 1 will be explained with reference to FIG. 6 . A control portion 105 of the sewing machine 1 is provided with the CPU 151 , a ROM 152 , a RAM 153 , a flash memory 64 and an input/output interface 66 . The CPU 151 , the ROM 152 , the RAM 153 , the flash memory 64 and the input/output interface 66 are electrically connected to each other via a bus 67 . Various programs, including programs for the CPU 151 to execute cutwork execution processing and the first cutting needle rotation processing to be explained later, are stored in the ROM 152 . Various information that is processed by the programs is temporarily stored in the RAM 153 .
[0056] The flash memory 64 includes a cutwork data storage area 641 , a cam number data storage area 642 , a cutting needle angle storage area 643 , a drive shaft stop angle storage area 644 and a rotation difference amount storage area 645 etc. Each of the storage areas will be explained in more detail later.
[0057] Cutting needle angles of the cutting needle 8 that are referred to in the cutwork execution processing (to be explained later) are stored in the cutting needle angle storage area 643 . Here, the cutting needle angle is an angle formed in a plan view between the width direction of the blade portion 89 of the cutting needle 8 and a reference direction (the left-right direction). The cutting needle angle is zero degrees when the width direction of the blade portion 89 extends in the left-right direction (a state of the blade portion 89 shown in FIG. 2 ), and in a plan view in FIG. 2 , the counterclockwise direction is the positive direction. The cutting needle angle of the cutting needle 8 that is initially attached to the needle bar 6 is zero degrees, and an initial value of the cutting needle angle stored in the cutting needle angle storage area 643 is also “0 degrees.”
[0058] As shown in FIG. 6 , the operation switches 35 , the touch panel 26 , a detection portion 27 and drive circuits 70 to 76 are electrically connected to the input/output interface 66 . The detection portion 27 detects a type of the embroidery frame that is mounted on the frame holder (not shown in the drawings). Although not shown in the drawings, the sewing machine 1 is provided with a plurality of types of the embroidery frame. The detection portion 27 detects at least which of the embroidery frame 9 and an embroidery frame 10 that will be explained later is mounted on the frame holder, and transmits a detection result to the CPU 151 via the input/output interface 66 . The drive circuits 70 to 76 drive the presser motor 99 , the sewing machine motor 79 , the movement motor 80 , the swinging motor 81 , the X axis motor 82 , the Y axis motor 83 and the liquid crystal display 15 , respectively.
[0059] An encoder 77 is a detector that detects a rotation angle of the drive shaft 72 . The encoder 77 detects the rotation angle of the drive shaft 72 and transmits the detected rotation angle to the CPU 151 via the input/output interface 66 .
[0060] Cutwork pattern data 100 will be explained with reference to FIG. 7 . The cutwork pattern data 100 is stored in the cutwork data storage area 641 (refer to FIG. 6 ). The cutwork pattern data 100 is data that is referred to by the CPU 151 in the cutwork execution processing and the first cutting needle rotation processing that will be explained later. The blade portion 89 of the cutting needle 8 has the width that is orthogonal to the axial line of the cutting needle 8 (the left-right direction in FIG. 4 ). Thus, the direction of a cut formed in the work cloth (not shown in the drawings) by the cutting needle 8 is the same as the width direction. As a result, when the work cloth is cut using the cutting needle 8 along a contour of a specific pattern that is formed of a curved line, for example, along with moving the embroidery frame 9 in the X direction and the Y direction, it is necessary to rotate the cutting needle 8 and change the direction of the cuts formed in the work cloth. The cutwork pattern data 100 is data to generate a specific pattern etc. by cutting out the work cloth. The cutwork pattern data 100 is stored in the cutwork data storage area 641 for each cutwork pattern that is formed in the work cloth by the sewing machine 1 .
[0061] The cutwork pattern data 100 includes a needle drop number N, X coordinate data, Y coordinate data and cutting needle angle data, and each of the data items are stored in association with each other. The needle drop number N is a variable that indicates an order in which the work cloth is cut. “CUT_END” that is noted in the lowest column of the needle drop number N is a final number of the needle drop number N and is a number such as 200 or 300 etc. In the following explanation, “CUT_END” is a maximum value of the needle drop number N of the cutwork pattern data 100 . The X coordinate data and the Y coordinate data are data of coordinates of needle drop points (points at which a center portion of the blade portion 89 pierces the work cloth) in an embroidery coordinate system that is specific to the sewing machine 1 and that is set in advance. It should be noted that a position at which a center point of the embroidery frame 9 is aligned with a needle drop point is an origin point of the embroidery coordinate system. The cutting needle angle data is data indicating the cutting needle angle of the cutting needle 8 .
[0062] The cam number data 210 will be explained with reference to FIG. 8 . The cam number data 210 is stored in the cam number data storage area 642 . The cam number data 210 is data that is referred to by the CPU 151 in the first cutting needle rotation processing that will be explained later. The cam number data 210 includes cutting needle angle difference data and data of a current cutting needle angle. Here, the cutting needle angle difference refers to a value that is obtained by subtracting the cutting needle angle of the cutting needle 8 at a present time (hereinafter referred to as a “current cutting needle angle”) from a cutting needle angle of the cutting needle 8 that is desired to be set (hereinafter referred to as a “set cutting needle angle”). The data of the current cutting needle angle further includes a number of contacts P. As described above, in the cam number data 210 , data of the contact cam number is stored in association with each item of the cutting needle angle difference data, the current cutting needle angle and the number of contacts P. The data of the contact cam number is “1” to “4” and corresponds to each of the cams 511 to 514 . The cutting needle angle difference data is “45 degrees,” “90 degrees” and “135 degrees.” The current cutting needle angle data is “0 degrees,” “45 degrees,” “90 degrees” and “135 degrees.” The cutting needle angle difference data only has three values because the cutting needle 8 only rotates by 45 degrees at a time and when the cutting needle angle is 180 degrees, that is the same as 0 degrees. The number of contacts P is divided into “P=1,” “P=2” and “P=3” for each of the current cutting needle angle data. The number of contacts P is 1 to 3 because the cutting needle 8 only rotates by 45 degrees at a time and when the cutting needle 8 performs four rotations, the cutting needle angle becomes 180 degrees, which means that the cutting needle angle is essentially 0 degrees.
[0063] Drive shaft stop angle data 220 that is stored in the drive shaft stop angle storage area 644 (refer to FIG. 6 ) will be explained with reference to FIG. 9 . The drive shaft stop angle data 220 is data that is referred to by the CPU 151 in the first cutting needle rotation processing that will be explained later. In the drive shaft stop angle data 220 , a cam number M and drive shaft stop angle data are stored in association with each other. The cam numbers M 1 to 4 correspond to the cams 511 to 514 , respectively. The drive shaft stop angle data 220 is data indicating a rotation angle at which the drive shaft 72 stops, and is data that is used to stop the needle bar 6 at a position at which the contact portion 322 is the same height as the contact receiving portion of the cam that corresponds to the cam number M.
[0064] Rotation difference amount data 230 that is stored in the rotation difference amount storage area 645 (refer to FIG. 6 ) will be explained with reference to FIG. 10 . The rotation difference amount data 230 is data that is referred to by the CPU 151 in the first cutting needle rotation processing that will be explained later. As will be described later, when the CPU 151 causes the contact portion 322 to successively come into contact with the cams 511 to 514 , the CPU 151 refers to the rotation difference amount data 230 . Here, the rotation difference amount data 230 is data of a rotation amount of the drive shaft 72 that is used to move and stop the needle bar 6 such that, after the contact portion 322 has come into contact with one of the cams 511 to 514 , the contact portion 322 is at a height at which it can come into contact with another of the cams 511 to 514 . In the rotation difference amount data 230 , data of the rotation difference amount is set and stored in association with each of the current cam number M and the cam number M with which contact will next be caused (hereinafter referred to as the next contact cam number M). The current cam number M is the number of the cam that was in contact with the contact portion 322 immediately before. The numbers 1 to 4 of the current cam numbers M correspond to the cams 511 to 514 , respectively. When the contact portion 322 comes successively into contact with the cams 511 to 514 , the next contact cam number M is the number of the cam that will next come into contact with the contact portion 322 . The numbers 1 to 4 of the next contact cam numbers M correspond to the cams 511 to 514 , respectively.
[0065] The cutwork execution processing that is performed by the CPU 151 will be explained with reference to FIG. 11 . The cutwork execution processing is started when the power source of the sewing machine 1 is turned on and the user inputs a command using the operation switches 35 and the touch panel 26 etc. When the CPU 151 of the sewing machine 1 detects the input of the start command of the cutwork execution processing, the CPU 151 reads the program to perform the cutwork execution processing from the ROM 152 (refer to FIG. 6 ) into the RAM 153 . Then, the CPU 151 performs each step of the processing as explained below, in accordance with instructions included in the program. The user uses the operation switches 35 and the touch panel 26 etc. to select the cutwork pattern to be made on the work cloth (not shown in the drawings), and commands the cutwork to be executed.
[0066] In the cutwork execution processing, first the CPU 151 acquires the cutwork pattern data 100 (step S 11 ). The CPU 15 refers to the cutwork data storage area 641 , and acquires the cutwork pattern data 100 associated with the cutwork pattern selected by the user. The CPU 151 sets the needle drop number N to “1” (step S 13 ). The set needle drop number N is stored in the RAM 153 . Next, the CPU 151 performs the first cutting needle rotation processing (step S 15 ).
[0067] The first cutting needle rotation processing will be explained with reference to FIG. 12 . The first cutting needle rotation processing is processing to match the angle indicated by the cutting needle angle data stored in association with the needle drop number N in the cutwork pattern data 100 (refer to FIG. 7 ) acquired at step S 11 with the cutting needle angle of the cutting needle 8 .
[0068] In the first cutting needle rotation processing, first the CPU 151 acquires the current cutting needle angle of the cutting needle 8 (step S 30 ). The CPU 151 refers to the cutting needle angle storage area 643 (refer to FIG. 6 ) and acquires the cutting needle angle stored therein. The CPU 151 determines whether the current cutting needle angle is the same as the cutting needle angle associated with the needle drop number N in the cutwork pattern data 100 (step S 31 ) The CPU 151 refers to the cutwork pattern data 100 stored in the cutwork data storage area 641 (refer to FIG. 6 ), acquires the cutting needle angle associated with the needle drop number N, and compares the acquired cutting needle angle with the current cutting needle angle acquired at step S 30 . When the current cutting needle angle and the cutting needle angle associated with the needle drop number N are the same (yes at step S 31 ), the CPU 151 ends the first cutting needle rotation processing and returns the processing to the cutwork execution processing (refer to FIG. 11 ).
[0069] When the cutting needle angle data acquired from the cutting needle angle storage area 643 is “0 degrees,” for example (step S 30 ), and the needle drop number N is “1,” the cutting needle angle data stored in the cutwork pattern data 100 is also “0 degrees” (yes at step S 31 ). In this case, the first cutting needle rotation processing is ended.
[0070] As shown in FIG. 11 , after the first cutting needle rotation processing is ended, the CPU 151 performs the cutwork of one stitch associated with the needle drop number N (step S 17 ). After the cutwork is performed, the sewing machine motor 79 drives the needle bar up-and-down movement mechanism 84 (refer to FIG. 6 ) until the needle bar 6 (that is, the cutting needle 8 ) moves to the top needle position. For example, when the needle drop number N is “1,” in the cutwork pattern data 100 , the X coordinate data of the needle drop point is “x1” and the Y coordinate data is “y1” as shown in FIG. 7 . The CPU 151 therefore controls the drive circuits 74 and 75 , drives the X axis motor 82 and the Y axis motor 83 , and moves the embroidery frame 9 such that the needle drop point is at the X coordinate “x1” and the Y coordinate “y1.” Then the CPU 151 controls the drive circuit 71 , drives the sewing machine motor 79 , and lowers the needle bar 6 . As a result of the above-described processing, the cutwork is performed in which the blade portion 89 of the cutting needle 8 cuts the work cloth. The CPU 151 controls the drive circuit 71 and drives the sewing machine motor 79 , and thus drives the needle bar up-and-down movement mechanism 84 (refer to FIG. 6 ) until the cutting needle 8 moves to the top needle position.
[0071] Next, the CPU 151 determines whether the needle drop number N is “CUT_END” (step S 19 ). The CPU 151 performs the determination by referring to the needle drop number N stored in the RAM 153 , and then comparing this needle drop number N to the needle drop number N “CUT_END” of the cutwork pattern data 100 that is stored in the cutwork data storage area 641 (refer to FIG. 6 ).
[0072] When it is determined that the needle drop number N is not “CUT_END” (no at step S 19 ), the CPU 151 increments the needle drop number N (step S 21 ), and the incremented needle drop number N is stored in the RAM 153 . After this, the CPU 151 returns the processing to step S 15 . For example, when the needle drop number N is “1” (no at step S 19 ), the needle drop number N is incremented to “2” (step S 21 ).
[0073] When the needle drop number N is “CUT_END” (yes at step S 19 ), the CPU 151 overwrites and stores the current cutting needle angle in the cutting needle angle storage area 643 (step S 23 ).
[0074] For example, when the needle drop number N is “CUT_END” (yes at step S 19 ), the cutting needle angle data in the cutwork pattern data 100 is “0 degrees” (refer to FIG. 7 ) and the current cutting needle angle is 0 degrees. The CPU 151 sets the current cutting needle angle as “0 degrees,” overwrites the cutting needle angle stored in the cutting needle angle storage area 643 , and stores the current cutting needle angle (step S 23 ).
[0075] Next, the CPU 151 controls the drive circuits 74 and 75 , drives the X axis motor 82 and the Y axis motor 83 , thus moving the embroidery frame 9 to the withdrawn position (step S 25 ). After the embroidery frame 9 has been moved to the withdrawn position, the CPU 151 ends the cutwork execution processing. Note that, when the cutwork execution processing is ended, the cutting needle 8 is in the top needle position.
[0076] In the first cutting needle rotation processing shown in FIG. 12 , in a case in which the current cutting needle angle is different to the cutting needle angle associated with the needle drop number N in the cutwork pattern data 100 (refer to FIG. 7 ), an explanation will be made when the needle drop number N is “2.” When it is determined that the current cutting needle angle and the cutting needle angle associated with the needle drop number N are different (no at step S 31 ), the CPU 151 acquires a cutting needle angle difference (step S 32 ). The CPU 151 refers to the cutwork pattern data 100 stored in the cutwork data storage area 641 (refer to FIG. 6 ), and thus acquires the cutting needle angle associated with the needle drop number N. The CPU 151 subtracts the value of the current cutting needle angle acquired at step S 30 from the acquired cutting needle angle associated with the needle drop number N, and thus acquires the cutting needle angle difference.
[0077] For example, when the needle drop number N is “2,” at step S 17 of the cutwork execution processing (refer to FIG. 11 ), the CPU 151 has completed the cutwork for one stitch when the needle drop number N is “1.” As shown in FIG. 7 , when the needle drop number N is “1,” the corresponding cutting needle angle data is “0 degrees.” Specifically, the current cutting needle angle of the cutting needle 8 is 0 degrees. When the needle drop number N is “2,” the corresponding cutting needle angle data is “45 degrees,” and is different to the current cutting needle angle (no at step S 31 ). The set cutting needle angle is 45 degrees. Thus, the CPU 151 subtracts the current cutting needle angle (0 degrees) from the set cutting needle angle (45 degrees) and thereby acquires 45 degrees as the cutting needle angle difference (step S 32 ).
[0078] As shown in FIG. 12 , the CPU 151 next sets “1” as the number of contacts P (step S 33 ) and stores the set number of contacts P in the RAM 153 . After that, the CPU 151 acquires the next contact cam number M (step S 34 ). For example, when the needle drop number N is “2,” as described above, the current cutting needle angle is “0 degrees” and the cutting needle angle difference acquired at step S 32 is “45 degrees.” Further, the number of contacts P is “1” (step S 33 ). In this case, as shown in FIG. 8 , in the cam number data 210 , the cam number “2” is stored in association with the cutting needle angle difference “45 degrees,” the current cutting needle angle “0 degrees” and the number of contacts P “1.” Thus, the CPU 151 acquires “2” as the next contact cam number M (step S 34 ).
[0079] Next, the CPU 151 controls the drive circuits 74 and 75 , drives the X axis motor 82 and the Y axis motor 83 , and lowers the embroidery frame 9 to the withdrawn position (step S 35 ). For example, when the needle drop number N is “2,” at step S 17 of the cutwork execution processing (refer to FIG. 11 ), the CPU 151 has completed the cutwork for one stitch when the needle drop number N is “1.” As shown in FIG. 7 , when the needle drop number N is “1,” the X coordinate data of the corresponding needle drop point is “x1,” and the Y coordinate data is “y1.” In other words, the embroidery frame 9 is not in the withdrawn position and therefore the CPU 151 controls the drive circuits 74 and 75 and moves the embroidery frame 9 to the withdrawn position (step S 35 ).
[0080] Next, the CPU 151 determines whether the needle bar 6 (that is, the cutting needle 8 ) is in the top needle position (step S 38 ). The CPU 151 determines whether the cutting needle 8 is in the top needle position, based on a signal output from the encoder 77 (refer to FIG. 6 ). When it is determined that the cutting needle 8 is in the top needle position (yes at step S 38 ), the CPU 151 refers to the drive shaft stop angle data 220 that is stored in the drive shaft stop angle storage area 644 (refer to FIG. 6 ), and thus acquires the drive shaft stop angle data associated with the cam number M acquired at step S 34 (step S 39 ).
[0081] For example, when the needle drop number N is “2” and the number of contacts P is 1, by the processing by the CPU 151 at step S 17 of the cutwork execution processing (refer to FIG. 11 ), the cutting needle 8 is in the top needle position (yes at step S 38 ). As described above, when the needle drop number N is “2,” the next contact cam number M acquired at step S 34 is “2.” In this case, as shown in FIG. 9 , a drive shaft stop angle “A2” that is stored in the drive shaft stop angle data 220 is acquired (step S 39 ). The contact receiving portion of the cam associated with the next contact cam number M “2” is the contact receiving portion 612 (refer to FIG. 5 ). Specifically, the drive shaft stop angle “A2” is set to move and stop the needle bar 6 such that the contact receiving portion 612 is at a height at which it can come into contact with the contact portion 322 (refer to FIG. 3 ).
[0082] Next, the CPU 151 controls the drive circuit 71 , drives the sewing machine motor 79 such that the rotation angle of the drive shaft 72 is the drive shaft stop angle “A2” acquired at step S 39 , and moves the needle bar 6 (step S 43 ).
[0083] Next, the CPU 151 controls the drive circuit 74 , drives the X axis motor 82 , and moves the embroidery frame 9 toward the right (the direction of an arrow A shown in FIG. 13 ) (step S 49 ). By this movement, the contact portion 322 comes into contact with and presses the contact receiving portion 612 of the cam 512 that corresponds to the cam number M “2” acquired at step S 34 . More specifically, the contact portion 322 presses a portion of the contact receiving portion 612 that is to the front and the right of the cutting needle 8 to the right. By this pressing, the contact portion 322 causes the cam 512 to rotate in the counter-clockwise direction (the direction of an arrow B) in a plan view, around the axial line of the cam member 51 . The cam member 51 , the cutting needle 8 , the rotation member 43 and the plate spring 44 also rotate integrally with the rotation of the cam 512 . When the plate spring 44 rotates, the engagement portion 442 resists the urging force imparted by the plate spring 44 , is displaced from the engagement receiving portion 414 with which it was engaged, and moves along the groove portion 415 while rotating in the counter-clockwise direction in a plan view (in the direction of the arrow B). The engagement portion 442 engages with the engagement receiving portion 414 that is adjacent to the engagement receiving portion 414 with which it was hitherto engaged (hereinafter referred to as the next engagement receiving portion 414 ). By the above-described processing, the plate spring 44 once more imparts an urging force in the direction in which the engagement portion 442 engages with the next engagement receiving portion 414 (in the direction toward the axial line of the support member 41 ). By this urging, the rotation of the cam member 51 , the cutting needle 8 and the rotation member 43 is locked. After the rotation of the rotation member 43 , the angles in the longitudinal direction of the cams 511 to 514 are 135 degrees, 0 degrees, 45 degrees and 90 degrees, respectively.
[0084] As shown in FIG. 12 , the CPU 151 next increments the number of contacts P (step S 54 ), and stores the incremented value P in the RAM 153 . After that, the CPU 151 determines whether the processing is complete (step S 55 ). The CPU 151 refers to the cam number data 210 (refer to FIG. 8 ) stored in the cam number data storage area 642 (refer to FIG. 6 ), and determines that the processing is complete when the cam number M associated with the current cutting needle angle acquired at step S 30 , the cutting needle angle difference acquired at step S 32 and the number of contacts P incremented at step S 54 is “_”. The CPU 151 further determines that the processing is complete when the number of contacts P is “4.” When it is determined that the processing is complete (yes at step S 55 ), the CPU 151 ends the first cutting needle rotation processing and returns the processing to the cutwork execution processing (refer to FIG. 11 ).
[0085] When the needle drop number N is “2,” for example, as described above, the current cutting needle angle acquired at step S 30 is “0 degrees” and the cutting needle angle difference acquired at step S 32 is “45 degrees.” When the number of contacts P is incremented from “1” to “2” (step S 54 ), in the cam number data 210 , the cam number associated with the cutting needle angle difference “45 degrees,” the current cutting needle angle “0 degrees” and the number of contacts P “2” is “-,” as shown in FIG. 8 . It is therefore determined that the processing is complete (yes at step S 55 ) and the CPU 151 ends the first cutting needle rotation processing.
[0086] Next, a case will be explained in which the execution of the first cutting needle rotation processing is started and it is determined at step S 55 that the processing is not complete. In the following explanation, it is assumed that the needle drop number N is “3.” When the needle drop number N is “3,” the outwork of one stitch has been performed when the needle drop number N is “2” at step S 17 in the cutwork execution processing (refer to FIG. 11 ). In the cutwork pattern data 100 (refer to FIG. 7 ), when the needle drop number N is “2,” the cutting needle angle data is “45 degrees,” and when the needle drop number N is. “3,” the cutting needle angle data is “135 degrees.” Therefore, the current cutting needle angle acquired at step S 30 is “45 degrees.” Further, the cutting needle angle difference acquired at step S 32 is “90 degrees,” which is obtained by subtracting 45 degrees from 135 degrees. In addition, in the cam number data 210 shown in FIG. 8 , the cam number data associated with the current cutting needle angle “45 degrees,” the cutting needle angle difference “90 degrees” and the number of contacts P “1” is “1.” As a result, the contact cam number M acquired at step S 34 is “1.”
[0087] When the needle drop number N is “3,” at step S 17 of the cutwork execution processing (refer to FIG. 11 ), the cutwork of the one stitch associated with the needle drop number N of “2” has already been performed, and the needle drop number N is incremented at step S 21 . After that, the execution of the first cutting needle rotation processing is started once more. In this case, the processing from step S 30 to step S 54 is the same as in the above explanation.
[0088] As shown in FIG. 12 , the CPU 151 determines whether the processing is complete (step S 55 ). When the needle drop number N is “3,” for example, as described above, the current cutting needle angle acquired at step S 30 is “45 degrees,” and the cutting needle angle difference acquired at step S 32 is “90 degrees.” As shown in FIG. 8 , in the cam number data 210 , the cam number associated with the current cutting needle angle “45 degrees,” the cutting needle angle difference “90 degrees” and the number of contacts P “2” that is incremented at step S 54 is “4” and is not “-.” Further, the incremented number of contacts P is “2” and is not “4.” As a result, it is determined that the processing is not complete (no at step S 55 ).
[0089] Next, the CPU 151 acquires the current cam number M (step S 57 ). The CPU 151 acquires the next contact cam number M (acquired at step S 34 ) as the current cam number. As described above, the cam number already acquired at step S 34 is “1,” for example. Therefore, the current cam number M is acquired as “1.”
[0090] The CPU 151 acquires the next contact cam number of the current cam number (step S 34 ). For example, in the cam number data 210 shown in FIG. 8 , the cam number associated with the current cutting needle angle “45 degrees,” the cutting needle angle difference “90 degrees” and the number of contacts P “2” is “4.” Thus, “4” is acquired as the next contact cam number M (step S 34 ).
[0091] Next, the CPU 151 performs step S 35 . This processing is the same as in the explanation above and an explanation is therefore omitted here.
[0092] Next, the CPU 151 determines whether the cutting needle 8 is in the top needle position (step S 38 ). When it is determined that the cutting needle 8 is not in the top needle position (no at step S 38 ), the CPU 151 advances the processing to step S 40 . For example, when the needle drop number N is “3” and the number of contacts P is “2,” the CPU 151 has already performed the processing associated with the number of contacts P “1.” In other words, the contact portion 322 is positioned at the height in which it can come into contact with the contact receiving portion 611 , and the cutting needle 8 is not in the top needle position (no at step S 38 ).
[0093] Next, the CPU 151 acquires the rotation difference amount (step S 40 ). The CPU 151 refers to the current cam number M acquired at step S 57 , the next contact cam number M acquired at step S 34 and the rotation difference amount data 230 stored in the rotation difference amount storage area 645 (refer to FIG. 6 ), and acquires the rotation difference amount.
[0094] When the needle drop number N is “3,” and the number of contacts P is “2,” for example, as described above, the current cam number M acquired at step S 57 is “1” and the next contact cam number M acquired at step S 34 is “4.” As shown in FIG. 10 , in the rotation difference amount data 230 , the rotation difference amount associated with the current cam number M “1” and the next contact cam number M “4” is “A14.” Therefore, the rotation difference amount “A14” is acquired (step S 40 ). The contact receiving portion of the cam that corresponds to the next contact cam number M “4” is the contact receiving portion 614 (refer to FIG. 5 ). In other words, the rotation difference amount “A14” is set that moves and stops the needle bar 6 such that the contact receiving portion 614 is at a height at which it can come into contact with the contact portion 322 (refer to FIG. 3 ).
[0095] Next, the CPU 151 controls the drive circuit 71 , drives the sewing machine motor 79 such that the drive shaft 72 is rotated by the rotation difference amount “A14” acquired at step S 40 , and moves the needle bar 6 (step S 43 ).
[0096] Next, the CPU 151 performs the processing at step S 49 . This processing is the same as that in the above explanation.
[0097] After incrementing the number of contacts P (step S 54 ), the CPU 151 determines whether the processing is complete (step S 55 ). For example, when the needle drop number N is “3” and the number of contacts P is “2,” the number of contacts P is incremented to “3” (step S 54 ). As described above, the current cutting needle angle acquired at step S 30 is “45 degrees” and the cutting needle angle difference acquired at step S 32 is “90 degrees.” As shown in FIG. 8 , in the cam number data 210 , the cam number associated with the current cutting needle angle “45 degrees,” the cutting needle angle difference “90 degrees” and the number of contacts P “3” is “-” It is therefore determined that the processing is complete (yes at step S 55 ) and the first cutting needle rotation processing is ended.
[0098] As explained above, the CPU 151 of the sewing machine 1 drives the sewing machine motor 79 and moves the cutting needle 8 to a position at which the contact portion 322 is the same height as one of the contact receiving portions 611 to 614 (step S 43 ). Then, the CPU 151 drives the X axis motor 82 , moves the embroidery frame 9 that is in the withdrawn position to the right, causes the contact portion 322 to come into contact with and rotate one of the contact receiving portions 611 to 614 (step S 49 ). By this rotation, the CPU 151 rotates the cutting needle 8 by 45 degrees in the counter-clockwise direction. Thus, the sewing machine 1 can automatically cause the cutting needle 8 to rotate. Further, as the contact receiving portions 611 to 614 have the width in the up-down direction, when the embroidery frame 9 moves to the right, the contact portion 322 reliably comes into contact with the contact receiving portion of the cam associated with the next contact cam number M acquired at step S 34 . As a result, the sewing machine 1 can cause the cutting needle 8 to rotate in a stable manner.
[0099] In the rotation direction centered on the axial line of the cam member 51 , the longitudinal direction of each of the contact receiving portions 611 to 614 is displaced by 45 degrees, in a plan view, with respect to the mutually adjacent contact receiving portion. With the above-described structure, among the contact receiving portions 611 to 614 , the contact portion 322 comes into contact with the contact receiving portion of the cam whose longitudinal direction angle is 135 degrees and the cutting needle 8 is rotated by 45 degrees. After that, the longitudinal direction angle of one of the cams with which contact was not made becomes 135 degrees. In other words, when the cutting needle 8 rotates by 45 degrees at a time, the longitudinal direction angle of one of the cams 511 to 514 becomes 135 degrees. When causing the contact portion 322 to come into contact with one of the cams 511 to 514 , the sewing machine 1 can always position the embroidery frame 9 at the same coordinate position. Namely, the sewing machine 1 can simplify the movement control of the embroidery frame 9 . As a result, the sewing machine 1 can cause the cutting needle 8 to rotate in a more stable manner.
[0100] In addition, the engagement portion 442 of the plate spring 44 engages with one of the plurality of engagement receiving portions 414 . As a result, the plate spring 44 urges the support member 41 in the direction in which the engagement portion 442 engages with the engagement receiving portion 414 . By this urging, the rotation of the rotation member 43 is locked and the rotation of the cutting needle 8 is also locked. The sewing machine 1 can suppress unnecessary rotation of the cutting needle 8 when performing the outwork on the work cloth. The sewing machine 1 can therefore perform the cutwork on the work cloth in a stable manner. Furthermore, the cutting needle angle of the cutting needle 8 is determined by the position at which the engagement portion 442 engages with the next engagement receiving portion 414 . As a result, the sewing machine 1 can accurately control the cutting needle angle of the cutting needle 8 .
[0101] Note that the present disclosure is not limited to the above-described embodiment, and various modifications are possible. For example, in the above-described embodiment, the four cams 511 to 514 of the cam member 51 are arranged such that their respective angles in the longitudinal direction are mutually displaced by 45 degrees in a plan view. In place of the above-described arrangement, six cams may be provided, and their respective angles in the longitudinal direction may be mutually displaced by 30 degrees. Further, each of the shape, the size, the number and the angle in the longitudinal direction of the cam may be changed as appropriate.
[0102] Further, in the above-described embodiment, the contact portion 322 is provided such that it extends to the right from the support portion 321 . However, the shape, size and installation position of the contact portion may be changed as appropriate. For example, the contact portion 322 may extend to the front or to the rear, and the embroidery frame 9 may be moved to the front or to the rear and caused to come into contact with the cam member 51 . Further, the contact portion 322 is provided on the outer frame 91 , but it may be provided on the inner frame.
[0103] Further, in the above-described embodiment, only the one protruding portion 320 is provided on the outer frame 91 of the embroidery frame 9 . Instead of the above-described structure, four protruding portions that correspond to each of the cams 511 to 514 may be provided. For example, as shown in FIG. 14 , four protruding portions 111 to 114 are provided, from the front to the rear of the outer frame 91 .
[0104] The protruding portion 111 is provided with a support portion 121 and a contact portion 131 , the protruding portion 112 is provided with a support portion 122 and a contact portion 132 , the protruding portion 113 is provided with a support portion 123 and a contact portion 133 , and the protruding portion 114 is provided with a support portion 124 and a contact portion 134 . The support portions 121 to 124 each protrude upward from the outer frame 91 . The height of each of the support portions 121 to 124 becomes increasingly higher in order, from the support portion 121 to the support portion 124 . Each of the contact portions 131 to 134 is a plate that extends to the right from the top end of each of the support portions 121 to 124 . The contact portions 131 to 134 all have the same shape and their width in the up-down direction is the same as the width of the cams 511 to 514 in the up-down direction. In a state in which the needle bar 6 is stopped such that the top surface of the cam 511 is at a same position as the top surface of the contact portion 134 , the top surfaces of the cams 512 to 514 are at the same heights as the contact portions 132 to 134 , respectively.
[0105] Specifically, when the cutting needle 8 is lowered by a predetermined amount from the top needle position, the contact portion 131 is at a height at which it can come into contact with the contact receiving portion 614 , the contact portion 132 is at a height at which it can come into contact with the contact receiving portion 613 , the contact portion 133 is at a height at which it can come into contact with the contact receiving portion 612 , and the contact portion 134 is at a height at which it can come into contact with the contact receiving portion 611 . In addition, a coordinate position of the embroidery frame 9 at which each of the contact portions 131 to 134 can press the contact receiving portions 611 to 614 may be stored in a specific storage area of the flash memory 64 . In this case, when the CPU 151 rotates the cutting needle 8 a plurality of times, such as when the CPU 151 rotates the cutting needle 8 by 45 degrees three times, for example, it is not necessary to re-set the height of the needle bar 6 after the first rotation has ended. In other words, after the first contact has ended at step S 49 in the first cutting needle rotation processing, at step S 35 , the CPU 151 moves the embroidery frame 9 while referring to the specific storage area in the flash memory 64 in order to selectively cause one of the contact portions 131 to 134 to come into contact with the cam member 51 . With the above-described structure, from the second contact onward, it is possible to render the processing at step S 40 and step S 43 unnecessary in the first cutting needle rotation processing.
[0106] Next, a sewing machine 2 according to a second embodiment of the present disclosure will be explained with reference to FIG. 15 to FIG. 21 . In FIG. 15 , members that are the same as those of the sewing machine 1 are assigned the same reference numerals. In the following explanation, an explanation will be omitted of configurations and operations that are the same as those of the sewing machine 1 according to the first embodiment. Note that, in the present embodiment, the cutting needle angle is 0 degrees in a state in which the blade portion 89 extends in the left-right direction (a state of the blade portion 89 shown in FIG. 16 ), and, in contrast to the first embodiment, the counter-clockwise direction in a plan view in FIG. 15 is the positive direction.
[0107] As shown in FIG. 15 and FIG. 16 , the sewing machine 2 is different to the sewing machine 1 in that the sewing machine 2 is provided with a cutting needle rotation mechanism 60 instead of the cutting needle rotation mechanism 50 (refer to FIG. 4 ) that is provided on the sewing machine 1 . The other physical structure and the electrical configuration of the sewing machine 2 are basically the same as those of the sewing machine 1 . The cutting needle rotation mechanism 60 is provided with a support mechanism 61 , a holding member 62 and the cutting needle 8 . The shape of the cutting needle 8 of the cutting needle rotation mechanism 60 is the same as the shape of the cutting needle 8 of the cutting needle rotation mechanism 50 .
[0108] The support mechanism 61 is provided with the support member 41 , a rotation member 63 and the plate spring 44 . The shape of the support member 41 and the plate spring 44 of the support mechanism 61 is the same as the shape of the support member 41 and the plate spring 44 of the support mechanism 40 and an explanation thereof is therefore omitted here.
[0109] The rotation member 63 is substantially cylindrical and is rotatably supported by the lower end of the support member 41 . The axial line of the rotation member 63 is aligned with the axial line of the needle bar 6 (refer to FIG. 3 ). The rotation member 63 is provided with a protruding portion 621 that extends in a direction orthogonal to the axial line of the rotation member 63 (in the left-right direction in FIG. 16 ). The protruding portion 621 is a shaft member that is pressed into a through hole (not shown in the drawings) provided in the rotation member 63 . The direction in which the protruding portion 621 extends is the same as the width direction of the blade portion 89 of the cutting needle 8 . The protruding portion 621 is provided with a first protruding portion 631 and a second protruding portion 632 . The first protruding portion 631 and the second protruding portion 632 protrude toward a direction that moves away from the axial line of the rotation member 63 . The first protruding portion 631 and the second protruding portion 632 are provided such that they are symmetrical, centering on the axial line of the rotation member 63 . Apart from the provision of the protruding portion 621 , the rotation member 63 of the support mechanism 61 is the same as the rotation member 43 of the support mechanism 40 .
[0110] The holding member 62 is a substantially cylindrical member that extends downward from a central portion of the lower end surface of the rotation member 63 . The holding member 62 is integrally formed with the rotation member 63 . The axial line of the holding member 62 is aligned with the rotation member 63 . In a similar manner to the can member 51 of the cutting needle rotation mechanism 50 , a shaft hole (not shown in the drawings) is provided in the lower end of the holding member 62 . The upper end of the cutting needle 8 is inserted into the shaft hole and is fixed by the screw 20 .
[0111] An embroidery frame 10 will be explained with reference to FIG. 15 , FIG. 17 and FIG. 18 . The sewing machine 2 is provided with the embroidery frame 10 in place of the embroidery frame 9 (refer to FIG. 1 ) with which the sewing machine 1 is provided. The embroidery frame 10 is the same as the embroidery frame 9 , apart from a support member 700 that is provided on the embroidery frame 10 in place of the protruding portion 320 provided on the embroidery frame 9 .
[0112] The support member 700 is a substantially rectangular shape that is longer in the front-rear direction in a plan view. The support member 700 is provided on a right side portion of an outer frame 11 of the embroidery frame 10 . The support portion 700 is formed integrally with the outer frame 11 . Four guide portions 711 to 714 are provided in a row on the support portion 700 , from the front to the rear. As will be described below, each of the guide portions 711 to 714 guides the protruding portion 621 of the cutting needle rotation mechanism 60 , and the cutting needle 8 can thus be rotated and the cutting needle angle can be changed.
[0113] The angle (the orientation) in a plan view of each of the four guide portions 711 to 714 is different, but apart from the angle, each of the guide portions 711 to 714 has the same shape. Thus, for ease of explanation, the structure of the guide portion 712 will be explained. Points of difference between the four guide portions 711 to 714 will be explained later. As shown in FIG. 17 and FIG. 18 , the guide portion 712 includes a first insertion hole 802 , a first inclined portion 812 , a second inclined portion 822 , a second insertion hole 872 and groove portions 832 . The first insertion hole 802 is a circular hole, in a plan view, that penetrates through the support portion 700 in the up-down direction. The inner diameter of the first insertion hole 802 is larger than the length between both ends of the protruding portion 621 .
[0114] The first inclined portion 812 and the second inclined portion 822 are provided along the inner peripheral surface of the first insertion hole 802 . The first inclined portion 812 and the second inclined portion 822 form a shape that has point symmetry with respect to the axial line of the first insertion hole 802 . A first guide surface 852 that is the top surface of the first inclined portion 812 , and a second guide surface 862 that is the top surface of the second inclined portion 822 are inclined downward along the inner peripheral surface of the first insertion hole 802 , in the clockwise direction in a plan view.
[0115] The second insertion hole 872 is formed on the inside of the first inclined portion 812 and the second inclined portion 822 . The second insertion hole 872 is a circular hole in a plan view that penetrates through the support portion 700 in the up-down direction. The axial line of the second insertion hole 872 is aligned with an axial line of the first insertion hole 802 .
[0116] The groove portions 832 are portions at which one end of the first inclined portion 812 (the end in the counter-clockwise direction in a plan view) and one end of the second inclined portion 822 (the end in the clockwise direction in a plan view) face each other and at which the other end of the first inclined portion 812 and the other end of the second inclined portion 822 face each other. The two groove portions 832 are provided on either side of the axial line of the first insertion hole 802 . The groove portions 832 are connected to the lower end of the first guide surface 852 and the lower end of the second guide surface 862 , respectively. The width of each of the groove portions 832 is slightly larger than the outer diameter of the protruding portion 621 .
[0117] The groove portions 832 extend toward the front right side from the rear left side in a plan view. Taking the left-right direction as a reference, when the counter-clockwise direction is taken as the positive direction in a plan view, the angle of the direction in which the groove portions 832 extend in a plan view (hereinafter referred to as an “extending direction angle”) is 45 degrees. As will be explained later, the protruding portion 621 that moves while being guided by the first guide surface 852 and the second guide surface 862 fits into the groove portions 832 . Specifically, the protruding portion 621 is guided by the first guide surface 852 and the second guide surface 862 and rotates around the axial line of the second insertion hole 872 , and the cutting needle angle becomes the same as the extending direction angle of the groove portions 832 . At that time, the head portion of the screw 20 that is screwed into the holding member 62 also rotates, but the size of the second insertion hole 872 is set such that interference with the head portion of the screw 20 does not occur.
[0118] As described above, the shape of the guide portions 711 , 713 and 714 shown in FIG. 17 is the same as that of the guide portion 712 , and each of the guide portions 711 , 713 and 714 is provided with a first insertion hole and a second insertion hole. Meanwhile, the angles at which respective first inclined portions, second inclined portions and groove portions of the guide portions 711 , 713 and 714 are provided are different in a plan view. The extending direction angle of groove portions 831 of the guide portion 711 is 0 degrees. The extending direction angle of groove portions 833 of the guide portion 713 is 90 degrees. The extending direction angle of groove portions 834 of the guide portion 714 is 135 degrees. The angle at which each of the inclined surfaces is provided is also different, in accordance with the angle of the groove portions. Note that, in FIG. 17 , the reference numerals of the structural members of the guide portions 711 , 713 and 714 are assigned in accordance with the reference numerals of the structural members of the guide portion 712 .
[0119] Next, guide portion number data 300 will be explained with reference to FIG. 19 . The guide portion number data 300 is stored in a guide portion number data storage area (not shown in the drawings) of the flash memory 64 . The guide portion number data 300 is data that is referred to by the CPU 151 in second cutting needle rotation processing that will be explained later. The guide portion number data 300 includes the cutting needle angle data, a guide portion number K, X coordinate data and Y coordinate data, and each of the data items are stored in association with each other. The guide portion number K is data indicating the guide portions 711 to 714 . The guide portion number K “1” corresponds to the guide portion 711 , the guide portion number K “2” corresponds to the guide portion 712 , the guide portion number K “3” corresponds to the guide portion 713 , and the guide portion number K “4” corresponds to the guide portion 714 . A value that is equal to the extending direction angle of the groove portions of the guide portion associated with the guide portion number K is stored in the cutting needle angle data. Among the guide portion 711 to 714 , the X coordinate data and the Y coordinate data indicate a coordinate position of the embroidery frame 10 at which a central position of the first insertion hole of the guide portion associated with the guide portion number K is the needle drop point.
[0120] Cutwork execution processing that is performed by the CPU 151 of the sewing machine 2 will be explained with reference to FIG. 11 and FIG. 20 . The cutwork execution processing performed by the sewing machine 2 is the same as that performed by the sewing machine 1 except that the first cutting needle rotation processing performed by the CPU 151 of the sewing machine 1 at step S 15 is replaced by the second cutting needle rotation processing performed by the CPU 151 of the sewing machine 2 at step S 15 . In the following explanation, the second cutting needle rotation processing will be explained for a case in which the needle drop number N is “2.” The second cutting needle rotation processing is processing to match the cutting needle angle data stored in association with the needle drop number N in the cutwork pattern data 100 (refer to FIG. 7 ) with the cutting needle angle of the cutting needle 8 .
[0121] As shown in FIG. 20 , in the second cutting needle rotation processing, first the CPU 151 acquires the current cutting needle angle of the cutting needle 8 (step S 60 ). The CPU 151 refers to the cutting needle angle storage area 643 (refer to FIG. 6 ) of the flash memory 64 and acquires the stored cutting needle angle. The CPU 151 determines whether the current cutting needle angle is the same as the cutting needle angle associated with the needle drop number N in the cutwork pattern data 100 (refer to FIG. 7 ) (step S 61 ). The CPU 151 refers to the cutwork pattern data 100 stored in the cutwork data storage area 641 (refer to FIG. 6 ) of the flash memory 64 and acquires the cutting needle angle associated with the needle drop number N, then compares it with the current cutting needle angle acquired at step S 30 . When the current cutting needle angle and the cutting needle angle associated with the needle drop number N are the same (yes at step S 61 ), the CPU 151 ends the second cutting needle rotation processing and returns the processing to the cutwork execution processing (refer to FIG. 11 ).
[0122] For example, when the cutting needle angle data acquired from the flash memory 64 is “0 degrees” (step S 60 ) and the needle drop number N is “1,” the cutting needle angle data stored in the cutwork pattern data 100 is also “0 degrees” (yes at step S 61 ). In this case, the second cutting needle rotation processing is ended.
[0123] When the current cutting needle angle and the cutting needle angle associated with the needle drop number N are different (no at step S 61 ), after acquiring the guide portion number K (step S 63 ), the CPU 151 sets the movement position of the embroidery frame 10 (step S 65 ). The CPU 151 refers to the guide portion number data 300 stored in the guide portion number data storage area (not shown in the drawings) of the flash memory 64 , and acquires the guide portion number K that is associated with the cutting needle angle data that is the same as the cutting needle angle acquired at step S 60 . Then, the CPU 151 refers to the guide portion number data 300 and acquires the coordinate data of the embroidery frame 10 associated with the acquired guide portion number K, then sets the movement position of the embroidery frame 10 (step S 65 ). The set movement position is stored in the RAM 153 . Next, the CPU 151 controls the drive circuits 74 and 75 and drives the X axis motor 82 and the Y axis motor 83 , thus moving the embroidery frame 10 toward the coordinate position set at step S 65 (step S 67 ).
[0124] When the needle drop number N is “2,” for example, the cutting needle angle data associated with the needle drop number N “2” in the cutwork pattern data 100 is “45 degrees,” which is different to the current cutting needle angle (no at step S 61 ). Thus, the CPU 151 acquires, from the guide portion number data 300 , the guide portion number K “2” that is associated with the cutting needle angle data “45 degrees” (step S 63 ). When the guide portion number K is “2,” the X coordinate data of the embroidery frame 10 is “u2” and the Y coordinate data is “v2.” For the movement position of the embroidery frame 10 , the CPU 151 sets the X coordinate data to “u2” and the Y coordinate data to “v2” (step S 65 ). Then, the CPU 151 moves the embroidery frame 10 to the set position (step S 67 ). Through the above-described processing, the movement position of the embroidery frame 10 is determined and the embroidery frame 10 is moved such that the protruding portion 621 can fit with the guide portion 712 , which is associated with the guide portion number K “2.”
[0125] Next, the CPU 151 controls the drive circuit 71 and drives the sewing machine motor 79 , thus lowering the needle bar 6 (namely, the cutting needle 8 ) from the top needle position to a bottom needle position (step S 73 ). More specifically, the CPU 151 rotates the drive shaft 72 by 180 degrees, based on a signal output from the encoder 77 . Here, the bottom needle position refers to a lowest position in the movement range of the needle bar 6 in the up-down direction.
[0126] When the cutting needle 8 is moved from the top needle position to the bottom needle position, as shown in FIG. 21 , when the cutting needle rotation mechanism 60 is lowered in the direction of an arrow C toward the guide portion 712 , the first protruding portion 631 comes into contact with the first guide surface 852 and the second protruding portion 632 comes into contact with the second guide surface 862 . When the cutting needle rotation mechanism 60 is then lowered further, the first protruding portion 631 is guided along the first guide surface 852 and the second protruding portion 632 is guided along the second guide surface 862 in the clockwise direction (the direction of an arrow D) in a plan view. Thus, the protruding portion 621 rotates in the clockwise direction in a plan view and finally fits into the groove portions 832 .
[0127] In accordance with the rotation of the protruding portion 621 , the rotation member 63 , the holding member 62 and the plate spring 44 also rotate integrally in the clockwise direction in the plan view. When the plate spring 44 rotates, the engagement portion 442 resists the urging force imparted by the plate spring 44 , is displaced from the engagement receiving portion 414 with which it was engaged, and moves along the groove portion 415 while rotating in the clockwise direction in a plan view. The engagement portion 442 moves along the groove portion 415 while rotating in the clockwise direction (the direction of the arrow D) in the plan view. The engagement portion 442 engages with the engagement receiving portion 414 that is adjacent to the engagement receiving portion 414 with which it was hitherto engaged (hereinafter referred to as the adjacent engagement receiving portion 414 ). Due to the above-described structure, the plate spring 44 once more urges the support member 41 , in the direction in which the engagement portion 442 engages with the adjacent engagement receiving portion 414 (the direction toward the axial line of the support member 41 ). By this urging, the rotation of the rotation member 63 is locked. Through the above-described processing, the cutting needle angle of the cutting needle 8 becomes 45 degrees, which is the same as the extending direction angle of the groove portions 832 .
[0128] Next, the CPU 151 controls the drive circuit 71 and drives the sewing machine motor 79 , thus raising the needle bar 6 (namely, the cutting needle 8 ) from the bottom needle position to the top needle position (step S 79 ). More specifically, the CPU 151 rotates the drive shaft 72 by 180 degrees, based on a signal output from the encoder 77 .
[0129] In the above explanation, the case is explained in which the needle drop number N is “2,” but the processing is performed in the same manner when the needle drop number N is “3,” “4,” or “CUT_END” etc. As shown in FIG. 7 , the cutting needle angle data that is associated with the needle drop number N “3,” “4,” and “CUT_END” in the cutwork pattern data 100 is, respectively, “135 degrees,” “90 degrees” and “0 degrees.” In this case, as shown in the guide portion number data 300 shown in FIG. 19 , the guide portion numbers K associated with the cutting needle angles “135 degrees,” “90 degrees” and “0 degrees” are, respectively, “4,” “3” and “1.” Thus, when the needle drop number N is “4,” “3” and “CUT_END,” the cutting needle 8 and the rotation member 63 are guided, respectively, by the guide portions 714 , 713 and 711 and the cutting needle angle is thus adjusted.
[0130] As explained above, after the embroidery frame 10 is moved to the position determined at step S 65 , the cutting needle 8 is lowered and thus the protruding portion 621 is guided by the first guide surface and the second guide surface of one of the guide portions 711 to 714 . The protruding portion 621 is rotated while being lowered to the position at which it fits with the groove portions 831 to 834 of the guide portions 711 to 714 . As a result; the sewing machine 2 can automatically rotate the cutting needle 8 . Further, the protruding portion 621 is guided by one of the first guide surfaces 851 to 854 and one of the second guide surfaces 861 to 864 of the guide portions 711 to 714 , and thus the protruding portion 621 rotates in a stable manner. The sewing machine 2 can therefore rotate the cutting needle 8 in a stable manner.
[0131] Furthermore, the first guide surfaces 851 to 854 and the second guide surfaces 861 to 864 of each of the guide portions 711 to 714 are inclined downward along the circumferential direction of the insertion hole provided in each of the guide portions 711 to 714 . Further, the respective groove portions 831 to 834 of the guide portions 711 to 714 are connected to the lower ends of the first guide surfaces 851 to 854 and the second guide surfaces 861 to 864 of the guide portions 711 to 714 . Therefore, the protruding portion 621 that is guided by the first guide surfaces 851 to 854 and the second guide surfaces 861 to 864 of the guide portions 711 to 714 easily rotates while being lowered, and the rotation stops at the position at which the protruding portion 621 fits with the groove portions. The cutting needle angle of the cutting needle 8 becomes the same as the extending direction angle of the groove portions 831 to 834 of each of the guide portions 711 to 714 . Thus, the sewing machine 2 can rotate the cutting needle 8 in a more stable manner and can also improve the accuracy of the set cutting needle angle of the cutting needle 8 .
[0132] The first guide surfaces 851 to 854 , the second guide surfaces 861 to 864 and the two groove portions of each of the guide portions 711 to 714 are provided such that they are symmetrical with respect to the axial line of the first insertion hole of each of the guide portions 711 to 714 . The protruding portion 621 is provided such that it is symmetrical, centering on the axial line of the rotation member 63 . Thus, when the cutting needle 8 and the rotation member 63 are inserted into the first insertion hole of one of the guide portions 711 to 714 , the first protruding portion 631 and the second protruding portion 632 are guided by one of the first guide surfaces 851 to 854 and one of the second guide surfaces 861 to 864 of the guide portions 711 to 714 . As a result, the sewing machine 2 can rotate the cutting needle 8 in an even more stable manner, compared to a case in which only one end of the protruding portion 621 is guided.
[0133] Further, by the engagement portion 442 of the plate spring 44 being engaged with one of the plurality of engagement receiving portion 414 , the plate spring 44 urges the support portion 41 in the direction in which the engagement portion 442 engages with the engagement receiving portion 414 . By this urging, the rotation of the rotation member 63 is locked and the rotation of the cutting needle 8 is also locked. The sewing machine 2 can inhibit the cutting needle 8 from rotating unnecessarily when performing the cutwork on the work cloth. As a result, the sewing machine 2 can perform the cutwork on the work cloth in a stable manner.
[0134] It should be noted that the present disclosure is not limited to the above-described embodiment and various modifications are possible. For example, in the above-described embodiment, the support portion 700 is formed integrally with the right side portion of the outer frame 11 . In place of the above-described structure, the support portion 700 may be a separate member from the outer frame 11 and may be fixed to the right side portion of the outer frame 11 by a screw or by adhesive.
[0135] In the above-described embodiment, the support portion 700 is provided with the four guide portions 711 to 714 whose extending direction angles differ by 45 degrees, respectively. In place of the above-described structure, six guide portions may be provided whose extending direction angles differ by 30 degrees, respectively. In this case, the angle of the cutting blade of the cutting needle 8 can be adjusted at 30 degree intervals. Further, each of the shape, the size, the number and the extending direction angle of the guide portion may be changed as appropriate.
[0136] In the above-described embodiment, the protruding portion 621 is a shaft member that penetrates through the rotation member 63 . In place of the above-described structure, the protruding portion may be formed integrally with the rotation member 63 .
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A sewing machine may comprise a needle bar driving mechanism, a cutting needle rotation mechanism, and an embroidery frame movement mechanism configured to move an embroidery frame comprising a protruding portion. A cam member may be fixed to the needle bar and comprise a plurality of cams. A processor of the sewing machine may set a height of the needle bar to a specific position from a plurality of positions. Each of the plurality of positions may represent that each of the plurality of cams is able to contact with the protruding portion. The processor may instruct the needle bar driving mechanism to move the needle bar to the specific position and instruct the embroidery frame movement mechanism to move the embroidery frame to a position where the protruding portion is able to contact with one of the plurality of cams.
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BACKGROUND OF THE INVENTION
The present invention relates to an automatic processing apparatus (hereinafter referred to simply as an automatic processing machine) for silver halide photographic light-sensitive materials wherein a silver halide photographic light-sensitive material is processed by processing solutions.
Due to recent proliferation of many minilab shops, the amount of light-sensitive materials processed by one unit of a minilab has been reduced, and the replacement rate of processing solution in their processing tanks per day has been lowered accordingly. Therefore, the processing solution is deteriorated, and stable processing power tends to be unsatisfactory. In the case of color developing solutions, in particular, processing solutions deteriorate markedly by air oxidization, and it is extremely difficult to maintain stable processing power.
Japanese Patent Publication Open to Public Inspection No. 324455/1994 (hereinafter referred to as Japanese Patent O.P.I. Publication) discloses a technology wherein a processing solution for processing a silver halide photographic light-sensitive material is supplied to the emulsion surface of a silver halide photographic light-sensitive material through a gas phase from a processing solution container in which the processing solution is contained hermetically.
By supplying a processing solution for processing a silver halide photographic light-sensitive material to the emulsion surface of a silver halide photographic light-sensitive material through a a gas phase from a processing solution container in which the processing solution is contained hermetically as in Japanese Patent O.P.I. Publication No. 324455/1994, it is possible for sure to improve keeping quality of a processing solution (in the case of a color developing solution, in particular), compared with a conventional method.
However, in the above-mentioned patent, neither a means nor a technology for reducing an amount of a processing solution to be supplied to the light-sensitive emulsion surface is described at all. This means that a processing solution supplied to the surface of an emulsion layer of a light-sensitive material is carried over to the following tank (for example, a bleach-fixing tank), though the amount of processing solution used due to the above-mentioned technology is small compared to a conventional type (a processing solution dipping type). It is natural that, as the amount of processing solution fed is larger, reduction of performance in the following tanks due to aforesaid carrying over is caused.
In addition, when the liquid surface of the processing solution inside the housing container is reduced, oxidation of the processing solution is caused under the running processing wherein the amount of processing solution is extremely small, even though the processing solution is tightly closed in the housing container. Specifically, if the processing solution is that for color developing, oxidized product of the color developing agent is produced inside the processing solution. It turned out that, due to the adherence of the above-mentioned oxidized product of the color developing agent on a white background portion, stain occurs.
SUMMARY OF THE INVENTION
An object of the present invention is to provide an automatic processing machine maintaining stable processing performance even when the amount of processing is extremely small and capable of reducing to minimum the consumption of processing agent component used for aforesaid automatic processing machine.
The present inventor studied laboriously for attaining the above-mentioned object. As a result, it turned out that the above-mentioned problem can be overcome by the following constitutions. Namely, the above-mentioned problems can be overcome by an automatic processing machine for silver halide photographic light-sensitive material having a processing solution container which houses a processing solution processing a silver halide photographic light-sensitive material, a means for feeding the processing solution processing a silver halide photographic light-sensitive material onto an emulsion surface of the silver halide photographic light-sensitive material through a a gas phase, an operation means which converts an image signal which is recorded onto aforesaid silver halide photographic light-sensitive material into an amount of processing solution fed onto the emulsion surface of the silver halide photographic light-sensitive material and an adjusting means which adjusts the amount of processing solution fed onto the emulsion surface of the silver halide photographic light-sensitive material.
By adjusting the amount of feeding the processing solution in accordance with an image signal recorded on a light-sensitive material, the above-mentioned automatic processing machine for silver halide photographic light-sensitive material of the present invention can stop feeding of the processing solution on a white portion of the image. Due to this, the amount of processing solution used and the amount of processing agent can further be reduced, and concurrently with this, it is not necessary to feed the processing solution on the white portion. Accordingly, it is possible to completely prevent the occurrence of stains due to the oxidized product of a color developing agent.
The image signal referred in the present invention may either be optical measurement density (integral density) read by a conventional image reading apparatus or an inputted signal such as a digital image signal housed in a photo CD. In addition, an outputted signal such as an amount of exposure to a light-sensitive material which has already been operated may be included. When the image signal of the present invention is the above-mentioned inputted signal, it is possible to convert this inputted signal directly to the amount of feeding of the processing solution.
In the present invention, as a processing solution feeding means which feeds the processing solution onto the emulsion surface of the light-sensitive material through a gas phase and a processing solution splashing means which splashes the processing solution onto the light-sensitive material through a gas phase and a processing solution coating means which coats the processing solution onto the light-sensitive material through a gas phase, for example, a curtain coater, are cited. As the processing solution splashing means which splashes the processing solution onto the light-sensitive material through a gas phase, one which has the same structure a the ink jet head section of an ink jet printer, one which generates pressure in a splashing means after processing the processing solution onto the light-sensitive material through a gas phase, and then, which actively splashes as described in Japanese Patent O.P.I. Publication No. 324455/1994 and one which splashes the processing solution due to solution pressure applied to the splashing means after processing the processing solution onto the light-sensitive material through a gas phase as in a spray bar are cited. As the processing solution splashing means which splashes the processing solution onto the emulsion surface of the light-sensitive material through a gas phase due to an identical structure as the ink jet head portion of the ink jet printer, one which feeds the processing solution due to vibration and one which feeds the processing solution due to sudden boiling are cited. These technologies are so preferable that they can control the amount of processing solution feeding amount and the position for processing the light-sensitive material.
As a processing solution feeding means, any method may be used including a method wherein the processing solution is fed onto the light-sensitive material through a gas phase from a bar-shaped feeding head, a method wherein the processing solution is fed onto the light-sensitive material through a gas phase from a surface-shaped feeding head and also a method wherein the processing solution is fed onto the light-sensitive material through a gas phase from a dot-shaped feeding head. In addition, when the light-sensitive material is a sheet type, the processing solution may be fed onto the light-sensitive material from the feeding head by the use of the surface-shaped feeding head corresponding to the size of the light-sensitive material under a condition in which the position relationship between the light-sensitive material and the feeding head is fixed. However, a method to feed the processing solution onto the light-sensitive material through a gas phase from the feeding head while shifting the position relationship between the light-sensitive material and the feeding head is preferable because sufficient processing solution can be fed onto the light-sensitive material even if the feeding head is small. In addition, when the bar-shaped feeding head is used, the feeding head may be shifted. However, in order to feed rapidly the processing solution onto the light-sensitive material, it is preferable to shift the light-sensitive material in other than the parallel direction with the bar-shaped feeding head. Specifically, in order to keep processing time constantly, it is preferable to shift the light-sensitive material in perpendicular direction with the bar-shaped feeding head. In addition, as the processing solution splashing means, when the processing solution is splashed onto the light-sensitive material through a gas phase from the feeding head while shifting the position relationship between the light-sensitive material and the feeding head, the number of splashing the processing solution onto the light-sensitive material per one second by the processing solution splashing means is preferably once or more, and specifically preferably 10 times or more. In addition, since the processing solution is splashed from the feeding head, it is preferable to be 1×10 6 times or less and more preferable to be 1×10 5 times or less.
In addition, when the processing solution feeding means feeds the processing solution through a feeding port, the shape of the feeding port may be anything including circular, square or ellipse. The area of the feeding port is preferably 1×10 -11 m 2 or more and specifically preferably 1×10 -8 m 2 or more in order to prevent clogging due to slight drying of the processing solution. In addition, in order to uniformly feed the processing solution onto the light-sensitive material, the area of each feeding port is preferably 1×10 -8 m 2 or less and specifically 1×10 -6 m 2 or less. In addition, the interval of each feeding port in terms of the average of two adjacent end of feeding port is preferably 5×10 -6 m 2 and specifically preferably 1×10 -3 m 2 in order to sufficiently feed the processing solution onto the surface of the light-sensitive material.
The distance between the processing solution feeding port and the emulsion surface of the light-sensitive material is preferably 50 μm or more (specifically 1 mm or more) in order to easily control this distance, and more preferably 10 mm or less (the most preferably 5 mm or less).
Heating means!
The temperature of the light-sensitive material heated by a heating means may be 35° C. or less. However, it is preferable to be 35° C. or more, specifically preferably 40° C. or more and the most preferably 45° C. or more. In addition, considering heat-durability of the light-sensitive material and control ease of processing, 100° C. or less is preferable and 90° C. or less is more preferable.
As a heating means for heating the light-sensitive material, a transfer heating means which heat due to contacting and transferring heat of the light-sensitive material with a heating drum or a heating belt and a irradiation heating means which heat the light-sensitive material by irradiating an infrared beam and high frequency electromagnetic wave are cited.
In addition, it is preferable to have a heating control means which controls in such a manner that the above-mentioned heating means heats the light-sensitive material when the light-sensitive material exists on a position of the heating means because unnecessary heating can be prevented. This can be attained by a structure having a conveyance means which conveys the light-sensitive material at a prescribed conveyance speed and a light-sensitive material sensing means which senses the existence of the above-mentioned light-sensitive material at a prescribed position on the upperstream side of the conveyance direction in the above-mentioned conveyance means compared to the position where the heating means heats the light-sensitive material, wherein the above-mentioned heating control means controls in accordance with sensing by the above-mentioned light-sensitive material sensing means. In this occasion, it is preferable that controlling is conducted in such a manner that the above-mentioned heating means conducts a prescribed heating since a prescribed time passed after the above-mentioned light-sensitive material sensed the existence of the silver halide photographic light-sensitive material from non-existence until a prescribed time passed after the above-mentioned light-sensitive material sensed the non-existence of the silver halide photographic light-sensitive material from existence.
In the present invention, when an image signal is an inputting signal such as the above-mentioned light measured density (integral density), the apparatus may have a means for converting the above-mentioned integral density to each of independent yellow, magenta and cyan (analysis density) (see Japanese Patent O.P.I. Publication No. 88344/1992). In addition, it may have a means for converting the above-mentioned Y, M and C analysis density to the amount of exposing the light-sensitive material to B, G and R light. As a method of converting from this analysis density to the amount of exposure to light, the analysis density may be converted in accordance with characteristics curves between the amount of exposure to each of R, G and B light and the analysis density (Y, M and C coloring density) of the panchromatic layer, the ortho layer and the regular layer, or may be converted from the relationship of the measurement density, provided that the analysis density is defined to be a measurement density in which the processed light-sensitive material was measured by a densitometer.
In the present invention, as a method for providing exposure to the light-sensitive material, a type using the CRT and a type using an LED array may be used.
As an operation method which converts the coloring density Dy, Dm, Dc of the present invention to a necessary color developing agent amount, a method to provide exposure which causes plural density steps for each of yellow, magenta and cyan which color respectively in a blue-sensitive layer, a green-sensitive layer and a red-sensitive layer to the light-sensitive material (wedge exposure), to measure the amount of coloring dye or the amount of developing metal per Y, M and C unit area produced in each density step and to prepare operational functions f(Dy), g(Dm), h(Dc) using a relationship between the above-mentioned amount of Y, M and C coloring dye or the amount of developing silver produced and the coloring density Dy, Dm, Dc.
A conventional method is applicable to a preparation method of an operational function. For example, it is described in a thesis for a degree to the University of Tokyo "Color-Measuring analysis of Color Reproduction in a Subtractive Method Color Photography", Volume 2nd, Chapter 1, "Retrograde reflective density".
When a light-sensitive material to be processed is a light-sensitive material for transmission use, provided that independent coloring density of the above-mentioned Y. M and C colorants are Dy, Dm and Dc and the amount of dye generation corresponding to each coloring density is My, Mm and Mc, the following equations are formed. ##EQU1## wherein εy, εm and εc independently represent mol light absorption coefficient of Y, M and C dye.
On the other hand, when the light-sensitive material to be processes is a photographic paper, (in the case that the above-mentioned coloring density Dy, Dm and Dc>1.3) ##EQU2## (in the case that the above-mentioned coloring density Dy, Dm and Dc<1.3) ##EQU3##
Necessary amount of color developing agent V (mol) is:
V=aMy+bMm+cMc=f(Dy)+g(Dm)+h(Dc) (d)
When the processed light-sensitive material is a photographic paper, it has a layer structure of the red-sensitive layer, the green-sensitive layer and the blue-sensitive layer from the top. Accordingly, a yellow coloring reactivity of the lowermost blue-sensitive layer is inferior to a magenta and cyan coloring reactivity in the upper layers. Accordingly, the relationship of the above-mentioned conversion functions f, g and h for the same coloring density D1 become
f(D1)≧g(D1) concurrently with f(D1)≧h(D1).
Therefore, in order to obtain identical coloring density between Y, M and C, it is preferable to provide the amount of color developing agent provided when coloring Y greatestly.
In the present invention, as a means for adjusting the amount of providing color developing agent, the following methods can be used:
(1) To adjust the amount of providing due to adjusting the number of sprayed dot per unit area in the same manner as in a conventional ink-jet method,
(2) To adjust the amount of feeding by adjusting the spraying number (frequency) of the processing solution per unit time.
(3) To adjust the amount of feeding by adjusting the amount of spraying the processing solution per unit. (for example, in the case of feeding the processing solution by means of a bubble-jet system, amount of unit feeding is adjusted by adjusting time for heating the heater to the processing solution sudden boiling temperature.)
In the present invention, a processing step to feed the processing solution onto the emulsion surface of the light-sensitive material through a gas phase is preferably located in the color developing step and/or bleaching step wherein the amount of reacted and resulting product changes depending upon the amount of exposure, and more preferably located in the color developing step wherein stable processing performance, especially stable processing agent storage property is desired.
A processing agent for color developing used in the present invention may be liquid or solid. However, from viewpoint of stability of the processing agent and handling property, a solid processing agent is preferable.
Solid processing agent supplying means!
As a solid processing agent supplying means which supplies a solid processing agent to a processing solution container, when the solid processing agent is a tablet, any means may be used, provided a tablet is supplied to the processing solution container, including conventional methods described in Japanese Utility Publication Open to Public Inspection (hereinafter, referred to as Japanese Utility O.P.I. Publication) Nos. 137783/1988, 97522/1988 and 85732/1989. When the solid processing agent is granule or powder, a gravity dropping type means as described in Japanese Utility O.P.I. Nos. 81964/1987 and 84151/1988 and Japanese Patent O.P.I. Publication No. 292375/1989 and a screw type or a tap type means described in Japanese Utility O.P.I. Publication Nos. 105159/1988 and 195345/1988 may be used. However, it is not limited thereto.
An amount of solid processing agent at one time is preferably 0.1 g or more from viewpoint of durability of the solid processing agent supplying means and accuracy of supplying amount at one time, and also preferably 50 g or less from viewpoint of dissolution time.
Replenisher water!
Replenisher water is a solution providing an effect to dissolve the solid processing agent supplied to the processing solution container. Ordinarily, it is water.
Solid processing agent!
The solid processing agent is a solid processing agent containing processing agent components of a processing solution which processes the light-sensitive material, including powder, tablet, pill and granule. In addition, as necessary, those provided with a water-soluble lamination on a surface thereof such as a water-soluble polymer. Powder in the present invention is an aggregate of fine particle crystal. Granule in the present invention is granulated product of powder, preferably particles having 50-5000 μm particle size. Tablet in the present invention is a powder or granule compressed and molded to a certain form. Pill or granule are molded to round (including a potato shape and a spherical shape) due to granulating or tableting. Of the above-mentioned solid processing agent, either of granule, tablet or pill is preferable, because dust few occurs during handling and supplying accuracy is high. Of them, tablet is preferably used because replenishing accuracy is high, handling property is simple and it dissolves rapidly without changing density so that the effects of the present invention is favorably provided.
In order to solidify a photographic processing agent, arbitrary means can be adopted, for example, a method wherein a photographic processing agent (a condensed solution, fine powder or granule type) and a water-soluble binder are kneaded for molding or a method wherein a laminated layer is formed by spraying a water-soluble binder on the surface of a temporarily-molded photographic agent (see Japanese Patent O.P.I. Publication Nos. 29136/1992 and 85533/1992 through 85536/1992 and 172341/1992).
A preferable production method of a tablet is to form a tablet by tableting granules after granulating powder solid processing agent. The above-mentioned production method has merits that dissolubility and storage stability thereof are improved compared to a solid processing agent prepared by a method wherein a solid processing component is simply mixed and a tablet is formed by a tableting process and thereby photographic performance is also stable. As a granulating method for preparing a tablet, a granule or a pill, conventional methods including a transmission granulation method, an extrusion granulation method, a compression granulation method, a crushing granulation method, a stirring granulation method, a fluid bed layer granulation method and a spray and drying granulation method can be used. In addition, when granulating, it is preferable to add a water-soluble binder by 0.01-20 wt %. As a water-soluble binder, celluloses, dextrins, saccharide alcohols, polyethylene glycols and cyclodextrin are preferable.
Hereinafter, examples of preferable compounds are described. However, the present invention is not limited thereto.
I. Water-soluble polymers
Polyethylene glycol, polyvinyl alcohol, pollvinyl pyrroridone, pollvinyl acetal, polyvinyl acetate, aminoalkyl methacrylate copolymer, methacrylic acid-methacrylic acid ester copolymer, methacrylic acid--acrylic acid ester copolymer and methacrylic acid-containing betaine type polymer.
II. Saccharides
Monosaccharides such as glycose and galactose, disaccarides such as maltose, saclose and lactose, alcohol saccharides such as mannitol, solbitol and erisrytol, pululane, methylcellulose, ethylcellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose, acetic acid phthalic acid cellulose, hydroxypropyl methylcellulose phthalate, hydroxypropyl methylcellulose acetate succinate, carboxymethylethylcellulose, dextrins and stark decomposed products.
Of these, specifically preferable compounds are block polymer (a Pluronic polymer) of polypropylene glycol and polyethylene glycol, polyethylene glycol (its average molecular weight is 2,000-20,000), methacrylic acid--methacrylic acid ester copolymers and methacrylic acid--acrylic acid ester copolymers whose typical one is Eudragid produced by Lame Firma Inc., dextrins and stark decomposed products whose typical ones are erysritol, maltose, mannitol, Pine Flow produced by Matsutani Chemical Co., Ltd. or Pinedex and methacrylic acid betaine polymer whose typical one is Yuka Former produced by Mitsubishi Yuka Co., Ltd.
These materials are preferably 0.5% or more and 20% or less against the weight of the solid processing agent, and specifically preferably 0.5% or more and 20% or less.
Next, when forming a tablet by compressing the resulting granule, conventional compressing machines, such as an oil-pressurers, a single pressure tableting machines, a rotary tableting machines and pricketing machines can be used. Preferably, it is preferable to separate each component such as an alkaline agent and a preserver and granulate them independently.
The tablet processing agents can be produced by conventional method as described in Japanese Patent O.P.I. Publication Nos. 61837/1976, 155038/1979 and 88025/1977 and British Patent No. 1,213,88. The granule processing agents can be produced by conventional methods described in Japanese Patent O.P.I. Publication Nos. 109042/1990, 109043/1990, 39735/1991 and 39739/1991. The powder processing agents can be produced by conventional methods described in Japanese Patent O.P.I. Publication No. 133332/1979, British Patent Nos. 725,892 and 729,862 and German Patent No. 3,733,861.
Color developing process!
Time for the color developing step is defined to be time since a color developing solution is fed onto the leading edge of the light-sensitive material initially until a time when the processing solution of the next step is fed onto the leading edge of the light-sensitive material or until the leading edge of the light-sensitive material is immersed in the processing solution of the next step. The time for the color developing step is 5 seconds or more, and specifically 8 seconds or more from viewpoint of sufficiently and stably conducting the color developing step. In addition, 180 seconds or less and specifically 60 seconds or less is preferable since provision of adverse influence on the light-sensitive material due to deterioration or drying of the color developing solution fed onto the light-sensitive material can be prevented.
In the color developing step, plural processing solution feeding means may be provided so that the processing solution may be fed to the light-sensitive material from the first processing solution feeding means and then another processing solution may be fed from the second processing solution feeding means onto the light-sensitive material wherein the processing solution is fed from the first processing solution feeding means. In this occasion, the following three preferable embodiments are cited.
The first embodiment is that, when the light-sensitive material is subjected to color developing by a color developing agent which becomes active at pH of 7 or more, the first processing solution feeding means feeds the processing solution containing a color developing agent whose pH is 6 or less onto the light-sensitive material and the second processing solution feeding means feeds a color developing processing solution whose pH is 7 or more. Due to the above-mentioned structure, alkaline components whose diffusion speed are high are supplied and diffused after the color developing agent whose diffusion speed is slow is sufficiently diffused to the thickness direction of the light-sensitive material. Accordingly, problems such as uneven developing due to noticeable difference of developing starting time in the thickness direction of the light-sensitive layer can be prevented. When the light-sensitive material is a multi-layered color photographic light-sensitive material, coloring property of each primary colors becomes disrupted if the developing starting time is noticeably different in the thickness direction of each light-sensitive layer. Therefore, it is specifically useful. In the case of multi-layered light-sensitive materials having 5 or more layers and specifically 10 or more layers, such effect becomes extremely great.
The second embodiment is that the first processing solution feeding means feeds water to the light-sensitive material and that the second processing solution feeding means feeds the color developing processing solution to the light-sensitive material. Due to this structure, the color developing processing solution is fed after the light-sensitive material is provided with water and is sufficiently swollen. Therefore, components whose diffusion speed is slow in a hardened light-sensitive material are diffused at sufficiently high speed. As a result, problems such as uneven development due to noticeable difference of developing starting time in a thickness direction of a light-sensitive layer can be decreased.
The third embodiment is that the first processing solution feeding means feeds water containing an oxidant such as hydrogen peroxide onto the light-sensitive material and that the second processing solution feeding means feeds a color developing processing solution.
It is preferable that a silver halide emulsion of the present invention contains at least one or more emulsion layers containing silver halide grains wherein the content of silver chloride is 90 mol % or more. It is more preferable that the content of the silver chloride is 98-99.9 mol %, and it is further more preferable that the content of silver chloride is 98-99.9 mol %. It is specifically more preferable that all layers contain a silver bromochloride emulsion wherein the content of silver chloride is 98-99.9 mol %.
In the present invention, bleaching solutions, fixing solutions, bleach-fixing solutions and stabilizing solutions described in japanese Patent O.P.I. Publication No. 181837/1995 can be used.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1(A) and 1(B) show a characteristic drawing of relationship between B exposure amount and Y coloring density, and also a characteristic drawing of relationship of Y dye produced amount corresponding to a Y coloring density D1.
FIG. 2 shows a process drawing of a step since a sample subjected to gray wedge developing is read until exposure is given to a color photographic paper.
FIG. 3 shows a perspective view of a process in which a photographic paper is subjected to exposure and color developing.
FIG. 4 shows a block diagram of a process since exposure to light until all of developing to drying steps.
FIG. 5 shows a side cross-sectional view of a solid processing agent replenishing device and a color developing device.
FIG. 6 shows a front cross-sectional view of a dissolution tank of the color developing device and the solid processing agent replenishing device.
FIG. 7 shows an enlarged drawing of an orifice front view in the processing solution station.
FIG. 8 shows a circuit drawing of a solution drop generation means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Hereunder, examples of the present invention will be explained. The examples mentioned below shows practical examples of the present invention. However, the present invention is not limited thereto.
EXAMPLE 1
First, QA-A6 paper (a color photographic paper) p produced by Konica Corporation was subjected to separation wedge exposure to B, G and R light. By the use of chemical process CPK-2-20 produced by Konica, the above-mentioned paper was processed. From these results, the relationships between B, G and R exposure amount and Y, M and C coloring density respectively (characteristics curves) were measured. Namely, due to a characteristics drawing shown in FIG. 1(A), yellow coloring density D1 corresponding to blue exposure amount B1 can be measured. Next, B, G and R exposure amount which was equivalent to each of Y, M and C separation wedge steps was provided to the above-mentioned 100 cm 2 QA-A6 paper. Following this, Y, M and C dyes in the processed samples were taken up and they were subjected to quantitative analysis. From these results, relationships between Y, M and C coloring densities and Y, M and C dyes produced amount can be calculated. Namely, in a characteristics curve shown in FIG. 1(B), the relationship of Y dye producing amount corresponding to Y coloring density D1 (a function of Y1=F(B1)) is calculated. Next, the amount of color developing agent (CD-3) necessary to produce the amount of Y, M and C dyes for each wedge step were measured by means of development experiments. From this result, when Y, M and C coloring densities are D Y , D M and D C , conversion functions f, g and h which result in the amounts of coloring developing agents (CD-3) V Y , V M and V C necessary to produce aforesaid coloring density were measured:
V Y =f(D Y )
V M =g(D m )
V C =h(D C )
Next, FIG. 2 shows a step since a sample image subjected to ordinary gray wedge development wherein the above-mentioned color photographic paper p was processed with CPK-2-20 was read until aforesaid color photographic paper p was subjected to exposure to light. First, image information (integral density) of the above-mentioned wedge-developed sample 1 was read by photo-scanner 2 (for example, Drum Scanning Densitometer Model 2605 produced by Abe Sekkei Co., Ltd.) was read. This image signal (integral density) was converted to analysis density by means of image processing device 3. Following this, this analysis density was further converted to the amount of exposure onto the above-mentioned color photographic paper p from silver halide photographic sensitive material light-exposure device (hereinafter, referred to as "light-exposure device") by means of image processing device 3. From the above-mentioned exposure device 4, aforesaid color photographic paper p was subjected to exposure to light.
When a photographic paper for color photography which is a color silver halide light-sensitive material (hereinafter, simply referred to as "photographic paper") is conveyed in the arrowed direction, red light source printing head 41 R having an LED array, green light source printing head 41 G having a vacuum fluorescent tube array and blue light source printing head 41 B are controlled to be exposed to light by light-exposure control unit 40 in accordance with image data so that a prescribed portions of photographic paper P are exposed to light for each color.
Next, FIGS. 3 and 4 show a processor which processes photographic paper p which had been exposed to light by a method of the present invention. FIG. 3 is a perspective view showing a process in which the above-mentioned photographic paper p is subjected to light exposure and color developing. FIG. 4 is a block diagram showing a process from light exposure to all developing processes and drying.
Downstream of the conveyance path of the photographic paper from the above-mentioned exposure device 4, color developing device 50 is provided which faces the emulsion surface of the photographic paper. Aforesaid color developing device 50 will be explained later. Below the above-mentioned light exposure device 47 and color developing device 50, photographic paper conveyance means 70 composed of conveyance roller 71, platen roller 72, conveyance belt 73 and heating unit 74 is provided. In addition, downstream of the conveyance path, a processing solution tank composed of bleach-fixing tank 81, first stabilizing tank 82A, second stabilizing tank 82B and the third stabilizing tank 82C and drying unit 83 are located. Numeral 84 is a replenishing device which replenishes a solid processing agent for bleach-fixing to the above-mentioned bleach-fixing tank 81, and numeral 85 is a replenishing device which replenishes a solid processing agent for stabilizing to the above-mentioned third stabilizing tank 82C. Numeral 86 is a replenishing water feeding container which feeds replenishing water W to the above-mentioned bleach-fixing tank 81 and third stabilizing tank 82C.
First, the above-mentioned image processing device 3 outputs a signal which converts the amount of light exposure onto the above-mentioned photographic paper p to the feeding amount of color developing solution. In accordance with this signal, color developing is conducted in developing device 5. Thus, printing is completed.
FIG. 5 is a side cross sectional view of solid processing agent replenishing device 50 and color developing processing device 60. FIG. 6 is a front cross-sectional view of a dissolution tank in aforesaid color developing processing device 60 and solid processing agent replenishing device 50.
As a solid processing agent for replenishing, a tablet type, a granule type, a powder type and a small particle type are used. Specifically, the tablet type is preferable. In the present example, a case where tablet-type solid processing agent J is used as a solid processing agent will be explained. However, the present invention is applicable also to granule type solid processing agent too.
Solid processing agent replenishing device 50 is composed of housing container which houses plural tablet type solid processing agent J, supplying means 52 which receives aforesaid solid processing agent J, rotates and drops aforesaid solid processing agent intermittently one by one, driving means 53 which drives aforesaid supplying means, control means (not illustrated) which controls aforesaid driving means 53 and supplies an appropriate amount of solid processing agent J to the dissolution tank described later and a guide member which introduces solid processing agent J dropped from the above-mentioned supplying means to in the vicinity of the processing solution surface of the above-mentioned replenishing tank 55.
Inside the above-mentioned dissolution tank 55, temperature sensor 56, heater 57 and liquid surface sensor 58 are provided. On one of side wall of aforesaid solution tank 55, processing solution communication opening 55A is penetrated. The processing solution inside dissolution tank 55 is communicated to adjoining developing solution tank 61 (processing solution container) through filter 59. The processing solution inside aforesaid developing solution tank 61 is circulated to the above-mentioned dissolution tank 55 by means of circulation pump 62.
As shown in FIG. 5, at the lower portion of the above-mentioned developing solution tank 61, processing solution feeding means 63 is fixed. Inside this processing solution feeding means 63 is composed of plural processing solution stations 64 and common processing solution path 65 which feeds the processing solution in the above-mentioned developing processing solution 61 by communicating with aforesaid plural processing solution stations 64. On each of plural processing solution stations 64, solution drop generation means 66 is respectively provided. Aforesaid solution drop generation means 66 may either be (1) one which sprays solution drops from orifices 67 by changing volume inside processing solution station (pressure station) 64 due to an electric-mechanical conversion means such as Piezo electric element, or (2) one which causes orifices 67 solution drop from orifices 67 by enhancing processing solution pressure due to generating and swelling bubbles inside the processing solution station (pressure station by means of a heating element. These technologies are put into practical use in ink jet printers. Solution drops which are sprayed from orifices 67 and fly through the air are adhered on the emulsion surface of photographic paper p so that latent images formed by the above-mentioned light exposure means 4 are subjected to color developing to form visual images.
The above-mentioned solution drop generation means 66 is connected to solution feeding control unit 68, and, due to a signal from operation means 69 which operates image signals, it generates drop of solution and cause splashing only necessary solution drop with necessary timing (on demand).
In FIGS. 3 and 4, numeral 51A is a solid processing agent housing container for the first color developing, numeral 52A is supplying means for the first color developing, numeral 55A is a dissolution tank for the first color developing, numeral 61A is a processing solution container for the first color developing, numeral 62A is a circulation pump for the first color developing and numeral 63A is a processing solution feeding means for the first color developing. In the same manner, numeral 51B is a solid processing agent housing container for the second color developing, numeral 52B is a supplying means for the second color developing, numeral 55B is a dissolution tank for the second color developing, numeral 61B is a processing solution container for the second color developing, numeral 62B is a circulation pump for the second color developing and numeral 63B is a processing solution feeding means for the second color developing.
FIG. 7 is an extended drawing of the front view of the orifice of the above-mentioned processing solution stations 64. Plural orifices 67 are provided in a form of two rows. By shifting the first orifice row and the second orifice row by a half pitch, the solution drop density of the lateral direction perpendicular to the conveyance direction of photographic paper is enhanced. The density of plural orifices 67 in the lateral direction is determined by the color developing density to be needed. In addition, plural orifices are not limited to two rows. It may be one row or three or more rows. The above-mentioned solution drop generation means 66 is provided on a side surface of processing solution stations 64 which communicates orifices 67 or on a plane facing orifices 67.
FIG. 8 is a circulation drawing of solution drop generation means 66. In FIG. 8, numeral 661 represents a power supply, numeral 662 is a heating element which generates and swell the above-mentioned bubble. Numeral 663 represents a latch. Numeral 664 is a flip-flop which amplifies image signals. Numeral 665 represents a clock which generates a standard pulse.
Supply amount of the color developing agent was adjusted by adjusting the number of spraying dots in a unit area, in the same manner as in an ordinary ink jet printer.
Next, the processing solution feeding head will be explained. For this, a bubble jet type bar-shaped feeding head will be used. This bar-shaped feeding head is perpendicular to the conveyance direction of the light-sensitive material. The conveyance speed of the light-sensitive material was set to be 30 mm/sec. As shown in FIG. 5, the arrangement of the feeding port is a two-row zigzag arrangement. The interval of the feeding port is 100 μm in terms of the distance of the fringes of two adjacent feeding ports. The diameter of the feeding port is 50 μm, and the number of feeding the processing solution per second is 3,000 times.
Next, a processing agent for silver halide photographic light-sensitive material used in the present example and the processing steps the same will be explained.
<Processing agent for Color developing>
Tablet-type processing agent for the first color developing
In a commercially available bandam mill, 400 g of a color developing agent VD-3, i.e., 4-amino-3-methyl-N-ethyl-N-(B-(methanesulfonamide)ethyl)aniline sulfate were crushed until their average particle size became 10 μm. To this fine particle, 100 g of polyethyleneglycol whose average molecular weight by weight was 4,000 was add, and then, mixed uniformly in a commercial mixer. Next, the resulting mixture was granuled in a commercially available granulator for 7 minutes at station temperature by adding it 15 ml of water. Following this, the granuled product was dried in a fluid bed layer drier at 40° C. for 2 hours so that moisture in the granulated product was removed almost completely. The resulting granulated product was subjected to continuous compression tableting in a rotary tableting machine (Clean Press Correct H18, produced by Kikusui Seisakusho) wherein the diameter was 20 mm, thickness was 7 mm, a filling amount per tablet was 3 g and tableting pressure was 4 t) so that a processing agent for the first color developing solution replenishing was prepared.
Tablet type processing agent for the second color developing
In a commercially available bandam mill, 40 g of pentasodium diethylenetriamine pendaacetic acid and 1200 g of sodium carbonate anhydride were crushed until their average particle size becomes 10 μm. To this fine particle, 100 g of polyethylene glycol whose average molecular weight by weight was 4000 added, and then, this mixture was uniformly mixed. Next, the resulting mixture was granuled in a commercially available stirring granulating machine for 7 minutes at station temperature by adding water of 30 ml. Following this, this granulated product was dried in a fluid bed layer drier at 40° C. for 2 hours so that moisture in the granulated product was removed almost completely. The resulting granulated product was mixed using a commercially available cross-rotary mixer at station temperature for 10 minutes. To the resulting mixture, 5 g of sodium N-myrystoil-alanine was added for additional mixing for 3 minutes. This mixture was subjected to continuous compression tableting wherein the diameter was 20 mm, thickness was 7 mm, a filling amount per tablet was 3 g and tableting pressure was 4 t so that a tablet-type processing agent for the second color developing solution replenishing was prepared.
Processing solution for the first color developing
In 1 liter of water, 25 tablets of the above-mentioned tablet-type processing solution for the first color developing was dissolved so that a processing solution for the first color developing was prepared.
Processing solution for the first color developing
In 1 liter of water, 60 tablets of the above-mentioned tablet-type processing solution for the second color developing was dissolved so that a processing solution for the second color developing was prepared.
<Processing agent for bleach-fixing>
Processing agents for CPK-2-J1 processing were used for a tablet-type processing agent for bleach-fixing and a processing solution for bleach-fixing were respectively used.
<Processing agent for bleach-fixing>
Processing agents for CPK-2-J1 processing were used for a tablet-type processing agent for stabilizing and a processing solution for stabilizing were respectively used.
<Processing steps>
Table 1 shows processing steps.
TABLE 1______________________________________ Amount of Processing replenishing Amount ofStep time water tablet supplied______________________________________Color 10 seconds (First) 39 ml/J 3.7 m.sup.2 /Jdeveloping (Second) 16 ml/J 1.3 m.sup.2 /JBleach-fixing 20 seconds 39 ml/J 0.81 m.sup.2 /JStabilizing 20 seconds × 3 1166 ml/J 9.72 m.sup.2 /JDrying 25 seconds -- --______________________________________
As a replenishing water for the bleach-fixing tank, a stabilizing processing solution for the stabilizing first tank was used. In addition, with regard to the stable tank, a three-tank cascade system was adopted.
Using the above-mentioned system, a running experiment in a processing amount of 0.1 m 2 per day was conducted for 10 days.
(Results)
It was confirmed that, owing to the above-mentioned system of the present invention, the amount of used color developing agent could be further reduced and that stable processing performance could be maintained without occurring stain under running status wherein the processing amount was extremely small as described above.
By setting conversion functions f, g and h which convert the coloring density to the amount of supplying color developing agent
f(D1)>g(D1)
and concurrently
f(D1)>h(D1)
coloring reaction of Y, M and C dyes can be advanced with well balance so that further rapid and stable processing performance can be provided.
EXAMPLE 2
Example 2 was conducted in the same manner as in Example 1, except that conversion functions f', g' and h' which respectively convert integral density inpY, InpM and InpC read by reflective original reading device 2 to the amount of supplying color developing agents V Y , V M and V C directly were set, the following conversions were conducted when reading aforesaid reflective original
V.sub.Y =F' (InpY)
V.sub.M =G' (InpM)
V.sub.C =H' (InpC)
and the amount of supplying the color developing agent in accordance with each image signal was determined. As a result, the following issues were confirmed: the amount of color developing agent used in the same manner as in Example 1 could be further reduced. In addition, under running status wherein the amount of processing is extremely small, stable processing performance could be maintained without occurring stain.
Incidentally, in Examples 1 and 2, a conversion table is prepared from the calculation result by the calculating means, and the conversion table can be stored in a form of a look-up table in a memory. By inputting an image signal representing a density level or an exposure signal representing a light amount into the look-up table, a processing signal representing a necessary amount of a color developing agent can be outputted from the look-up table without a calculation.
The present invention forms images by feeding necessary color developing solution on-demand as processing solution drops against latent images formed on a color photographic paper, and it provides an automatic processing machine maintaining stable processing performance even when the amount of processing is extremely small and capable of reducing to a minimum the consumption of processing agent component used for aforesaid automatic processing machine.
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An apparatus for processing a silver halide photographic material having an emulsion surface, includes a supply device to supply processing solution from a container to the emulsion surface through a space; a converter to convert one of density level of an image signal and a light amount of a exposure signal into a processing signal representing an amount of the processing solution; a regulating device to regulate an amount of the processing solution in accordance with the processing signal so that the regulated amount of the processing solution is supplied to the emulsion surface of the silver halide photographic material through the space by the supply device.
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BACKGROUND OF THE INVENTION
Revolver handguns have changed very little in their operating mechanisms for about 100 years. Each gun includes about 60 different parts, some of which, such as pins and screws, are used in more than one location making the total number of parts to be greater than 60. While these pieces have been refined over the years so as to function well in the handgun, they necessarily provide many possibilities for breakage and malfunctioning. More recent designs of other types of firearms have simplified the mechanisms by eliminating several parts.
It is an object of this invention to provide a novel revolver handgun with many fewer operating parts. It is another object of this invention to provide a safer revolver handgun. It is another object of this invention to provide a novel system for rotating the cylinder of a revolver. It is another object to provide a revolver handgun that can be manufactured without the necessity for hand finishing each gun to make it operate smoothly. Still other objects will become apparent from the more detailed description which follows.
BRIEF SUMMARY OF THE INVENTION
This invention relates to a revolver handgun having a revolving cylinder with a trigger and hammer mechanism that causes the cylinder to rotate when the trigger or hammer is moved, wherein said mechanism includes a transfer rod linearly slidably mounted in the bore of an extractor assembly having a star-shaped head and a tubular shaft, said rod being connected to said trigger and hammer assembly to move linearly in said bore by pulling of said trigger or operating of said hammer; said rod having a network of grooves on its surface to mate with a protrusion directed radially inward from the surface of said bore whereby linear movement of said rod causes progressive radial rotation of said extractor assembly, said shaft of said extractor assembly being mounted in a central bore in said cylinder by means permitting relative linear movement but no relative rotational movement, said network of grooves providing a continuous pathway of repeating cam sections around the outside surface of said transfer rod, each repeating cam section having a first location where said trigger and hammer are in their normal positions after firing, and a second location where said cartridge primer and said hammer are aligned in firing position.
In preferred embodiments the cylinder and hammer are aligned between cartridge chambers when the trigger is released after firing, and transport rod engages 1-6 protrusions in the extractor assembly which, in turn, is keyed to the cylinder bore so that linear movement of the transport rod produces rotational movement of the cylinder. Other preferred features include (1) advertisements or warnings of danger of gun stamped on cylinder and/or handle; (2) a manually removable hammer nose to enhance safety of gun; (3) an inspection shield for viewing the bases of the cartridges in the cylinder to see which are spent; (4) means for sealing the cylinder to the barrel to prevent expulsion of gases when firing; (5) means for using the force of the explosion gases to rotate the cylinder, cock the hammer, and to eject spent cartridge casings from the cylinder, and (6) a novel design for a revolver in which the cylinder is totally enclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed to be characteristic of this invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which:
FIG. 1 is a side elevational view partially in cross section of a revolver handgun of this invention;
FIG. 2 is a side elevational view of the transport rod;
FIG. 3 is a front elevational view of the transport rod;
FIG. 4 is a front elevational view of an extractor assembly for use with standard cartridges;
FIG. 5 is a side elevational view of the extractor assembly of FIG. 4;
FIG. 6 is a top plan view of the cylinder;
FIG. 7 is a cross sectional view taken at 7--7 of FIG. 6;
FIG. 8 is a layout of the surface of the transport rod;
FIG. 9 is a side elevational view of the extractor rod;
FIG. 10 is a top plan view of the extractor rod;
FIG. 11 is a top plan view of the hex-hex washer;
FIG. 12 is a side elevational view of the hex-hex washer;
FIG. 13 is an end elevational view of a hexagonal cylinder;
FIG. 14 is a side elevational view of a hexagonal cylinder;
FIG. 15 is a side elevational view of the hammer with one type of safety lock;
FIG. 16 is a rear elevational view of the hammer of FIG. 15;
FIG. 17 is a perspective view of the thumb piece of FIG. 14;
FIG. 18 is a side elevational view of the hammer with a second type of safety lock;
FIG. 19 is a rear elevational view of the hammer of FIG. 18;
FIG. 20 is a perspective view of the thumb piece of FIG. 18;
FIG. 21 is a rear elevational view of the inspection shield;
FIG. 22 is a side elevational view of the inspection shield;
FIG. 23 is a side elevational view of the gas sealing embodiment;
FIG. 24 is a partial side elevational view of an alternate gas sealing embodiment;
FIG. 25 is a side elevational view of the embodiment wherein explosion gases are employed to rotate the cylinder and eject the spent cartridge;
FIG. 26 is a front elevational view of an extractor assembly for use with rimless cartridges;
FIG. 27 is a side elevational view of the extractor assembly of FIG. 26;
FIG. 28 is a side elevational view of an enclosed cylinder revolver;
FIG. 29 is a side elevational view of the revolver of FIG. 28 broken open to show removal of the cylinder;
FIG. 30 is a rear elevational view taken at 30--30 of FIG. 29;
FIG. 31 is a layout of the surface of the cylinder of the revolver of FIGS. 28-30;
FIG. 32 is a cross sectional view taken at 32--32 of FIG. 29;
FIG. 33 is a top plan view of the trigger of the revolver of FIGS. 28-30; and
FIG. 34 is a side elevational view of the trigger of FIG. 33.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 of the attached drawings there is an illustration that shows the principal feature of this invention. The revolver handgun of this invention comprises a simplification of the internal mechanism of any of the standard well known guns of today, such as Colt, Smith and Wesson, and the like. The simplification is in the mechanism which turns the cylinder when the trigger is pulled or the hammer is cocked in the operation of firing the gun. Generally, all other parts of the revolver are standard.
Gun frame 90 houses cylinder 91 and has attached thereto the barrel 92. Underneath barrel 92 is the extractor rod 93, which, when cylinder 91 is released and is pivoted away from alignment with barrel 92, is pushed toward cylinder 91 to cause all cartridges to be ejected from their respective chambers. Trigger 26 pivots around pin 27 to fire the gun when pulled to the rear. Hammer 30 pivots around pin 32 and carries hammer nose 31 which strikes the primer of a cartridge to fire the bullet.
The principal feature of the revolver of this invention is that a transfer rod 95 is employed to move linearly and reciprocally in the central bore in extractor assembly 94 to cause cylinder 91 to rotate. In modern revolvers the cylinder is rotated by means of several levers and springs in a ratchet action functioning on the outside of the cylinder. The linear movement of transfer rod 95 is accomplished by engagement of pin 29 in a slot 28 in trigger 26. When trigger 26 is pulled to the rear or when hammer 30 is pulled back to cock it preparatory to firing, transfer rod 25 moves forward. After firing an internal rebound spring moves trigger 26 forward causing transfer rod 95 to move linearly to the rear, ready for the next pulling of trigger 26 or cocking of hammer 30 to repeat the cycle.
In FIGS. 2-5 there are shown the details of transfer rod 95 and extractor assembly 94, which will make it clear how these two parts work together. Transfer rod 95 has a cylindrical cam section 33 having a network 36 of grooves around its outer surface at the forward end thereof. Shank portion 34 of transfer rod 95 is a flat section with a transverse hole 35 to receive pivot pin 29 that moves in slot 28. Network 36 of grooves engages one or more protrusions 39 directed inwardly from bore 38 in the shank 40 of extractor assembly 94. In the embodiment where the remainder of the handgun is unchanged from that which is known today the notches between fingers in extractor star 37 fit under the flanges at the base of cartridges causing them to be ejected from cylinder 91 when extractor rod 93 is pushed toward the rear with cylinder 91 rotated outside of the frame of the revolver. In the case where rimless cartridges (such as used in automatic handguns) are used in revolvers the extractor assembly is designed differently as shown in FIGS. 26-27 so as to provide a spring action to grip the cartridges. Each point 83 of the extractor star is split with a slot which permits notches 85 to spread apart sufficiently to grip the base of a rimless cartridge in a spring action. The remainder of the extractor assembly of FIGS. 26-27 is the same as that of FIGS. 4-5.
The general movement caused by protrusions 39 in network 36 can best be seen and understood in FIG. 8 which shows a flat layout of the network 36 of grooves on cam section 33 of transfer rod 95. The shaded portions of FIG. 8 show the lands while the unshaded portions are the grooves. Small circles in the grooves represent one of protrusions 39 (see FIG. 4) of the extractor assembly 94. The grooves may take the form of straight angled grooves 48 shown in solid lines or curved grooves 49 shown in dotted lines. Preferably the grooves are straight intersecting at angles with each other as at 48. The curved grooves are of special interest in providing a different "feel" to the trigger when it is fired. The functions of the straight grooves and curved grooves are, however, the same. In any event, the end result is a continuous undulating groove around the surface of transfer rod 95 which has as many repeating sections as there are cartridges in cylinder 91.
As the cam section 33 of transfer rod 95 is moved linearly (to the right or left on the drawing as shown by arrow 53) with protrusion 39 of extractor assembly 94 following the grooves, protrusion 39 and its extractor assembly 94 and cylinder 91 will move upward as shown by arrow 54, which is the same as a counter-clockwise motion of extractor assembly 95 shown by arrow 55 in FIG. 4. If protrusion 39 is at 50 and transfer rod 95 is moved to the right, it causes protrusion 39 to bear against angled land 56 which moves protrusion 39 to position 51 in the direction of arrow 54 (counterclockwise in the direction of arrow 55 in FIG. 4). When transfer rod moves to the left while protrusion 39 is at position 51, protrusion 39 will contact angled land 57 and move up to position 58 (which is identical to position 50 for the next series of moves). The succeeding movement of transfer rod 95 to the right will begin the cycle all over again. It can therefore be appreciated that the lands and grooves in network 36 are several repeats of a single cam pattern for cocking and firing of the handgun. The number of cam patterns is the same as the number of cartridges in cylinder 91 (six patterns in the case of a "six-shooter"). The cam patterns extend exactly around the circumference of cam section 33 of transfer rod 95 to produce an unending continuous groove in which protrusion 39 travels. Generally, it is preferred to employ 3-6 protrusions 39 for a network 36 having six repeating cam patterns.
At position 50 and position 58 the hammer is forward, the trigger is forward and the hammer is aligned with a position half way between adjacent cartridges in cylinder 91. It is, therefore, a safe position where an accidental firing cannot occur because the hammer nose 31 is not able to contact a primer. At position 51 the gun is in the firing position (i.e., final movements of firing the gun), the trigger is pulled to the rear and the hammer has been released from its full rearward position and jumped forward by the action of a spring to cause the hammer nose 31 to strike the primer of a cartridge aligned therewith. Position 51 is substantially reached by pulling hammer 30 to the rear to its fully cocked position, where only a minute additional pull of trigger 26 will release hammer 30 to fire the gun. An additional position for protrusion 39 is shown at 52 where protrusion 39 is completely removed from engagement with network 36. This is reached by pushing forward on hammer 30 which in turn pulls transfer rod 95 to the rear and out of engagement with any groove in network 36. This releases cylinder 91 which may be pivoted laterally outside of the frame of the gun to permit access to cartridge chambers for ejection of cartridges or for loading of the chambers. When ejection or loading is completed, cylinder 91 may be swung back into alignment and transfer rod 95 will automatically engage its protrusion 39 into network 36 of grooves due to the bias of spring (not shown) which tends to keep transfer rod 95 engaged with protrusion 39 in the position 50 or 58.
Cylinder 91 is keyed to extractor assembly 94 by any convenient means. In these drawings there is shown a preferred means in which the outside of shank 40 of extractor assembly 94 is provided with a series of flat surfaces to mate with a similar series of flat surfaces in bore 42 of cylinder 91. A hexagonal cross section of shank 40 and of bore 42 is preferred since this shape is used frequently in other applications.
In FIGS. 9-12 are shown the remaining component parts for this mechanism of the revolver of this invention. Extractor rod 93 has a cylindrical handle portion 43 and a hexagonal sliding portion 44. The threaded tip 59 of extractor rod 93 is attached to tapped hole 60 in shank 40 of extractor assembly 94. A washer (FIGS. 11-12) having an inside hexagonal opening to slidingly mate over the outside of hexagonal section 44, a hexagonal boss 46 to mate with the inside of bore 42, and a circular body 47 to mate with the cylindrical bore 61 of cylinder 91 functions as a guide. The washer is press fitted into place at the junction of bore 42 and bore 61 and serves as a guide to bring shank portion 40 accurately back into mating relationship with bore 42 after extractor rod 93 is pushed to the rear to remove cartridges from cylinder 91.
Another embodiment of this invention is to employ the reverse of the above described locations of protrusions 39 and network 36 of grooves. Thus transfer rod 95 may have one or more protrusions 39 projecting outwardly from its surface with protrusions 39 engaging themselves in a network 36 of grooves machined on the bore 38 of extractor assembly 94. In such a system exactly the same rotating action of cylinder 91 occurs by linear movements of transfer rod 95 in extractor assembly 94.
It also is a feature of this invention to employ a cylinder 91 having a polygonal cross section, which results in a series of flat rectangular outside surfaces on cylinder 91. Such flat surfaces may then easily be stamped or etched with warnings as to safety measures in using the revolver or advertising material. FIGS. 13-14 illustrate this embodiment. Such warnings may also be placed on the handle of the gun in the form of raised lettering to provide a better grip.
In FIGS. 15-20 there are shown two versions of a novel safety feature of the revolver handgun of this invention. Hammer 30 has a lock 62 with a lug 63 which turns by means of a key 64 attached to removable thumb piece 69. Key 64 can be turned to move lug 63 from the firing position 70 to the safe locked position 71 where lug 63 is keyed into a grooved recess 72 in the frame of the gun. When in the locked position 71 with thumb piece 69 and key 64 removed, the gun cannot be fired nor can cartridges be inserted or removed from cylinder 91 because it cannot be pivoted outwardly until hammer 30 can be moved forward to place protrusion 39 in position 52 as described above. The version shown in FIGS. 18-20 is similar to that of FIGS. 15-17 in that a thumb piece 73 is removable from hammer 30. In this version, however, hammer nose 31 is removable with thumb piece 73 and locks into hammer 30 by means of a lug 74 engaging a keyway groove 75 in hammer 30. After being fully inserted, thumb piece 73 is rotated 90° and locked in place as at 76. To remove thumb piece 73 it is first rotated 90° and then pulled out of hammer 30. In this version the gun cannot be fired because there is no hammer nose 31 to strike a primer. However, cylinder 91 can be made to pivot away from the frame by pressing hammer 30 forward, and so this version is not as fully safe as that of FIGS. 15-17.
Another safety feature is shown in FIGS. 21-22 as an inspection shield 65 which is placed immediately behind the rear of cylinder 91 where prior art revolvers have solid ears projecting laterally outward from the frame of the gun to protect against an accidental firing of a cartridge by a sharp object hitting a primer. Shield 65 is shown with two curved observation ports 66 each of which permits one to see the bases of three cartridges so that it can be determined, without swinging cylinder 91 away from its normal position, which are live and which are spent. All six cartridges can be seen because the transfer rod 95 engages protrusion 39 at position 50 (see FIG. 8) where hammer 30 is half way between adjacent cartridges in cylinder 91. Ports 66 are covered with a transparent glass or plastic which permits observation but does not permit a sharp pointed object to inadvertently strike a primer. Alternatively, the entire shield 65 may be made of a suitable glass or plastic which is transparent and is sufficiently tough not to be shattered or broken in normal use. Shield 65 is attached to the frame of the gun in an immovable position and with a central bore for transfer rod 25 to pass through without obstruction. Shield 65 is preferably sufficiently large in diameter that it serves as a stop to prevent cylinder 91 from falling off extractor rod 23 when cylinder 91 is pivoted out of the gun frame as at 77 to load or eject cartridges. This eliminates the necessity of having a frame lug now used on revolvers for this same purpose.
Another novel feature of this revolver is to provide a good gas seal between the forward surface of cylinder 91 and the rear surface of barrel 92 when the revolver is fired. Prior art guns provide close tolerances in this position so as to minimize any lateral gas pressure losses. In this invention as shown in FIG. 23 the mating surfaces of cylinder 91 and barrel 92 are cylindrically shaped with a male projection 67 preferably on cylinder 91 and the corresponding female recess 68 on barrel 92. It is to be understood, however, that this arrangement may be reversed with equivalent results such that the male projection is on barrel 92 and the female recess on cylinder 91. In order for the mating surfaces to be joined they must be able to be easily pushed together, but with a small tolerance (e.g., 0.001-0.005 inch) and the material of construction must have a sufficient elasticity to permit male projection 67 to expand slightly under the pressure of the explosion gases to make a tight fit momentarily, and then to contract immediately to allow projection 67 to be withdrawn easily from recess 68. The movement to insert projection 67 into recess 68 is produced by the forward movement of transfer rod 95 as the hammer reaches its fully cocked position immediately before firing. Upon firing, the release of the trigger permits a small rearward movement of transfer rod 95, which causes a small rearward movement of cylinder 91 sufficient to free male projection 67 from female recess 68 so cylinder 21 is free to rotate. Springs may be employed to assist in these movements of cylinder 91. FIG. 25 shows an alternate embodiment in which male projection 67 and female recess 68 are not cylindrical but are each formed of two frustoconical sections with the small ends abutting to form a ridge 86 in projection 67 and a corresponding ridge 87 in recess 68. This arrangement provides a better seal but is more difficult to manufacture.
In FIG. 25 there is shown a system for employing a portion of the explosion gases produced when firing the gun to eject a spent shell casing. When the bullet is propelled down the bore of barrel 92 there are high pressure gases behind the bullet. When the bullet passes port 78 some of the gases go into passageway 79 and exert pressure against the end of transfer rod 95 forcing it to the rear which causes cylinder 91 to rotate so that protrusion 39 is in position 50 (see FIG. 8). Meanwhile the bullet has proceeded out of the bore in barrel 92 and passed port 80 permitting the explosion gases to go into passageway 81 which is directed into the receiver 41 in cylinder 91 where the spent cartridge is located and there is sufficient gas pressure to blow the cartridge casing out of the receiver. This embodiment cannot of course be used unless there is no obstruction to the ejection of the shell casing. For example, inspection shield 65 (see FIGS. 21-22) must have an ejection notch cut into it. This feature is particularly adaptable to the use of rimless cartridges and the use of the extractor assembly of FIGS. 26-27. An offset housing 82 must be present to provide space for passageway 81 to be directed into receiver 41.
In FIGS. 28-34 there is shown a novel design for a revolver handgun wherein the cylinder is totally enclosed and is rotated by a modification of the system described above with respect to FIGS. 1-8. The revolver of this embodiment has a barrel section 88 and a handle section 89 connected pivotally to each other by pivot pin 96 so as to open to the position shown in FIG. 29. Latch 97 engages keyway 98 when barrel section 88 and handle section 89 are closed in the operating position shown in FIG. 28. Latch 97 is on one end of the latch sight bar 98 while rear sight 99 is on the other end of bar 98. A spring (not shown) urges latch into the position shown in FIG. 28 and the position shown in solid lines in FIG. 29. In order to open the gun, rear sight 99 is pressed downward to raise latch 97 to the position shown in dotted lines in FIG. 29. Cylinder 100 is seated in a cylindrical recess 101 in barrel section 88 and may be removed by opening the gun to the position shown in FIG. 29. Cylinder 100 rotates in recess 101 without the necessity of bearings, although such bearings may be included, if desired. Cartridge receivers 102 in cylinder 100 are aligned with barrel 103 when cylinder 100 is rotated to the aligned position. Trigger 104 is movable linearly forward and rearward in an appropriate keyway in barrel section 88. 0n the upper edge of trigger 104 is a retractable protrusion 105 held in a recess 106 by a spring 107 and a screw 108 which permits protrusion 105 to be retracted when pushed downward against the action of spring 107 which urges protrusion 105 to the position shown in FIG. 34. The outside surface of cylinder 100 contains a repeating network of grooves 109 which engage protrusion 105. As trigger 104 is moved linearly in firing the gun protrusion 105 rides in grooves 109 causing cylinder 100 to rotate from one aligned position to the next aligned position for firing cartridges. The network of grooves 109 is discontinuous at positions 110. Protrusion 105 passes over the discontinuous position 110 by being retracted and then protruding again when it reaches the next portion of groove 109. The general profile of grooves 109 is shown in FIG. 32 where the sloping part 111 causes protrusion 105 to withdraw as it moves in the direction of arrow 114 in traveling from groove portion 112 to groove portion 113. In FIG. 31 there is shown a flat layout of a portion of grooves 109 in the network on cylinder 100. In each repeating section of grooves 109 there are positions 115 and 116 where protrusion 105 is located at two moments during the firing of the gun. At position 115 the gun is at rest with trigger 104 in its normal position (see FIG. 28) with rebound spring (not shown) urging trigger 104 to its most forward position. As trigger 104 is pulled in the act of firing it moves protrusion 105 in the direction of arrow 118 which causes network of grooves 109 to move in the direction of arrow 119 which translates to a movement of cylinder 100 in the counterclockwise direction when viewed from the rear as in FIG. 30. Protrusion 105 follows the path of groove 120 as trigger 104 is pulled and protrusion 105 is at position 116 when the final movement of trigger 104 fires the gun. Upon release of trigger 104 after firing the rebound spring moves trigger 104 back to the position of rest (see FIG. 28) which causes protrusion 105 to move from position 116 to position 117 to begin a new cycle. This illustrates a variation in the system of using protrusions and grooves to rotate the cylinder. Here a retractable protrusion 105 permits grooves 109 to include a nongrooved portion 110, while the system described in connection with FIGS. 1-8 has a fixed protrusion 39 operating in a continuous groove 48, both systems accomplishing the same final result. The gun of FIGS. 28-34 is particularly desirable in employing a totally enclosed cylinder which avoids, therefore, nearly all possibilities for fouling the rotating mechanism due to dirt and other outside agents.
While the invention has been described with respect to certain specific embodiments, it will be appreciated that many modifications and changes may be made by those skilled in the art without departing from the spirit of the invention. It is intended, therefore, by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention.
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A simplified revolver handgun comprises an interacting trigger and hammer mechanism which in their normal movements cause a transfer rod to move linearly inside the extractor assembly of the cylinder, the transfer rod having on its outside surface a network of grooves which mate with an inwardly directed protrusion in the bore of the extractor assembly, the network being a repeating series of cam action sections, each section including a location for firing when said hammer and a cartridge are aligned, and a location when the hammer rests in close proximity to the cylinder but between adjacent cartridges in a nonfiring position. Other optional features include (1) placing warnings of the dangers of a handgun on the outside of the cylinder and/or the handle; (2) providing a removable hammer nose to render the handgun safe when not in use; (3) a transparent inspection shield for viewing the bases of cartridges in the cylinder; (4) a means for moving the cylinder forward against the barrel to effect a gas seal during firing; (5) a means for using explosion gases to rotate the cylinder, cock the hammer, and eject spent shells from the cylinder; and (6) a revolver with a totally enclosed cylinder.
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This application is a 371 of PCT/US97/21227, filed Nov. 18, 1997, and claims benefit of provisional application 60/032,390, filed Dec. 04, 1996.
FIELD OF THE INVENTION
A polarizing glass produced from a phase-separated glass containing silver, copper, or copper-cadmium halide crystals and a method of production.
BACKGROUND OF THE INVENTION
A polarizing effect can be generated in glasses containing silver, copper, or copper-cadmium halide crystals. These crystals can be precipitated in aluminosilicate glasses having compositions containing suitable amounts of an indicated metal and a halogen other than fluorine.
The polarizing effect is generated in these crystal-containing glasses by stretching the glass, and then exposing its surface to a reducing atmosphere. The glass is placed under stress at a temperature above the glass annealing temperature. This elongates the glass, and thereby elongates and orients the crystals. The elongated article is then exposed to a reducing atmosphere at a temperature above 250° C., but not over 25° C. above the glass annealing point. This develops a surface layer in which at least a portion of the halide crystals are reduced to elemental silver or copper (hereafter “metal”).
The production of a polarizing glass, then, involves, broadly, these four steps:
1. Melting a glass batch containing a source of silver, copper, or copper-cadmium and a halogen other than fluorine, and forming a body from the melt,
2. Heat treating the glass body at a temperature above the glass strain point to generate halide crystals having a size in the range of 200-5000 Å,
3. Stressing the crystal-containing glass body at a temperature above the glass annealing point to elongate the body and thereby elongate and orient the crystals, and
4. Exposing the elongated body to a reducing atmosphere at a temperature above 250° C. to develop a reduced surface layer on the body that contains metal particles with an aspect ratio of at least 2:1.
The growth of halide particles cannot occur at temperatures below the strain point of the glass because the viscosity of the glass is too high. Higher temperatures, above the annealing point, are preferred for crystal precipitation. Where physical support is provided for the glass body, temperatures up to 50° C. above the softening point of the glass can be employed.
The production process is described in detail in U.S. Pat. No. 4,479,819 (Borrelli et al.). There it is pointed out that the halide crystals should have a diameter of at least about 200 Å in order to assume, upon elongation, an aspect ratio of at least 5:1. When reduction to elemental metal particles occurs, the particles having an aspect ratio of at least 5:1 will display an aspect ratio greater than 2:1. This places the long wavelength peak at least near the edge of the infrared region of the radiation spectrum, while avoiding serious breakage problems during the subsequent elongation step. At the other extreme, if the diameter of the initial halide particles exceeds about 5000 Å, significant haze develops in the glass. This is accompanied by a decreased dichroic ratio resulting from radiation scattering.
The dichroic ratio is a measure of the polarizing capability of a glass. It is defined as the ratio existing between the absorption of radiation parallel to the direction of elongation and the absorption of radiation perpendicular to the direction of elongation. To attain an adequate ratio, the aspect ratio of the elongated halide crystals must be at least 5:1 so that the reduced metal particles have an aspect ratio of at least 2:1.
Crystals having a small diameter demand very high elongation stresses to develop a necessary aspect ratio. Also, the likelihood of glass body breakage during a stretching-type elongation process is directly proportional to the surface area of the body under stress. These are very practical limitations on the level of stress that can be applied to a glass sheet, or other body of significant mass. In general, a stress level of about five thousand psi has been deemed to be a practical limit.
The literature indicates that firing of the elongated body in a reducing atmosphere should be undertaken at temperatures above 250° C., but no higher than 25° C. above the annealing point of the glass. A reduction temperature as high as is compatible with the tendency for crystals to respheriodize is desirable. The time required decreases dramatically with increase in temperature. In particular, there is an abrupt change in the time required to achieve complete reduction above 400° C., that is, above the melting temperature of the metal halide phase. It is thought, although not clearly proven, that the metal from the halide phase grows considerably faster when the halide phase is molten. This experimental fact means that, to carry out the reduction treatment in a practical time interval, requires a temperature above 400° C., preferably above 415° C. Looking at the phenomenon in another way, in order to produce, in a reasonable time, a depth of reduced layer necessary for a high contrast, the reduction treatment must be carried out at a high temperature.
One of the key measures of the effectiveness of a polarizing glass body is its contrast ratio, or, as referred to in the art, contrast. Contrast comprises the ratio of the amount of radiation transmitted with its plane of polarization perpendicular to the elongation axis to the amount of radiation transmitted with its plane of polarization parallel to the elongation axis. In general, the greater the contrast, the more useful, and valuable, the polarizing body.
Another important feature of a polarizing body is the bandwidth over which the body is effective. This property takes into consideration not only the degree of contrast, but the portion of the spectrum within which the contrast is sufficiently high to be useful. A contrast ratio of 100,000 has been taken as a point of reference for comparison purposes. Clearly, the lower the reference contrast, the broader the corresponding bandwidth. We have chosen 100,000 (50 db) because it represents a common high performance value specified for polarizer applications.
The peak contrast wavelength is determined by the aspect ratio of the elongated particle. The aspect ratio increases with the degree of stress applied to stretch the glass, and thereby the crystals. The wavelength at which the peak contrast occurs increases with the aspect ratio. Most applications in the infra-red require a peak in the wavelength range of 1300-1550 nm. However, other applications require contrast peaks outside this range, for example, as low as 600 nm.
Heretofore, it has been necessary to produce polarizing glass articles on an individual basis. Thus, it was necessary to design a separate set of processing conditions tailored to provide the peak contrast for each application wavelength. Then care had to be taken to control the process quite rigidly. The particle elongation is controlled by controlling the elongating stress applied.
The maximum bandwidth available heretofore has been about 300 nm, with a commercially practical figure being no more than 200 nm.
For example, an article might be designed having a center wavelength (CWL), that is, a contrast peak, at about 900 nm. The article would, however, have an optimum bandwidth of about 200 nm covering the range of 800-1000 run. As a result, the article would not be effective at wavelengths outside this range, e.g. 1240, 1310 and 1560 nm.
It would, of course, be highly desirable to provide a polarizing glass having a much broader bandwidth of contrast ratios above the practical use level that is now available. Ideally, this would extend from the visible into the infrared portions of the spectrum.
It is then a basic purpose of the present invention to meet this need. Another purpose is to provide a polarizing glass that is effective over a broad range of wavelengths. A further purpose is to provide a single polarizing glass article that is broadly useful in a variety of applications. A still further purpose is to provide a method of making such a polarizing glass article.
SUMMARY OF THE INVENTION
The invention resides in a polarizing glass article that exhibits a broad band of high contrast polarizing properties in the infrared region of the radiation spectrum, that is phase-separated by precipitating silver, copper, or copper-cadmium halide crystals in the glass within a size range of 200-5000 Å, and that contains elongated silver, copper, or copper-cadmium metal particles having an elongated aspect ratio of at least 2:1 and formed on or in the halide crystals, the article having a contrast ratio of at least 100,000 over a range of at least 300 nm.
The invention further resides in a method for making a glass article exhibiting a relatively broad band of high contrast polarizing properties in the infrared region of the radiation spectrum from glasses which are phase-separable to form silver, copper, or copper-cadmium halide crystals, the method comprising the steps of:
(a) melting a batch for a glass containing a source of silver, copper, or copper-cadmium and at least one halogen other than fluorine,
(b) cooling and shaping the melt into a glass article of a desired configuration,
(c) subjecting the glass article to an elevated temperature for a period of time sufficient to generate and precipitate silver, copper, or copper-cadmium crystals in the glass, the crystals ranging in size between about 200 and 5000 Å,
(d) elongating the glass article under stress at a temperature above the annealing point of the glass to elongate the crystals and align them in the direction of the stress, and,
(e) exposing the elongated glass article to a reducing atmosphere at a temperature above about 250° C., but below about 400° C. to initiate reduction, to silver or copper metal, of spots on, or in, the halide particles to form nuclei, and conducting the reduction at a pressure of at least 10 atmospheres for a period of time sufficient to develop a reduced surface layer on the glass article within which the nuclei are grown into particles of varying aspect ratio deposited in and/or upon said elongated crystals, the aspect ratio being at least 2: 1, whereby the glass article exhibits a relatively broad range of high contrast polarizing properties in the infrared region of the radiation spectrum.
Prior Art
Prior literature of possible interest is listed and described in an attached document.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphical representation showing the contrast ratio curve for a polarizing glass article produced in accordance with prior conventional practice.
FIGS. 2-5 are graphical representations of typical contrast ratio curves obtained with the present invention.
DESCRIPTION OF THE INVENTION
The present invention adopts, and improves on, the known method of producing a polarizing glass body. Basically, it embodies the steps of melting a glass containing a source of silver, copper, or copper-cadmium and one or more halogens other than fluorine, forming a body from the glass, and cooling. It further embodies the conventional steps of heat treating the glass body to form and precipitate halide crystals of silver, copper, or copper-cadmium and then heating and subjecting the body to stress to elongate the halide crystals. In accordance with conventional practice, the body is then subjected to a thermal reduction step, preferably in a hydrogen atmosphere, to reduce a portion of the silver or copper halide crystals in a surface layer on the body to elongated metal particles having an aspect ratio of at least 2:1.
Practice of the present invention contemplates employing all of the steps in the conventional manner without changes, except for the final reduction step. The present invention is concerned only with the final step in which reduction of metal halide, to metal takes place. In a broad sense, it is proposed to carry out the reduction step at a lower temperature below 400° C. and at a high pressure. This produces reduced metal particles of a different nature, and that have a different effect on polarizing characteristics.
As indicated earlier, present practice produces a polarizing glass with a relatively narrow bandwidth. Bandwidth is determined by the distribution of elongated particles that result after hydrogen reduction of the stretched glass. In particular, it is the summation of the aspect ratios of the particle shapes. Each shape produces a peak contrast at a different wavelength. The shape of a contrast versus wavelength curve for a polarizing glass is therefore the superposition of the peaks for all the particles.
The aspect ratio of the crystal particles is a function of elongating stress. Consequently, the contrast peak and bandwidth shift across the infrared spectrum depending on the elongating stress. For example, the values for a polarizer effective at 1500 nm are quite different from one effective at 600 nm. With the reduction of the halide to metal in accordance with conventional practice, the aspect ratio changes, but the distribution remains essentially the same.
The present invention is based on a way of producing a broader distribution of metal particle aspect ratios using the same initial halide crystal distribution. It has been observed that reduction of the halide crystals to the metal state occurs very slowly at temperatures below 400° C. It appears that, in order to obtain reduction within a reasonable time under normal practice, it is necessary that the halide be molten. Silver halide melts at 400° C.
The reduction process is pictured as occurring by formation of metal nuclei at spots on, or in, the halide particles. Growth of the nuclei then occurs, but at a very slow rate below 400° C. While ultimate complete reduction of a halide particle would be expected to occur, it has not been observed to occur within any practical time at a temperature below 400° C.
We have now found that the rate of reduction can be greatly increased at a temperature below 400° C. by operating at pressure markedly above the normal one atmosphere. While some effect is achieved at a pressure on the order of 10 atmospheres, it is preferred to operate at 50-100 atmospheres, and even higher if practical. We have found that the reduction rate varies as the square root of the pressure. Also, the reaction proceeds with a dependence on the square root of time. Consequently, by employing a reduction pressure of 100 atmospheres at a given temperature, the time required at one atmosphere is reduced by a factor of 100. This then provides a practical reduction process at a temperature below 400° C.
The significance of this discovery is not simply the ability to operate at a temperature below 400° C. Rather, it is the ability to achieve a much broader bandwidth than heretofore attainable. This is due to the fact that metal particles grown from nuclei on, or in, the metal halide particles have a different shape and aspect ratio from that of the crystal itself. As a result, there are, effectively, a range of other aspect ratios added to the available distribution. This in turn provides the desired broader bandwidth as measured at a contrast of 100,000. Thus, with pressure of 100 atmospheres of hydrogen, we can obtain bandwidths of 700-900 nm, as compared to the commercial value of 200 nm heretofore available.
The glass employed may be any of the known glasses that can be phase-separated to form silver, copper, or copper-cadmium crystals in the glass. Such glasses are disclosed, for example, in U.S. Pat. Nos. 4,190,451 (Hares et al.) and 3,325,299 (Araujo) disclosing photochromic glasses and 5,281,562 (Araujo et al.) disclosing non-photochromic glasses. Each of these patents is incorporated by reference, particularly for its teaching of glass composition ranges and their production. Preferred glasses are those disclosed in the Hares et al. patent.
It is, of course, necessary to form halide crystals of silver, copper, and/or copper-cadmium in the glass article. This may occur during cooling. However, the preferred practice is to cool quickly, and then reheat under controlled conditions to precipitate the necessary crystals. It has been customary to perform the steps at a temperature below 750° C. However, a companion application, provisional no. 60/027,256 filed Sep. 30, 1996 in the names of D. G. Grossman et al., describes a method characterized by heating at a temperature of 750° C. or higher, preferably for at least an hour. This provides various advantages as described in that application.
As indicated, the glass containing halide crystals, must be elongated to stretch and orient the crystals. This prepares the crystals for further treatment to prepare them for reduction to produce a polarizing glass. Conventional practice is to conduct this step at about 710° C.
The present invention is concerned with, and modifies, the final step in which the glass is subjected to a thermal reduction treatment. In accordance with prior practice, the thermal reduction treatment was carried out at a temperature on the order of 415° C. for times of 3-6 hours and at a pressure of one or two atmospheres. It was considered desirable to employ as high a temperature as compatible with the tendency to respheriodize.
In contrast, the production treatment step of the present invention is carried out at a temperature below 400° C. and at a high pressure. While some improvement may be obtained at pressures of 5-10 atmospheres, it is more practical to operate at a higher pressure, for example, 100 atmospheres reducing gas pressure. The maximum pressure is dependent on the capability of the chamber employed.
As explained earlier, this modified reduction treatment permits achieving high contrasts over a much broader bandwidth. Our preferred practice, then, is to achieve contrasts greater than 100,000 over a broad bandwidth by exposing the glass to a reducing gas, preferably hydrogen at as high a pressure as practical for a period of one hour at a temperature of 350-380° C.
The time of treatment will depend on the depth of reduction layer desired. While the depth is not critical, we prefer a depth of about 100 m. At temperatures of 350-380° C., this may be obtained in a time of about one hour.
A reducing atmosphere of H 2 is most effective. However, this may be diluted for safety considerations, and other known reducing atmospheres may also be employed.
The procedure just described is effective to increase bandwidth across the infra-red spectrum. However, it is most effective at lower wavelengths of 600-1200 nm.
We have further found that the effect at longer wavelengths can be further enhanced by a subsequent treatment at a temperature above 400° C., for example at 415° C. This produces a much shallower reduced layer of about 10-15 m. Strangely enough, the two reduced layers appear to operate independently and do not have a detrimental effect on each other. As a result, the order of treatment is not important. However, it is usually more convenient to conduct the lower temperature treatment first.
The invention is further described with reference to test pieces of glass processed in identical manner, except for the hydrogen atmosphere conditions employed during the reduction step. Data obtained from measurements on the test pieces after the reducing treatments are plotted in the accompanying drawings. The glass employed in making test pieces to obtain the data presented in the drawings has the following composition in % by weight as calculated from the batch on an oxide basis:
SiO 2
56.3
ZrO 2
5.0
B 2 O 3
18.2
TiO 2
2.3
Al 2 O 3
6.2
Ag
0.24
Na 2 O
5.5
CuO
0.01
Li 2 O
1.8
Cl
0.16
K 2 O
5.7
Br
0.16.
FIG. 1 is a graphical representation in which contrast ratios are plotted on the vertical axis. Wavelengths in nm are plotted on the horizontal axis. The glass test piece employed in this test was stretched at a temperature in the range of 580-610° C. in accordance with commercial practice for attaining a peak central wavelength of 1300 nm. It was then exposed to a hydrogen atmosphere at one atmosphere pressure for four hours at 420° C.
The curve in the drawing is based on contrast ratios of the two components of polarized light as measured between about 800 and about 1500 nm. The horizontal, dashed line shows the wavelength range over which the contrast ratio is over 100,000. The breadth of this range is about 200 nm between 1200 and 1400 nm.
FIG. 2 is a corresponding graphical representation of data measured on the test piece of FIG. 1 after a subsequent treatment. This treatment was carried out for 1 hours at 350° C. in a hydrogen atmosphere at a pressure of 100 atmospheres.
As in FIG. 1, contrast ratios are plotted on the vertical axis and wavelengths in nm on the horizontal axis. Likewise, the horizontal, dashed line shows the wavelength range over which the contrast ratios are above 100,000 nm. The breadth of this range is about 700 nm and extends between about 700 and about 1400 nm. It is evident that the treatment of the present invention greatly expands the breadth of the range at the 100,000 ratio, as well as extending it down to lower wavelengths. Thus, this polarizer would be effective for use at effective wavelengths of 900, 1100 and 1300 nm.
Similar tests were carried out on comparable test pieces that were stretched at a somewhat higher stress to provide a CWL of about 1480 nm. This produced a breadth of about 240 nm between 1360 and 1600 nm with one test piece subjected to the standard one atmosphere hydrogen pressure at 420° C. Treatment with 100 atmospheres at 350° C. produced a breadth of about 900 nm between about 600 and 1500 nm on the other test piece.
FIG. 3 is a graphical representation corresponding to FIGS. 1 and 2, but showing data measured on another test piece. This test piece was stretched under a stress adapted to produce a CWL of about 900 nm, and received only a single thermoreduction treatment. This treatment was at a temperature of 350° C. for 1 hours with a pressure of 100 atmospheres hydrogen. The curve in the FIG., like that in FIG. 1 is based on contrast ratios of the two components of polarized light measured at wavelengths from 600 to 1700 nm. The dotted line shows the breadth of the wavelength band at a contrast ratio of 100,000. The value is about 600 nm from 600 to 1200 nm.
It will be appreciated that the specific embodiments merely illustrate, rather than limit the invention. Thus, wavelength bands for a contrast ratio of 100,000 may be obtained at different wavelengths by varying the stretching stress.
FIGS. 4 and 5 are further graphical representations corresponding to FIGS. 1-3. They show contrast versus wavelength curves for test pieces treated under different conditions.
The test piece represented by FIG. 4 was heated in a hydrogen atmosphere at a pressure of 100 atmospheres for 16 hours at 280° C. While a bit long to be commercially practical, this data illustrates the effectiveness of the invention at a low temperature approaching the minimum temperature of about 250° C. The bandwidth is about 500 nm.
The test piece of FIG. 5 shows the result of reducing a test piece for a present commercial time under a pressure of 100 atmospheres of hydrogen and a temperature of 350° C. This demonstrates that the bandwidth of about 200 nm, obtainable by conventional practice, can be extended to 900 nm, a four to five fold increase.
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A polarizing glass article, and a method of making the article, that exhibits a broad band of high contrast polarizing properties in the infrared region of the radiation spectrum, that is phase-separated by precipitating silver, copper, or copper-cadmium halide crystals in the glass within a size range of 200-5000 Å, and that contains elongated silver, copper, or copper-cadmium metal particles formed on or in the halide crystals, and having an elongated aspect ratio of at least 2:1, the article having a contrast ratio of at least 100,000 over a range of at least 300 nm.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a calender roll cleaning apparatus for smoothing a surface of a magnetic layer of a magnetic recording medium.
2. Description of the Related Art
During production of a magnetic recording medium, after coating a magnetic coating material on a non-magnetic support, a calender apparatus for smoothing a surface of a magnetic layer is used. The calender apparatus includes a plurality of calender rolls, that is, metal rolls and elastic rolls, alternately disposed. After placing the side of the magnetic layer of the magnetic recording medium next to the metal roll, the magnetic recording medium is fed into a nip portion located between the metal roll and the elastic roll, whereby the surface of the magnetic layer is smoothened.
However, in the calender apparatus, a binder, a hardening agent and a lubricant of the magnetic coating material coated on the magnetic recording medium are released, whereby the surfaces of the metal rolls or the elastic rolls are stained. Also, the stains on the surfaces of rolls are transferred onto the magnetic layer, etc. of the magnetic recording medium, thereby causing drop-out of the magnetic recording medium and spoiling the recording and reproducing qualities.
In order to remove the stains from the surfaces of the metal rolls of the calender apparatus, there has hitherto been proposed a roll cleaning apparatus that brings a cleaning tape into sliding contact with the surfaces of the metal rolls.
However, in this conventional roll cleaning apparatus, the cleaning tape is brought into sliding contact with the surfaces of the metal rolls in a dry system, and therefore, the stains on the roller surfaces cannot be adequately removed. As a result, production is interrupted every hour or two, and the stains on the surfaces of the metal rolls are wiped off by hand, resulting in poor productivity.
SUMMARY OF THE INVENTION
It is an object of the present invention to adequately remove the stains from the surfaces of the calender rolls and improve productivity of the calender treatment.
A first aspect of the present invention relates to a calender roll cleaning apparatus for smoothing a surface of a magnetic layer of a magnetic recording medium passed through a plurality of calender rolls. The cleaning apparatus comprises a wiping cloth feeding apparatus that feeds a calender roll surface wiping cloth at a definite rate and tension. A cleaning liquid supplying apparatus supplies a controlled amount of cleaning liquid such that the cleaning liquid permeates into the wiping cloth fed from the wiping cloth feeding apparatus. A wiping cloth pressing apparatus presses the permeated wiping cloth at a controlled pressing load.
Incidentally, the term “definite” of “definite tension” and “definite feeding rate” means a tension and a feeding rate, respectively, generated under a mechanically definite control. For example, not only does “definite feeding rate” include the case of setting the feeding rate to a definite rate of 10 cm/minute but also the case of varying the feeding rate by from 5 to 15 cm/minute by control rollers. The same logic is also applicable to the “definite tension.”
A second aspect of the present invention relates to the calender roll cleaning apparatus according to the first aspect, wherein the cleaning liquid supplying apparatus is equipped with a porous member that oozes the cleaning liquid and is brought into contact with the wiping cloth.
A third aspect of the present invention relates to a calender roll cleaning apparatus according to the first or the second aspect, wherein the cleaning liquid supplying apparatus controls the cleaning liquid supply amount to the amount at which the cleaning liquid applied to the calender roll from the wiping cloth is vaporized before reaching a magnetic recording medium nip portion located between the rolls.
Still another aspect of the present invention relates to a calender roll cleaning apparatus according to any aspects above, wherein the feeding rate of the wiping cloth is from 3 to 60 cm/minute and the pressing load is from 5 to 7 kgf.
According the first aspect of the present invention, the following advantageous effects are obtained. The use of a fresh wiping cloth fed at a proper feeding rate from the wiping cloth feeding apparatus. The use of a wet wiping cloth permeated with a cleaning liquid is supplied at a proper amount controlled by the cleaning liquid supply apparatus. The use of a wiping cloth pressed against the calender rolls at a proper pressing load controlled by the wiping cloth pressing apparatus so as to adequately remove stains from the surfaces of the calender rolls.
According to the second aspect of the present invention, the following advantages are obtained. The cleaning liquid supply apparatus is equipped with a porous member that oozes a cleaning liquid. By contacting the porous member with the wiping cloth, the cleaning liquid is uniformly distributed throughout the entire wiping cloth, whereby the stains on the surfaces of the calender rolls are adequately removed.
According to the third aspect of the present invention, the following advantages are obtained. The cleaning liquid supply apparatus controls the cleaning liquid supply amount to the amount at which the cleaning liquid applied to the calender rolls from the wiping cloth is vaporized before reaching the magnetic recording medium nip portion of the rolls. Thus, the cleaning liquid applied to the calender rolls disappears immediately after acting to remove the stains from the surfaces of the calender rolls, whereby the cleaning liquid is not brought into contact with a magnetic recording medium in the nip portion of the calender rolls to dissolve the magnetic coating material coated thereon.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view showing a calender roll cleaning apparatus.
FIG. 2 is a schematic view showing a cleaning liquid supplying apparatus of the calender roll cleaning apparatus of FIG. 1 .
FIG. 3 is a schematic view showing a calender apparatus.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The calender apparatus 10 of FIG. 3 has, for example, three metal rolls 11 A to 11 C and two elastic rolls 12 A and 12 B alternately disposed in parallel. Nip portions 13 A to 13 D are formed between the adjacent metal roll 11 A and elastic roll 12 A, between the adjacent elastic roll 12 A and metal roll 11 B, between the adjacent metal roll 11 B and elastic roll 12 B, and between the adjacent elastic roll 12 B and metal roll 11 C, respectively. In the metal rolls 11 A to 11 C, for example, a chromium plating is applied to a surface of a steel roll, and the surface thereof is polished. The surfaces of the elastic rolls 12 A and 12 B are each provided with cotton, etc. Guide rolls 14 are also provided.
The calender apparatus 10 feeds a magnetic recording medium 1 while holding the medium using each of the nip portions 13 A to 13 D of the metal rolls 11 A to 11 C and the elastic rolls 12 A and 12 B. The magnetic layer side of the magnetic recording medium 1 faces the metal rolls 11 A to 11 C, and pressure and heat are applied to the magnetic layer of the magnetic recording medium 1 , whereby the magnetic layer surface is smoothed.
However, in the calender apparatus 10 , as shown in FIG. 1, a roll cleaning apparatus 20 is provided in each of the metal rolls 11 A to 11 C. In this case, the roll cleaning apparatus 20 can also be provided in each of the elastic rolls 12 A and 12 B. The roll cleaning apparatus 20 provided in the metal roll 11 A (the same as the roll cleaning apparatus 20 provided in other metal rolls 11 B, etc.) is hereinafter explained.
The roll cleaning apparatus 20 has a wiping cloth feeding apparatus 21 , a cleaning liquid supply apparatus 22 , and a wiping cloth pressing apparatus 23 .
The wiping cloth feeding apparatus 21 has a brake-equipped unwinding reel 21 A, a motor-equipped winding reel 21 B, and feeding gears 21 C. The wiping cloth feeding apparatus 21 feeds a wiping cloth 24 for wiping the surface of the metal roll 11 A at a definite feeding rate while maintaining a definite tension. The feeding gears 21 C are composed of a pair of adjustable driving spur gears holding the wiping cloth 24 and apply a feeding force to the wiping cloth 24 .
The cleaning liquid supply apparatus 22 has a pump 22 A and a supply head 22 B. The cleaning liquid supply apparatus 22 supplies a cleaning liquid so that the cleaning liquid is permeated into the wiping cloth 24 fed from the wiping cloth feeding apparatus 21 , and the supply amount thereof can be controlled by controlling the discharge amount of the pump 22 .
The wiping cloth pressing apparatus 23 has two press rolls 23 A, 23 A and pressing apparatuses 23 B, 23 B for pressing the press rolls 23 A, 23 A against the metal roll 11 A. The wiping cloth 24 fed from the unwinding reel 21 A of the wiping cloth feeding apparatus 21 is wound around the press rolls 23 A, 23 A to regulate the feeding route of the wiping cloth 24 around the metal roll 11 A. The wiping cloth 24 permeated with the cleaning liquid by the cleaning liquid supply apparatus 22 is pressed against the metal roll 11 A, and the pressing load is controlled by press controlling the pressing apparatus 23 B.
As the wiping cloth 24 , for example, “SAVINA” (a Japanese Registered Trade Mark) “MINIFMAX” (a Japanese Registered Trade Mark) grade using super fine fibers made by Kanebo, Ltd., can be used. Also, as the cleaning liquid, a solvent for cleaning, for example, methyl ethyl ketone, can be used.
Also, in the cleaning liquid supply apparatus 22 , the supply head 22 B can be equipped with a porous member 22 C made of, for example, a fluorocarbon resin sintered material. The porous member 22 C is contacted with the wiping cloth 24 that is made to back up to the press roll 23 A and can ooze the cleaning liquid into the wiping cloth 24 .
Further, the cleaning liquid supply apparatus 22 controls the cleaning liquid supply amount by controlling the discharge amount of the pump 22 A to the amount at which the cleaning liquid applied to the metal roll 11 A from the wiping cloth 24 is vaporized before reaching the nip portion 13 A located between the metal roll 11 A and the elastic roll 12 A.
The roll cleaning apparatus 20 performs the cleaning process in the following manner.
The fresh wiping cloth 24 unwound from the unwinding reel 21 A of the wiping cloth feeding apparatus 21 is wound around the press rolls 23 A, 23 A and fed via the feeding route around the metal roll 11 A at a definite tension and a definite rate. The cleaning liquid oozed from the porous member 22 C of the supply head 22 B of the cleaning liquid supply apparatus 22 is permeated into the wiping cloth 24 . In this case, the supply amount of the cleaning liquid supplied to the wiping cloth 24 is controlled to the amount at which the cleaning liquid applied to the metal roll 11 A from the wiping cloth 24 is vaporized before reaching the nip portion 13 A located between the metal roll 11 A and the elastic roll 12 A. Finally, the wiping cloth 24 permeated with the cleaning liquid is pressed against the metal roll 11 A by the wiping cloth pressing apparatus 23 . In this case, the pressing load is controlled by the pressing apparatus 23 B.
There are many advantages obtained by the present invention. The use of a fresh wiping cloth 24 fed at a proper feeding rate from the wiping cloth feeding apparatus 21 . The use of a wet wiping cloth 24 permeated with a proper amount of cleaning liquid controlled by the cleaning liquid supply apparatus 22 . The use of a wiping cloth 24 pressed against the calender roll 11 A, etc. at a proper pressing load controlled by the wiping cloth pressing apparatus 23 so as to ensure that stains are removed from the surfaces of the calender roll 11 A, etc.
The cleaning liquid supply apparatus 22 is equipped with the porous member 22 C that oozes a cleaning liquid. By contacting the porous member 22 C with the wiping cloth 24 , the cleaning liquid is uniformly distributed throughout the entire wiping cloth 24 , whereby the stains on the surfaces of the metal roll 11 A, etc. are adequately removed.
The cleaning liquid supply apparatus 22 controls the cleaning liquid supply amount such that the cleaning liquid applied to the metal roll 11 A, etc. from the wiping cloth 24 is vaporized before reaching the magnetic recording medium nip portion 13 A, etc. of the roll 11 A, etc. Thus, the cleaning liquid applied to the metal roll 11 A, etc., disappears immediately after removing stains from the surfaces of the metal roll 11 A, etc., such that the cleaning liquid is not brought into contact with a magnetic recording medium in the nip portion 13 A, etc. of the metal roll 11 A, etc. to dissolve the magnetic coating material coated thereon.
EXAMPLES
Preferred values of the cleaning working conditions of the roll cleaning apparatus 20 provided in the above-described calender apparatus 10 were as follows.
(A) Feeding Rate of the Wiping Cloth 24
A preferred value of the feeding rate of the wiping cloth 24 was from 3 cm/min. to 60 cm/min., and more preferably from 5 cm/min. to 40 cm/min.
(B) Supply Amount of the Leaning Liquid
Preferred values of the common values (gf/min) in the case of using methyl ethyl ketone as the cleaning liquid are shown in Table 1 with respect to the roll temperature of the metal roll 11 A, etc. and the line speed of the magnetic recording medium 1 .
TABLE 1
Line speed
Roll temperature
Supply amount of
m/min.
° C.
Cleaning liquid gf/min.
100
70
2.5
80
4.4
90
6.8
200
80
6.5
90
8.2
(C) Pressing Load of the Wiping Cloth 24
A preferred value of the pressing load of the wiping cloth 24 was from 5 to 7 kgf.
A specific embodiment of the present invention has been described in detail with reference to the attached drawings. However, the invention is not limited thereto. Variations may be made without deviating from the spirit and scope of the invention.
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The present invention relates to a calender roll cleaning apparatus for smoothing a surface of a magnetic layer of a magnetic recording medium passed through a plurality of calender rolls. The cleaning apparatus comprises a wiping cloth feeding apparatus that feeds a calender roll surface wiping cloth at a definite rate and tension. A cleaning liquid supplying apparatus supplies a controlled amount of cleaning liquid such that the cleaning liquid permeates into the wiping cloth fed from the wiping cloth feeding apparatus. A wiping cloth pressing apparatus presses the permeated wiping cloth at a controlled pressing load.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of application Ser. No. 11/582,465 filed Oct. 18, 2006, which is a continuation of application Ser. No. 09/656,709 filed Sep. 7, 2000 now U.S. Pat. No. 7,151,729, and claims the benefit of U.S. Provisional Application No. 60/214,734, filed Jun. 29, 2000, in the U.S. Patent & Trademark Office, the disclosures of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a recording medium having a read-only storage area and a writable storage area and a recording/reproducing apparatus and method therefor, and more particularly, to a recording medium having a read-only storage area complying with a digital versatile disc (DVD) specification and a writable storage area physically compatible with a DVD-writable specification and a recording/reproducing apparatus therefor.
[0004] 2. Description of the Related Art
[0005] Generally, read-only optical recording media that are manufactured by injection molding have characteristics in that information is configured in the form of embossments referred to as pits so that user information is recorded on a mold, and the information is transferred during injection. Accordingly, read-only optical recording media are advantageous in increasing production efficiency compared to the case where information is recorded on a floppy disc or a magnetic recording medium and distributed.
[0006] However, read-only optical recording media on which users cannot record data have a problem in that data cannot be modified or added in application examples such as an encyclopedia and popular music data for accompaniment which frequently require modification of data and addition of data.
[0007] Meanwhile, among digital versatile disc specifications, read-only discs are defined in a digital versatile disc read only memory (DVD-ROM) specification (DVD Specification for read-only memory Part 1 version 1.0). Discs on which a user can record data are defined in a digital versatile disc random access memory (DVD-RAM) specification (DVD Specification for rewritable memory Part 1), in a digital versatile disc recordable memory (DVD-R) specification (DVD Specification for recordable memory Part 1), and in a digital versatile disc rewritable memory (DVD-RW) specification (DVD Specification for re-recordable memory Part 1).
[0008] However, discs having both a read-only specification and a recordable specification are not defined so that requirements for modification of data and addition of data, which are characteristics of a recordable disc, and requirements for mass copying of the same data, which is a characteristic of a read-only disc, cannot be simultaneously satisfied.
[0009] When proposing a new optical disc satisfying the above requirements, compatibility with a recording/reproducing apparatus according to a conventional specification should be considered. In other words, it is important to make a new optical disc satisfying the above requirements to be compatible with a conventional recording/reproducing apparatus which is made and performs, without consideration of a medium having the characteristics of both a recordable disc and a read-only disc.
[0010] In this case, it is apparent that complete compatibility cannot be achieved because the characteristic of a particular area on a single disc changes. Accordingly, as for compatibility, the characteristics of a read-only medium are primarily considered such that data in a read-only storage area can be reproduced in a conventional apparatus for only reproducing, and simultaneously, a writable storage area is considered to be compatible with physical recording/reproducing characteristics defined in a conventional rewritable specification taking into account the fact that data can be additionally recorded or updated in the writable storage area while a user is using a disc.
[0011] In addition, it is preferable that an optical recording medium having a read-only storage area and a writable storage area has drive compatibility with a conventional DVD-ROM drive and a conventional DVD-RAM drive.
[0012] For a clear understanding of the present invention, a structure of an optical disc (optical recording medium) defined according to a digital versatile disc read only memory (DVD-ROM) specification will be described in detail. FIG. 1 is a sectional view of a conventional dual layer optical disc 10 defined according to the DVD-ROM specification. The optical disc 10 defined according to the DVD-ROM specification comprises first and second substrates 12 , 14 . Information layers 16 , 18 are formed on the first and second substrates 12 , 14 , respectively, and the first and second substrates 12 , 14 are united such that the information layers 16 , 18 face each other. The information layer ( 16 in this instance) nearer to a substrate on which a read laser beam is incident is defined as a first recording layer, and the underlying information layer ( 18 in this instance) is defined as a second recording layer.
[0013] Such an optical disc 10 includes a lead-in area (not show) at an innermost part of the optical disc 10 and a lead-out area (not shown) at an outermost part of the optical disc 10 , or a middle area in which various control information (not shown) and information on the physical characteristics of the optical disc 10 is recorded, so that data in the inner part and the outer part can be steadily read.
[0014] Generally, a read-only optical disc is molded by injecting a polycarbonate resin material into a die, referred to as a stamper, on which information is formed in the form of embossed pits, such that the information can be transferred to the read-only disc. After forming the read-only optical disc by injection, a material such as aluminum having a characteristic of reflecting light is sputtered on an information surface to form a reflective layer.
[0015] A DVD-ROM (the optical disc 10 ) is formed by uniting two discs (the first and second substrates 12 , 14 ), each of which is molded according to the above method to have a thickness of 0.6 mm, so as to have a total DVD-ROM thickness of 1.2 mm. One substrate may not have a recording layer, or each substrate may have two recording layers. In the case where each of first and second substrates 12 , 14 has a single recording layer, when the optical disc is formed such that data can be read from only one side of the optical disc, the optical disc is referred to as a dual layer optical disc. When a disc is formed such that data can be read from layers on both sides of the optical disc 10 , the optical disc 10 is referred to as a double sided disc.
[0016] As described above, since information is recorded on a read-only optical disc while it is being formed by injecting a polycarbonate resin material into a stamper on which information is formed, the information can be formed on the read-only optical disc in a short time as compared to a magnetic recording medium or a writable recording medium. Accordingly, the read-only optical disc is suitable for mass producing the same data, such as a film or a computer game which needs to be copied in large quantity.
[0017] FIG. 2 is a diagram showing a structure of a conventional optical disc recording medium 20 having two data storage areas having different characteristics. Data which can be reproduced using a laser of 780 nm is recorded in a first recording area 26 on the optical disc 20 , and data which can be reproduced using a laser of 635-650 nm is recorded in a second recording area 27 . Referenced numeral 22 denotes a standard density information layer for a compact disc (CD), reference numeral 23 denotes a high-density information layer for a DVD, reference numeral 24 denotes a second substrate layer, reference numeral 25 denotes a first substrate layer, reference numeral 26 denotes the first recording area which is readable using the laser of 780 nm, and reference numeral 27 denotes the second recording area which is readable using the laser of 635-650 nm. The dual layer high-density optical disc 20 of FIG. 2 is disclosed in U.S. Pat. No. 5,732,065, entitled “Optical Information Carrier Including Standard and High Density Layers,” and filed on Sep. 4, 1996.
[0018] FIG. 3 shows a structure of a complex recording layer 32 of a typical writable, optical recording medium 30 . Since user data is not recorded on a disc during manufacturing of a writable medium such as a digital versatile disc random access memory (DVD-RAM), substrates can be formed using the same stampers. Unlike a read-only medium in which a reflective layer is simply formed, a complex recording layer including a plurality of films (i.e., a dielectric layer 34 , a recording layer 36 , another dielectric layer 38 and a reflective layer 40 shown in FIG. 3 ) needs to be formed on a substrate 42 to allow a user to record data on the optical recording medium 30 . A DVD-RAM or a digital versatile disc-rewritable (DVD-RW) has a complex recording layer having a multi-layered structure such that recording can be achieved using a change in a material of the recording layer 36 , that is, a change between an amorphous state and a crystalline state.
SUMMARY OF THE INVENTION
[0019] To solve the above and other problems, a first object of the present invention is to provide an optical recording medium that is compatible with a digital versatile disc (DVD) specification and also has a read-only storage area and a writable storage area.
[0020] A second object of the present invention is to provide an optical recording medium which has a read-only storage area and a writable storage area, and on which control information for the writable storage area is recorded in the read-only storage area so that the optical recording medium can be compatible with a DVD specification.
[0021] A third object of the present invention is to provide a recording/reproducing apparatus for an optical recording medium that is compatible with a DVD specification and also has a read-only storage area and a writable storage area.
[0022] In order to achieve at least the first and second objects, the present invention provides an optical recording medium comprising a substrate; a read-only storage area at an inner part of the substrate; and a writable storage area at an outer part of the substrate.
[0023] To achieve at least the third object of the present invention, there is provided an apparatus for recording/reproducing data onto/from an optical recording medium having a read-only storage area at an inner part of a substrate and a writable storage area at an outer part of the substrate, the apparatus comprising a system controller which generates identification information for indicating that the optical recording medium is a hybrid disc having the read-only storage area and the writable storage area; and a recording unit which records the data of the read-only storage area, which is updated for use by correction, modification and addition, in the writable storage area, and the generated identification information in the lead-in area of the read-only storage area.
[0024] Preferably, the recording/reproducing apparatus further comprises a reproducing unit which reproduces data from the optical recording medium by controlling a reference linear velocity for reproduction at the read-only storage area to be the same as a reference linear velocity at the innermost part of the writable storage area.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The above and other objects and advantages of the present invention will become more apparent by describing in detail preferred embodiments thereof with reference to the attached drawings in which:
[0026] FIG. 1 is a sectional view of an optical recording medium compatible with a conventional digital versatile disc read only memory (DVD-ROM) specification;
[0027] FIG. 2 is a diagram showing a structure of a conventional optical recording having two kinds of data storage areas having different characteristics;
[0028] FIG. 3 is a diagram showing a structure of a conventional recording layer of a writable optical recording medium, which provides for a clear understanding of the present invention;
[0029] FIGS. 4 through 9 are examples of structures of embodiments of an optical recording medium having a read-only storage area and a writable storage area according to the present invention;
[0030] FIG. 10 is a diagram showing a control information format in a lead-in area on an optical recording medium according to the present invention;
[0031] FIG. 11 is a diagram showing a structure of hybrid disc identification information of the control information shown in FIG. 10 ;
[0032] FIGS. 12A and 12B are diagrams showing an information structure of a lead-in area on an optical recording medium having a writable specification and an information structure of a lead-in area on an optical recording medium having a read-only specification, respectively, for clear understanding of the present invention; and
[0033] FIG. 13 is a block diagram of a recording/reproducing apparatus using an optical recording medium according to embodiments of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0034] Reference will now made in detail to the present preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below in order to explain the present invention by referring to the figures.
[0035] When an optical recording medium (hereinafter, referred to as a hybrid disc) having both a read-only storage area and a writable storage area, which are defined in a DVD specification, is defined under the situation that conventionally, individual DVD specifications for a read-only medium and a writable medium exist, compatibility of the specification for the hybrid disc with the conventional specifications becomes a problem as described before. The term “writable” may indicate “recordable” for a DVD-R, “rewritable” for a DVD-RAM and “re-recordable” for a DVD-RW.
[0036] A recording medium having a ROM and a RAM area is mainly used for supplying the same content in bulk by taking advantage of easy duplication, which is the characteristic of a read-only medium. Accordingly, the read-only storage area needs to be primarily considered in solving a compatibility problem.
[0037] In addition, since a physical space on a disc is divided such that a specific space is assigned as a read-only storage area, and another specific space is assigned as a writable storage area, the physical characteristics of a space on a hybrid disc are different from those of a space on a disc having only one kind of storage area. Accordingly, it is apparent that the specification for the hybrid disc cannot be completely compatible with conventional specifications.
[0038] In this specification, as for the compatibility, it is preferable that the read-only storage area has a compatibility such that data in the read-only storage area can be reproduced in a conventional reproducing apparatus, and a writable storage area is compatible with the recording/reproducing characteristics of a conventional writable medium such that additional circuits necessary for implementing a recording/reproducing apparatus for recording, modifying or reproducing data on the writable storage area can be minimized. By doing this, user data stored in the read-only storage area can be reproduced in a conventional reproducing apparatus at least so that the hybrid disc can be used for the same usage as that of a conventional DVD-ROM. In addition, a recording/reproducing apparatus for the hybrid disc according to the present invention can modify data stored in the read-only storage area or add new data to the data stored in the read-only storage area, thereby securing compatibility of the hybrid disc with a conventional DVD reproducing apparatus.
[0039] A first embodiment which considers the requirements for such compatibility is shown in FIG. 4 . In this diagram, a portion of a hybrid disc 40 is shown, wherein a data area 42 , in which user data can be prerecorded according to a conventional DVD-ROM specification, has a start diameter of 48 mm indicating the beginning of the data area and a maximum diameter of 116 mm (in the case of a disc having a diameter of 120 mm) or 76 mm (in the case of a disc having a diameter of 80 mm). In other words, the start diameter is predetermined, but the end diameter of the data area is not fixed to a certain value. A range is given for the end diameter.
[0040] Accordingly, the start diameter of the data area is set to 48 mm, and the end diameter of the data area is set to be larger than 48 mm and smaller than 116 mm in the case of an optical disc having a diameter of 120 nm (or 76 mm in the case of an optical disc having a diameter of 80 mm), and a writable storage area is defined in the remaining area other than an information area for recording control information among the area in which read-only data is not recorded, thereby obtaining optimal compatibility with a conventional DVD-ROM.
[0041] When considering the fact that a recording area is divided into a plurality of zones using a zoned continuous linear velocity (ZCLV) method in a DVD-RAM, it is preferable to assign at least an area corresponding to the size of a single zone defined in a DVD-RAM specification for the writable storage area.
[0042] In the case of the conventional DVD-RAM, various control information, such as the rotation speed of a disc and defect management information, are closely related to the size and the location of a zone. In particular, the rotation speed of the DVD-RAM is not only connected with a zone but also closely related to the recording characteristics of such a phase-change recording medium. Accordingly, to be compatible with the physical recording characteristics of the conventional DVD-RAM, it is preferable to consider size and location in the assignment of zones when the read-only storage area and the writable storage area are defined on the hybrid disc of the present invention.
[0043] In addition, the conventional DVD-ROM specification defines a dual layer disc. Accordingly, it is preferable to dispose the read-only storage area 44 defined by the dual layer DVD-ROM specification in an inner part of the hybrid disc 40 and the writable storage area of a single layer structure 50 in an outer part of the hybrid disc 40 beyond the read-only storage area 44 on the hybrid disc, as shown in FIG. 4 .
[0044] Since the conventional specification for the writable storage area 50 defines only the single layer structure, it is preferable to dispose the writable storage area 50 on a first recording layer 46 , LAYER 0 , on a first substrate 52 . This is because a heat transfer characteristic changes, and this may result in a change in a recording characteristic in a writable medium including a recording layer having a multi-layer structure when the order of a substrate on which the recording layer is formed and a plurality of layers included in the recording layer, changes in view of an incident laser beam.
[0045] The structure of the hybrid disc 40 shown in FIG. 4 defines a dual layer read-only storage area 44 , thereby realizing a capacity of 4.7 Gbytes, which is the size of the most widely used DVD-ROM, by applying the dual layer read-only storage area 44 , while including the writable storage area 50 .
[0046] FIG. 5 illustrates a second embodiment of the optical recording medium according to the present invention wherein a hybrid disc 60 is shown. A first substrate 62 has a transparent area 66 without having any storage area at its inner part and the writable storage area 50 at the outer circumference thereof. Meanwhile, the second substrate 54 has the recording layer 48 , LAYER 1 , in a read-only storage area 64 at its inner part, which is spatially separated from the writable storage area 50 of the first substrate 62 .
[0047] The two optical recording media, i.e., the second substrate 54 having the read-only storage area 64 , and the first substrate 62 having the writable storage area 50 , are combined with each other, thereby forming an optical recording medium 60 having both the read-only storage area 64 and the writable storage area 50 . As for the present embodiment of the optical recording medium, a writable medium manufacturing process and a read only medium manufacturing process can be applied separately, and different stampers (not shown) can be used in manufacturing the second substrate 64 having the read-only storage area 64 and the first substrate 62 having the writable storage area 50 . For this reason, even if the content of data to be written onto the read-only storage area 64 is changed, there is no need to change the stamper for the writable medium (the first substrate 62 ). On the other hand, an advantage in view of the read only medium, is that it is unnecessary to form a recording layer.
[0048] Also, the hybrid disc 60 as shown in the second embodiment in FIG. 5 enables a read only disc manufacturer to produce a recording medium having a writable storage area and a read-only storage area by simply combining a medium having a writable storage area, which is commercially available, with a medium having a read-only storage area produced by the manufacturer.
[0049] FIG. 6 illustrates a third embodiment of the optical recording medium according to the present invention, wherein a hybrid disc 70 is shown. The hybrid disc 70 has a single read-only storage area 74 at its inner part and a writable storage area 50 at its outer part. Thus, the hybrid disc 70 having the read-only storage area 74 and the writable storage area 50 , which have different features, can be implemented with a single substrate, which is a first substrate 52 .
[0050] To avoid the read-only storage area 74 from being exposed during the formation of a recording layer 76 in a writable storage area 60 , the read-only storage area 74 is covered with a mask (not shown) during formation of the recording layer 76 in the writable storage area 50 , and the mask is removed before formation of an outermost reflective layer (not shown) of the hybrid disc 70 , so that the hybrid disc 70 can be constructed. A second substrate 84 has a dummy recording layer 58 in both the read-only storage area 74 and the writable storage area 50 , so that no data is recorded on the entire dummy recording layer 58 The hybrid disc having both a read-only storage area and a writable storage area 50 can be produced through such successive processes using a single stamper.
[0051] FIG. 7 illustrates a fourth embodiment of the optical recording medium according to the present invention, showing a hybrid disc 90 , in which a dual layered read-only storage area 92 is formed at the inner part of each of the first and second substrates 102 and 104 by a two photo polymerization ( 2 P) technique, and a writable storage area 100 adopting a DVD-RAM format and having the recording/reproducing characteristics defined by a DVD-RAM format, is formed at the outer part of each of the first and second substrates 102 and 104 . For this case, writing or reading data onto or from the first and second recording layers 106 and 108 , LAYER 0 and LAYER 1 , formed at the first substrate 102 is performed through an incident side of entrance on the hybrid disc 90 of a laser beam of the first substrate 102 . Also, writing or reading data onto or from the first and second recording layers 106 and 108 , LAYER 0 and LAYER 1 , formed at the second substrate 104 is performed through an incident side of entrance on the hybrid disc 90 of a laser beam of the second substrate 104 . In the hybrid disc 90 having such a structure, formation of the recording layer at a portion of the storage area may be omitted. For example, the first substrate 102 may have a single layered read-only storage area or the second substrate may have no writable storage area.
[0052] FIG. 8 illustrates a fifth embodiment of the optical recording medium according to the present invention, wherein a hybrid disc 110 is shown. The structure of the hybrid disc 110 is the same as that shown in FIG. 4 , except that the writable storage area 120 is formed with a dual layered structure (the writable storage area 120 of the first and second recording layers 46 and 48 ), and is arranged at the outer part of each of the first and second substrates 52 and 114 . As shown in FIG. 8 , writing and reading operations are performed through the incident side of the first substrate 52 . For this case, recording/reproducing characteristics in the dual layered structure are different from those of the writable storage area having a single layered structure, so that the structure of a recording/reproducing apparatus for the optical recording medium may be complicated. Meanwhile, such a dual layered structure is advantageous due to an increased data writing capacity in the writable area.
[0053] FIG. 9 illustrates a sixth embodiment of the optical recording medium according to the present invention showing a hybrid disc 130 , in which a read-only storage area 134 is formed over a first substrate 142 , and a writable storage area 150 is formed over a second substrate 144 . The read-only storage area is formed of a first recording layer 146 , LAYER 0 , and the writable storage area is formed of a second recording layer 148 . This configuration may lower the compatibility in reading operations with other recording media. In addition, the recording characteristics are changed and thus the compatibility in writing operations with other recording media may be lowered. Advantages of the hybrid disc 130 shown in FIG. 10 are that a writable medium and a read only medium can be separately manufactured, as described previously, and data writing capacity increases.
[0054] In the case where the writable storage area 150 is formed at the second substrate 144 and the read-only storage area 134 is formed at the first substrate 142 , the hybrid disc 130 can be constructed to enable reading or writing of data from or to two recording layers through the incident side of the first substrate 142 , rather than one side of the hybrid disc 130 for one layer and the other side of the hybrid disc 130 for the other layer.
[0055] On the other hand, when the writable storage area 150 is formed at the first substrate 142 , the second recording layer 148 must be formed of a semi-transmissive layer, and data from the read-only storage area 134 formed at the second substrate 144 must be reproduced with a higher read power so as to compensate for reduced read laser power due to the first recording layer 146 of the first substrate 142 . For this case, it is very likely that data of the first recording layer 146 will be erased or changed by interference. The configuration shown in FIG. 9 contributes to minimizing such a problem with an increased writable storage area.
[0056] FIG. 10 illustrates the control information for correct playback from the optical recording medium according to the first through fifth embodiments of the present invention by a recording/reproducing apparatus.
[0057] As for a hybrid disc medium having a read-only storage area and a writable storage area, as previously mentioned, the read-only storage area is constructed to have compatibility with a conventional DVD-ROM reproducing apparatus. For this case, there is no problem in using a conventional DVD reproducing apparatus. However, a disc identifier for use in distinguishing a hybrid disc from a conventional DVD-ROM is required to enable an apparatus for recording/reproducing data onto/from the writable storage area to identify the hybrid disc. The need for such identification information may be satisfied by adding particular information to the lead-in area.
[0058] To implement the compatibility with a DVD reproducing apparatus which is able to recognize only a conventional DVD-ROM, it is preferable that data writing is performed with reserved bytes, without using the physical format information of the control data zone. This is because modifying the physical format information, for example, the BP 0 , of the existing control data zone including book type information indicating the type of specification book, and part version information of the specification book, to be suitable for a new medium, may result in losing compatibility.
[0059] In particular, DVD-ROMs do not utilize the 17 th through 32 nd bytes of the physical format information, and thus hybrid disc identification information indicating a hybrid disc having a read-only storage area and a writable storage area can be written using some reserved bytes for other writing formats. As shown in FIG. 11 , such hybrid disc identification information includes information on the presence or absence of the writable storage area, which is an indicator of the hybrid disc, and on part version for the hybrid disc.
[0060] Comparing the lead-in information of a DVD-ROM with the lead-in information of a DVD-RAM that is a writable medium, the lead-in information of the writable medium contains all fields of the lead-in information of the DVD-ROM. On the other hand, the lead-in information of the DVD-ROM uses only 16 bytes and the remaining bytes are reserved.
[0061] As for the writable medium, a plurality of information areas are allocated to the lead-in information for adding information on, for example, the recording characteristics of the medium. Also, the recording density belonging to the lead-in information of the DVD-RAM is constructed to be different from that of a DVD-ROM disc.
[0062] As shown in FIG. 10 , when reproduction is carried out from the lead-in area of the read-only storage area, the data area of the read-only storage area, the lead-out area of the read-only storage area, and the lead-in area of the writable storage area consecutively, the data transmission rate and the rotation speed of a spindle motor are varied, thereby slowing down a data recording/reproducing speed. To solve this problem, it is preferable for the hybrid disc to store the physical format information of the control data zone for the writable storage area in the lead-in area of the read-only storage area.
[0063] For this case, the reserved bytes among 2048 bytes allocated for the physical format information of the read-only storage area, i.e., the bytes after the 1024 th byte, are used to store the physical format information for the writable storage area, and thus the storage of corresponding information in the lead-in area of a writable medium can be omitted. As a result, a delay in writing and reading operations due to the difference in transmission rate and rotation speed of a spindle motor can be avoided.
[0064] FIG. 10 shows that the control data zone of the lead-in area of the read-only storage area includes physical format information, disc manufacturer information and reserved bytes. The physical format information comprises bytes BP 0 to BP 2047 . BP 0 includes the book type (DVD-ROM disc, DVD-RAM disc) and part version. In the present invention, the book type will be “DVD-ROM” so as to be readable by a conventional DVD-ROM player. BP 0 to BP 16 includes physical format information for a DVD-ROM, or in this instance, the read-only storage area. BP 17 to BP 18 includes the hybrid disc identification information as shown in FIG. 11 . BP 19 to BP 1023 are reserved bytes. BP 1024 to BP 2047 are physical format information for a DVD-RAM, or in this instance, the writable storage area.
[0065] As shown in FIG. 12A , a DVD-RAM, which has a writable format, has the same information structure of an embossed data zone having pits in the lead-in area as that of a DVD-ROM shown in FIG. 12B . In other words, a reference code, a buffer zone, an initial zone and the like are the same in terms of size and data value between the two information structures. The only difference between the two information structures lies in that a portion of information of the control data zone is different. This minor difference means that the two lead-in areas can be integrated with the identical information.
[0066] If the information of the two lead-in areas is integrated into the lead-in information for the read-only storage region, it is sufficient for the lead-in area of the writable storage area to only include a connection zone for connecting the read-only storage area and the writable storage area, defect management zones DMA 1 and DMA 2 , and a drive test zone.
[0067] The rewritable lead-in area is located in the writable storage area, and the connection zone is a mirror zone formed of a reflective layer without including any information, which is effective in minimizing the unnecessary space between the read-only storage area and the writable storage area.
[0068] FIG. 13 is a block diagram of an apparatus for recording/reproducing information onto/from the optical recording medium according to the embodiments of the present invention.
[0069] For a writing operation, an AV CODEC and/or host interface 210 compresses an A/V signal from the outside according to a predetermined compression scheme, and outputs information on the size of the compressed A/V data. A digital signal processor (DSP) 220 receives the compressed A/V data from the AV CODEC and/or host interface 210 , adds additional information to the received compressed AV data for error correction coding (ECC), and modulates the data according to a predetermined modulation scheme. A radio frequency amplifier (RF AMP) 230 converts the data modulated by the DSP 220 into an RF signal. A pickup unit 240 writes the RF signal from the RF AMP 230 onto the writable storage area of a disc (any of the hybrid discs 40 , 60 , 70 , 90 , 110 and 130 disclosed herein) mounted on a turn table. A servo unit 250 receives information required for servo control from a system controller 260 , and stably servo controls the disc.
[0070] The system controller 260 generates identification information for indicating a hybrid disc having a read-only storage area and a writable storage area, and controls the apparatus to write the identification information onto the lead-in area of the read-only storage area through the DSP 220 and the RF AMP 230 .
[0071] On the other hand, for a reading operation, the pickup unit 240 picks up the data, which is in the form of an optical signal, from a hybrid disc having a read-only storage area and a writable storage area, and outputs an electrical signal. The RF AMP 230 extracts a servo signal for use in servo controlling and the modulated data. The DSP 220 demodulates the modulated data from the RF AMP 230 based on the modulation scheme used for the previous modulation, corrects errors through ECC, and removes the data added for the ECC. The servo unit 250 receives information required for servo controlling from the RF AMP 130 and the system controller 260 , and performs servo controlling. The AV CODEC and/or host interface 210 decompresses the compressed AV data from the DSP 220 to output the original A/V signal. The system controller 260 controls the entire system for reading and writing information data from and to the hybrid disc seated on the turn table by user interfacing.
[0072] A problem of hybrid discs having a read-only storage area in a DVD-ROM format and a writable storage area in a DVD-RAM format is that a reference linear velocity is different for each area. Especially, a change in reference linear velocity for the writable storage area varies the recording characteristics, and thus data cannot be recorded on the area. On the other hand, as can be seen from an existing multiple speed reproducing system for DVD-ROMs, data can be reproduced from the read-only storage area at variable reproduction speeds, without causing any serious problem.
[0073] In the apparatus for alternately and repeatedly reproducing or recording data from or onto the read-only storage area and the writable storage area, respectively, it is preferable that the servo unit 250 reproduces the data from the read-only storage area at the same reference velocity as the reference linear velocity for recording and reproducing the data at the innermost part of the writable storage area.
[0074] As previously described, the present invention provides an optical recording medium having composite recording/reproducing characteristics, in which both a read-only storage area in the existing DVD-ROM format, and a writable storage area having the recording/reproducing characteristics defined by a DVD-RAM format are present on an optical recording medium such as a hybrid disc. In the hybrid disc according to the embodiments of the present invention, data correction, modification and addition of data stored in the read-only storage area is possible, using the writable storage area. In addition, the hybrid disc can be efficiently manufactured by various methods according to the present invention.
[0075] Although a few preferred embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
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An optical recording medium having a read-only storage area and a writable storage area and a recording/reproducing apparatus and method therefor. The optical recording medium is a hybrid disc having both the read-only storage area, which is suitable for mass production of information having the same contents, and the writable storage area on which data can be recorded, updated or added at a user's option. The read-only storage area has a structure that is completely compatible with a digital versatile disc read only memory (DVD-ROM) specification, and the writable storage area is compatible with the recording/reproducing characteristics of a writable DVD specification so that an existing reproducing-only apparatus can read information from the read-only storage area, and data can be recorded in the writable storage area using an apparatus obtained by minimally changing an existing recording/reproducing apparatus while maintaining the physical recording characteristics of the existing recording/reproducing apparatus.
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BACKGROUND OF THE INVENTION
The invention relates to a manipulator for deflecting a beam of laser radiation onto a microscope-observed field of surgical operation, the laser beam being deflected via a plane mirror which is rotatable about two different axes.
From Federal Republic of Germany OS 2,710,995, a laser-optical instrument is known for operations beneath a microscope in which a plane mirror aligns the laser beam and an optical axis of the microscope, and in which the position of the plane mirror is controlled by a servomechanism.
BRIEF STATEMENT OF THE INVENTION
The object of the invention is to provide a mirror-actuating mechanism for controlled deflection of a laser beam within an operating area, which mechanism can be operated sensitively by hand and the sensitivity of which is adjustable.
The invention achieves this object in conjunction with an actuating lever which is manually manipulable with two degrees of angular freedom about a fixed center of manipulation. The lower end of this lever is characterized by a cylindrical guide bore on a bore axis through the fixed center of rotation. A second lever is fulcrumed on an axis transverse to the rotary axis of an axially fixed member, and one end of the second lever has a motion pick-off connection to the handle lever, via the guide bore. The other end of the axially fixed member provides pivotal support of the mirror about a pivot axis transverse to the rotary axis of the axially fixed member, the pivot axis being parallel to the fulcrum axis of the second lever. And a link connection from the other end of the second lever to a point on the mirror (at offset from the mirror-pivot axis) completes a four-bar linkage; for one component of angular manipulation of the handle, the four-bar linkage is bodily rotatable to rotate the mirror about the rotary axis (of the axially fixed member), and for an orthogonally related component of angular manipulation of the handle, the four-bar linkage is angularly compressed or expanded, to change the tilt of the mirror about its pivot axis.
In order to adjust the transmission ratio of handle movement to mirror movement, the effective length of the second lever arm is advisedly variable, to enable adjustment of its point of motion pick-off from the first lever.
In one advantageous embodiment of the invention, the motion pick-off end of the second lever is characterized by a spherical enlargement guided in the guide bore of the handle lever, and the second lever arm can be adjusted by shifting the position of its spherical pick-off end within the cylindrical guide bore.
The advantages obtained with the invention reside, in particular, in the fact that the focused spot of the laser beam is deflected within the viewed operating area in the same direction as the handle is manipulated and that, as a result of the favorable transmission ratio of the lever motion pick-off relation, large angular displacements of the handle correspond to small laser-spot displacements on the operating area. Another great advantage of the manipulator resides in the possibility of changing the transmission ratio by changing the length of the second lever arm to change the point of motion pick-off; as a result, manipulated deflection of the laser beam on the operating area can be adapted to different magnification ratios in the surgical microscope.
DETAILED DESCRIPTION
The invention will be illustratively described in conjunction with the accompanying drawings, in which:
FIGS. 1a to 1d are similar basic diagrams to illustrate mirror-actuating lever mechanism of the invention, FIG. 1a showing the mechanism for a centered position of angular deflection in response to a first direction y of manual actuation about a first component axis, FIG. 1b showing the mechanism for an off-center displacement about the first axis, FIG. 1c showing the mechanism for a centered position of second-axis deflectability and FIG. 1d showing the mechanism for an off-center displacement about the second axis;
FIG. 2 is a view in partial section through a surgical microscope with an integrated manipulator for laser radiation; and
FIG. 3 is an enlarged fragmentary section through lever mechanism of FIG. 2.
In the diagrams of FIGS. 1a to 1d, 4 identifies an actuating handle or lever arm for moving a mirror 3 to deflect a laser beam. The handle 4 is provided with an enlarged spherical bearing formation 5 at its lower end. Within this spherical formation 5 is a cylindrical guide 6 within which the enlarged spherical end formation 7 of a second lever arm 8 is movable. An arm member 10 is axially retained at a bearing 24 and at one end is pinned to lever arm 8, thus providing a fulcrum for arm 8 action in response to y-directed actuation of handle 4; the other end of arm member 10 is forked at 10b where it is pinned (at 11-11a) to opposite sides of mirror 3, thus providing a fulcrum for mirror 3 displaceability; the fulcrums at the respective ends of member 10 are on parallel axes. A link arm 9 connects the lower end of lever arm 8 to the lower end (12) of the mirror. In the handle-centered position of FIG. 1a, mirror 3 is shown in a 45-degree beam-reflecting position, and upon displacement of handle 4 in the y direction, as though a relatively large angle α, mirror 3 is correspondingly moved through a relatively small angle α'.
Arm 10 is rotatable in bearing 24 to permit mirror (3) displacement in response to handle (4) actuation in the second-component or x direction. For this second component, FIGS. 1c and 1d illustrate that a relatively large angle β of handle (4) actuation causes a relatively small angle β' of mirror (3) rotation about the axis of bearing 24.
Link arm 9 will be seen to complete a four-bar linkage which also involves mirror 3, lever 8 and arm member 10; for x-component manipulation of handle 4, the four-bar linkage (including mirror 3) bodily rotates about the axis of arm member 10, and for y-component manipulation, the four-bar linkage is compressed or expanded to change the tilt of the mirror.
In FIGS. 2 and 3, parts which perform the same function as in the basic diagrams 1a to 1d have been provided with the same reference numbers.
In FIG. 2, an optical fiber 13 is shown delivering laser-beam radiation 1 to a beam-expanding optical system 15, which in turn serves an optical system 16 for focus of laser radiation (via mirror 3) at a point within a surgical operating area 2 which appears in the field of view of an operation microscope. The axis of entering laser radiation is normal to the observation axis of objective 17 and is substantially aligned with the rotary axis of member 10. The microscope is shown to include an objective 17 and an observation optical system 18 whereby its observation-ray path 14 may serve the field of view 2. Mirror 3 is preferably a splitter mirror, deflecting about 99 percent of incident laser radiation onto the operating area, and for protection of the observer, a laser-protection filter 21 is positioned in the observation-ray path 14.
The microscope is also shown to include a field-illuminating system wherein a mirror 19 folds projected light for passage through the main objective 17. This illuminating system can incorporate customary provision for adjustability, as to size and brightness of the illuminated field. And to change the size of the focal spot of laser radiation at the operating area 2, the beam-expanding optical system 15 may be axially adjustable, as suggested by a double-headed arrow 22. Since the wavelength of therapy laser radiation may be invisible, it is advisable to superpose a target-light laser radiation onto the therapy radiation; this superpositioning is not part of the invention and is therefore not shown but it will be understood to have been incorporated in the radiation delivered by optical fiber 13, so that both the therapy and the target-light laser radiations are expanded by optical system 15.
Upon movement of handle 4, for example in the direction x, the focal spot of laser radiation also travels in the correct coordinate sense and in the same direction. Upon movement of handle 4 in the direction y, the focal spot of laser radiation also travels over the operating area in the correct coordinate sense and in the direction y.
As shown, the lever 8 comprises outer and inner telescoping parts 8-8', and the connection of arm 10 to lever 8 is via a V bearing in an L-shaped forked connecting end part 10a of arm 10; the connection is to the outer lever part 8 via a transverse pin 23 (parallel to the mirror-pivot axis 10-10a), and pin 23 is loaded by spring means 31 to seat in the V bearing. Thus, upon actuating movement of handle 4 in the x-direction, arm 10 and mirror 3 are rotated in the direction indicated by double arrow 25. The link arm 9 is connected by ball-and-socket means 26 to mirror 3 and 26' to lever 8, so that upon actuating movement of handle 4 in the y-direction, link 9 moves in the direction indicated by double arrow 27, in transmitting its motion to mirror 3. It is seen that arms 9-10 can carry out their respective motions simultaneously, thus enabling laser focus at any desired spot within the field of view.
FIG. 3 illustrates a particularly advantageous embodiment for developing the lever mechanism, whereby the proportion of mirror displacement is adjustable, in relation to actuating displacement of handle 4. In FIG. 3, the point of handle-motion pick-off (by spherical formation 7) is adjustable within the cylindrical guide bore 6 of handle 4. The internal telescoping part 8' retains spring 31 and carries the spherical formation 7, so that spring 31 necessarily urges formation 7 upwardly in guide bore 6. A given adjusted position of formation 7 in guide bore 6 is determined by an adjustable stop screw 28 and pin 30; stop screw is an internally threaded part of handle 4 and is available for adjustment when a rotatable grip 4' of handle 4 is engaged to screw 28, as by a temporary insertion of a locking key 4" of square section (key 4" being part of grip 4') in the conforming end recess of screw 28; as shown, a compression spring 29 relieves such keyed engagement, but it is only necessary to press the grip 4' downwardly onto handle 4 to effect the engagement and then to rotate screw 28 to change the radial offset of the center of formation 7 with respect to the center of universal action of formation 5. Preferably, guide 6 is sufficiently elongate to range the point of motion pick-off by spherical formation 7, from a point substantially coincident with the fixed center of handle 4 manipulability, to an outer adjusted point that is substantially 25 percent of the radial offset distance between the axis of arm 10 and the fixed center of handle 4 manipulability.
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A manipulator is provided for a surgical microscope in order to deflect a laser beam on the viewed operating area, the movement of a handle being transmitted via a lever mechanism to the movement of a mirror which reflects the laser beam to a point and via a path within the viewed operating area. The sensitivity of transmitted motion can be adapted to the selected magnification of the surgical microscope by changing the length of a transmission lever in order to change its point of motion pick-off from the handle.
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This application claims priority to EP Patent Application No. 12382459.1 filed 22 Nov. 2012, the entire content of which is hereby incorporated by reference.
FIELD OF THE INVENTION
The present invention refers to an aircraft lifting surface and more in particular to the main supporting structure of the lifting surface.
BACKGROUND OF THE INVENTION
An aircraft lifting surface usually comprises a torsion box as its main supporting structure. For example, an aircraft tail plane (horizontal or vertical) is usually structured by a leading edge, a torsion box and a trailing edge with control surfaces (flaps, elevators, rudders, etc.). The torsion box is the main supporting structure responsible for supporting all loads involved (aerodynamic, fuel, dynamics, etc.) and comprises several structural elements.
Composite materials with an organic matrix and continuous fibers, especially CFRP (Carbon Fiber Reinforced Plastic), are nowadays widely used in the aeronautical industry in a great variety of structural elements. Specifically, all the elements which make up the torsion boxes of aircraft tail planes can be manufactured using CFRP.
The design of composite torsion boxes requires combining two perspectives of different nature: that of structural design and that of manufacture.
The traditional approach is the design of the torsion box defining the structural elements that form it (skins, spars, stringers, ribs), the separate manufacture of these elements and their subsequent joint in the assembly plant following schemes similar to those used in the aeronautical industry when only metallic materials were used.
The manufacture can be done using prepreg technology. In a first step, a flat lay-up of composite prepreg plies for each element is prepared. Then a laminated preform of the element with the required shape is obtained by means of a classical hot-forming process, being in some cases substituted by a press-forming process due to high curvatures. After getting the required shape, the laminated preform is cured in a male or female tooling depending on the tolerances required and the overall manufacturing cost. In the case of certain elements comprising sub-components cured separately, such as a rib and a vertical stiffener of it, a second curing cycle is needed for co-bonding said sub-components. Finally, after all the curing cycles, the element contours are trimmed getting the final geometry, and then the element is inspected by an ultrasonic system to assure its quality. The cost of a torsion box manufactured with said method is high because said steps shall be carried out independently for each structural element. Additionally, the cost related to the assembly of the torsion box is also high due to the long length and high complexity of the tasks required to install and to fit all structural elements together. This approach is being followed for manufacturing multi-rib torsion boxes such as that of the horizontal tail plane (HTP) shown in FIGS. 1 a , 1 b , 1 c.
The HTP is structured by leading edges 11 , torsion boxes 13 and trailing edges 15 with control surfaces (flaps, elevators, rudders, etc.).
The leading edge is the structure responsible for keeping the aerodynamic surface with the torsion box surface, for supporting the static or cyclic structural loads involved and for protecting the torsion box from bird impacts. It is the part of the HTP surface that first contacts the air and the foremost edge of the airfoil.
A known leading edge 11 comprises, on the one side, several ribs 10 , called leading edge ribs, attached to the front spar 18 of the torsion box 13 and, on the other side, an aerodynamic profile 12 —commonly known as “nose”—attached to the leading edge ribs 10 and to the flanges of the front spar 18 in order to keep the overall aerodynamic shape of the HTP.
Similarly the trailing edge 15 comprises, on the one side, several ribs, called trailing edge ribs attached to the rear spar 20 of the torsion box 13 and, on the other side, an aerodynamic profile 16 attached to the trailing edge ribs and to the flanges of the rear spar 20 in order to keep the overall aerodynamic shape of the HTP between the torsion box and the control surfaces.
The structural elements of torsion boxes 13 are upper and lower skins 21 , 23 stiffened by longitudinal stringers, a front spar 18 , a rear spar 20 and transverse ribs 17 attached to the front and rear spars 18 , 20 and to the upper and lower skins 21 , 23 in order to keep the torsion box shape and reinforce the load introductions areas linked to the HTP structural arrangement in the aircraft and to the actuators for handling the HTP control surfaces.
An alternative approach is to manufacture the whole or a part of a torsion box in an integrated manner for obtaining a monolithic ensemble comprising all or part of the structural elements of the torsion box. In this respect one example is described in WO 2008/132251 for a multi-spar torsion box.
Due to the complexity of aircraft tail planes the aeronautics industry is constantly demanding new proposals and new manufacturing methods that improve efficiency and/or costs of known aircraft tail planes.
The present invention is directed to the attention of that demand.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a main supporting structure of an aircraft lifting surface of a composite material allowing weight and cost reductions with respect to a comparable structure of known aircraft lifting surfaces.
It is another object of the present invention to provide a method of manufacturing said main supporting structure.
In one aspect, these and another objects are met by a main supporting structure comprising an upper skin, a lower skin, a front spar, a rear spar (and optionally intermediate spars) and a plurality of leading and/or trailing edge ribs; the upper skin including at least a part of the upper aerodynamic profile of the leading edge and/or of the trailing edge; the main supporting structure being a monolithic structure (i.e. without joints). The spars ensure torsional stiffness and overall stability to withstand the required loads and the ribs keep the aerodynamic shape and support movable surfaces (if any).
In embodiments of the invention, the lower skin includes at least a part of the lower aerodynamic profile of the leading edge and/or of the trailing edge.
In embodiments of the invention, the upper and lower skins of the main supporting structure include reinforcing stringers in all the cells delimited by spars.
In another aspect, the above-mentioned objects are met by a method of manufacturing said main supporting structure comprising the following steps: a) providing a set of laminated preforms of a composite material for forming said main supporting structure, each laminated preform being configured to form a part of it; b) arranging said laminated preforms in a curing assembly comprising a first set of tools for forming the closed part of the main supporting structure and a second set of tools for forming the open part of the main supporting structure; c) subjecting the curing assembly to an autoclave cycle to co-cure said laminated preforms; d) demoulding the first set of tools in a spanwise direction and the second set of tools in a chordwise direction. The invention therefore provides a high integrated solution to include leading and/or trailing edge ribs and leading and/or trailing edge aerodynamic profiles in a “one-shot” manufacturing process of a main supporting structure of an aircraft lifting surface of composite material, allowing the reduction of the amount of components and fasteners and consequently the weight and cost.
Other desirable features and advantages of the invention will become apparent from the subsequent detailed description of the invention and the appended claims, in relation with the enclosed drawings.
DESCRIPTION OF THE FIGURES
FIG. 1 a is a perspective view of a known horizontal tail plane showing the torsion boxes, the leading edges and the trailing edges with control surfaces.
FIG. 1 b is a perspective view of a known torsion box, where the upper skin has been moved upwards to improve the visibility inside the box.
FIG. 1 c is perspective view of one side of the horizontal tail plane surface of FIG. 1 a with cutaways to improve the visibility of the leading edge structure showing the leading edge ribs and the leading edge profiles.
FIG. 2 is a schematic perspective view of an embodiment of a main supporting structure according to the present invention comprising first and second leading edge ribs and first and second trailing edge ribs.
FIG. 3 a is a schematic perspective view of an embodiment of a main supporting structure according to the present invention comprising second trailing edge ribs.
FIG. 3 b is a schematic cross section of FIG. 3 a by plan C-C.
FIGS. 4 a and 5 a are schematic cross sections of an embodiment of the curing assembly of the main supporting structure of FIG. 3 a by, respectively, the planes A-A and B-B.
FIGS. 4 b and 5 b are schematic cross sections of the monolithic main supporting structure obtained after the curing and the demoulding of the tooling of the curing assembly by, respectively, the planes A-A and B-B of FIG. 3 a.
FIGS. 6 a and 6 b are, respectively, schematic cross sections of another embodiment of the curing assembly of said main supporting structure and of the monolithic main supporting structure obtained after the curing and the demoulding of the tooling of the curing assembly by, respectively, the planes A-A and B-B of FIG. 3 a.
FIGS. 7 a and 7 b are schematic cross sections of the tooling used to form laminated preforms having a C and a double C shape.
FIG. 7 c is a sketch of the process for obtaining a rib laminated preform.
FIG. 8 a is a diagram illustrating the arrangement of the preforms of one of the modules to be integrated in the rear part of the main supporting structure, FIG. 8 b is a schematic perspective view of the set of said modules (assuming that they have the same dimensions) and FIG. 8 c is a schematic perspective view of the rib resulting from the integration of two rib laminated preforms.
FIG. 9 a is a diagram illustrating the arrangement of the preforms of one of the modules to be integrated in the rear part of the torsion box in another embodiment of the invention and FIG. 9 b is a schematic perspective view of all these modules.
FIG. 10 is a schematic view of the demoulding process of the curing assembly.
FIGS. 11 a , 11 b and 11 c are schematic representations of the demoulding process of the tooling of the open part of the monolithic ensemble in a particular embodiment of said tooling.
FIG. 12 is a schematic cross section of an embodiment of a main supporting structure according to the invention having trailing edge ribs which are covered by its upper skin and are not covered by its lower skin.
FIG. 13 is a schematic cross section of a main supporting structure according to the invention having leading and trailing edge ribs which are covered by its upper skin and are not covered by its lower skin.
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description we would refer to the main supporting structure of an HTP but the invention is applicable to the main supporting structure of any lifting surface of an aircraft.
FIG. 2 shows a monolithic main supporting structure 14 of an HTP according to an embodiment of the invention comprising the following structural elements:
A front spar 18 and a rear spar 20 . An upper skin 21 and a lower skin 23 including a part of the aerodynamic profiles of the leading edge 11 and the trailing edge 15 . First leading edge ribs 22 extended inside the leading edge 11 and second leading edge ribs 24 extended inside a region of the leading edge 11 covered by the upper skin 21 and the lower skin 23 . First trailing edge ribs 25 extended inside the trailing edge 15 and second trailing edge ribs 26 extended inside a region of the trailing edge 15 covered by the upper skin 21 and the lower skin 23 .
Consequently the main supporting structure 14 comprises the torsion box of known HTP plus part of the leading edge and of the trailing edge.
This configuration, which is very advantageous from a manufacturing standpoint, addresses the specific loading issues of the front and rear parts of the torsion box which occur in many of the typical HTP architectures.
Obviously the number and location of leading and trailing edge ribs depends on the specific architecture of the HTP.
Other embodiments of a monolithic main supporting structure 14 of an HTP according to the invention comprise different configurations of its front and rear sides including or not including all or part of the above-mentioned leading and trailing edge ribs, and including or not including parts of the aerodynamic profile of the leading edge 11 and/or of the trailing edge 15 . One of them is shown in FIGS. 3 a and 3 b and comprises the following structural elements:
A front spar 18 , a rear spar 20 and intermediate spars 19 , 19 ′. Several trailing edge ribs 26 including both structural ribs and bearing ribs (for example the ribs which support the elevator hinge line). An upper skin 21 and a lower skin 23 including a part of the aerodynamic profile of the trailing edge 15 covering the trailing edge ribs 26 .
Other embodiments of the main supporting structure 14 with different configurations of the upper and lower skin are shown in FIGS. 12 and 13 .
FIG. 12 show an embodiment where only the upper skin 21 covers the trailing edge ribs 26 .
FIG. 13 shows an embodiment having leading edge ribs 22 and trailing edge ribs 26 where only the upper skin 21 covers the trailing edge ribs 26 and part of the leading edge ribs 22 .
A method for manufacturing the monolithic main supporting structure 14 shown in FIGS. 3 a and 3 b according to the invention is based on prepreg technology and comprises the following steps:
Preparing a set of laminated preforms that will form the monolithic main supporting structure 14 , laying-up for each of them a flat lay-up of composite prepreg plies and subjecting the flat lay-up to a hot-forming process on a suitable tool to give it the desired shape or performing the desired lay-up over a surface with the desired shape. The term “laminated preform” as used in this specification designates a composite that is intended to be integrated with other elements in the manufacturing process of the product to which it belongs. Arranging together all the laminated preforms on a curing assembly 40 with a suitable tooling and subjecting the curing assembly 40 to an autoclave cycle to co-cure the laminated preforms. Demoulding the tooling. Trimming and inspecting the assembly.
The laminated preforms used to manufacture the monolithic main supporting structure 14 of FIGS. 4 b and 5 b , comprising upper and lower skins 21 , 23 , with reinforcing stringers 32 , 34 in all the closed cells, are the following (see FIGS. 4 a , 5 a ):
Laminated preforms 41 , 43 , 45 , 47 , 49 , 51 having a double C-shaped transversal section to form the inner part of the monolithic main supporting structure 14 between the front spar 18 and the rear spar 20 . Laminated preforms 53 having a C-shaped transversal section to form the inner part of the monolithic main supporting structure 14 between the rear spar 20 and the rear end together with pairs of laminated preforms 35 , 37 having a C-shaped transversal section and a lateral wall in their inner ends to form the trailing edge ribs 26 (see also FIGS. 8 a , 8 b and 8 c ). In the embodiment shown in FIGS. 9 a and 9 b a single laminate preform 54 having a C-shaped transversal section is used instead of said laminated preforms 53 . Laminated preforms 57 , 59 with the shape of upper and lower skins 21 , 23 to form its outer part.
FIG. 6 b shows another embodiment of the monolithic main supporting structure 14 comprising upper and lower skins 21 , 23 without reinforcing stringers. FIG. 6 a shows the set of laminated preforms for this embodiment comprising laminated preforms 42 , 44 , 46 , 48 , 50 , 52 having a C-shaped transversal section instead of the laminated preforms 41 , 43 , 45 , 47 , 49 , 51 of the embodiment shown in FIG. 4 a.
The double C-shaped laminated preforms 41 , 43 , 45 , 47 , 49 , 51 , configured by a web, two primary flanges and two secondary flanges, are formed (see FIG. 7 b ) bending the ends of a flat lay-up on a tooling 39 in two steps to get the primary flanges and the secondary flanges. The latter are those that form the reinforcing stringers 32 , 34 of upper and lower skins 21 , 23 (see FIG. 4 b ).
The C-shaped laminated preforms 53 , 54 , 42 , 44 , 46 , 48 , 50 , 52 configured by a web and two flanges, are formed (see FIG. 7 a ) bending the ends of a flat lay-up on a tooling 38 to get the flanges.
The rib preforms 35 , 37 configured by a web, two flanges and a lateral wall are formed bending a flat laminate. FIG. 7 c shows the bending operations—indicated by arrows F1, F2, F3—needed to form the flanges and the lateral wall of a rib laminated preform 35 (the tooling is not shown).
FIG. 8 c shows the rib 26 resulting from the integration of preforms 35 , 37 which is configured by a web 27 , two flanges 28 , 28 ′ and a lateral wall 29 having the same height as the web 27 and the same width as the flanges 28 , 28 ′.
The thickness and composite material of each laminated preform are defined according to the structural needs of the structural elements of the main supporting structure 14 .
As illustrated in FIGS. 4 a , 5 a and 6 a said preforms are arranged on a tooling (see also FIG. 10 ) forming a curing assembly 40 which will be subjected to an autoclave cycle to get the main supporting structure 14 .
Said tooling comprises the following elements:
A tool 61 extended on the space foreseen to be delimited by the front spar 18 and the intermediate spar 19 . A tool 63 extended on the space foreseen to be delimited by the intermediate spars 19 , 19 ′. A tool 65 extended along the space foreseen to be delimited between the intermediate spar 19 ′ and the rear spar 20 . Tools 67 , 69 , 71 , 73 , 75 , 77 extended on the spaces foreseen to be delimited by ribs 26 . FIG. 8 a shows particularly the assembly of the module corresponding to the tool 69 with the rib preforms 37 , 35 and the C-shaped preform 53 .
As illustrated particularly in FIG. 10 , tools 61 , 63 , 65 are demoulded in the spanwise direction D1 of the curing assembly 40 and tools 67 , 69 , 71 , 73 , 75 , 77 are demoulded in the chordwise direction D2 of the curing assembly 40 .
In the case of a main supporting structure 14 having upper and lower skins 21 , 23 with substantial curvature may be desirable to divide the tools 67 , 69 , 71 , 73 , 75 , 77 into parts to facilitate the demoulding process. See FIGS. 11 a , 11 b , 11 c in which the tool 67 has been divided into three parts 67 ′, 67 ″, 67 ′″ for demoulding the central part 67 ″ in the chordwise direction in the first place and the tools 67 ′, 67 ′″ in the second place, separating them from the upper and lower skins 21 , 23 in a vertical direction in a first step and removing them in a chordwise direction in a second step.
In another embodiment of the invention for a main supporting structure 14 having upper and skins 21 , 23 with substantial curvature, the part of the lower skin 23 covering the trailing edge ribs 26 is joined to the rest of the lower skin 23 in an articulated manner (for example by means of hinges) so that the tools 67 , 69 , 71 , 73 , 75 , 77 can be demoulded in a vertical direction.
After completing the demoulding process, the monolithic main supporting structure 14 is located in the trimming machine in order to get the final geometry and is subjected to an automatic ultrasonic inspection for verifying that it does has not have any defects.
These manufacturing methods are applicable mutatis mutandi to other embodiments of the main supporting structure according to the invention.
Although the present invention has been described in connection with various embodiments, it will be appreciated from the specification that various combinations of elements, variations or improvements therein may be made, and are within the scope of the invention.
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An aircraft lifting surface with a monolithic main supporting structure of a composite material including an upper skin having at least a part of the upper aerodynamic profile of the leading edge and/or of the trailing edge, a lower skin, a front spar, a rear spar, and leading edge ribs and/or a trailing edge ribs. The main supporting structure allows a weight and cost reduction of aircraft lifting surfaces.
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FIELD OF THE INVENTION
In its most general aspect, the present invention relates to a process for the production of cellulose.
In particular, the invention concerns a process for the continuous production of cellulose from vegetable materials containing same, and especially from annual plants.
BACKGROUND OF THE INVENTION
It is known that the consumption of paper and cardboard is constantly and progressively increasing throughout the world and that there is an increasingly urgent need to resort to sources of supply for cellulose as raw material for paper manufacture other than those hitherto used traditionally, that is to say plants with a wooden stem such as conifers, broadwoods etc., also with consideration of the adverse environmental impact connected with the massive felling of forest trees.
For this reason, various studies of the possibilities of using annual plants such as wheat, sorghum, maize, hemp etc. in the production of cellulose have been carried out in recent years.
The major problem encountered with the use of annual plants in the production of cellulose is represented by their low density and consequently the enormous volumes of raw material which must be transported from the growing fields to the paper mills.
This entails such an increase in costs that, from an economic point of view, the use of annual plants as sources of cellulose is rendered unsuitable, which per se already give yields lower than those obtainable with the use of plants with a wooden stem, when they are worked according to the processes conventionally used in paper mills.
These latter are by themselves already characterized by a low profitability, since they are based on the use of now technologically obsolete equipment. Moreover, the equipment of conventional paper mills is necessarily of considerable size and involves very high installation costs.
The abovementioned problem of the high transport costs could be overcome by locating production units for the extraction of cellulose in the vicinity of the places where the plants are grown. However, because of the high investment required for the construction of a conventional paper mill plant, it would be difficult to propose locating a plurality of production units in the vicinity of places where the plants are grown.
SUMMARY OF THE INVENTION
The problem underlying the present invention is that of providing a process for the production of cellulose from vegetable materials containing same, and in particular annual plants, which process makes it possible to avoid the drawbacks demonstrated above with respect to the state of the art.
Such a problem is solved according to the invention by a process for the production of cellulose from vegetable raw materials containing same, comprising a preliminary size reduction of said raw materials to give a pumpable material, which process is characterized in that it comprises a heat treatment of said material, arranged in a thin layer and maintained in a state of high turbulence, with at least one digesting agent.
According to a further characteristic of the invention, the said treatment is effected by causing said pumpable material to flow continuously in a thin and turbulent layer in contact with a heated wall.
Advantageously, the process of this invention is effected by using an apparatus comprising a cylindrical tubular body with horizontal axis, closed at the opposite ends and fitted with a heating jacket, with inlet and discharge openings for the material to be treated and the material treated respectively, with openings for the introduction of the digesting agents and a bladed rotor which is rotatably mounted in the cylindrical body and caused to rotate at a peripheral velocity of 20-40 meters per second.
When a turboreactor of the abovementioned type is used, the process of this invention is characterized in that it comprises the following phases:
feeding a continuous stream of said pumpable material to a turboreactor comprising a cylindrical tubular body with horizontal axis, provided with openings for introducing said at least one digesting agent and for discharging the final product, a heating jacket for bringing the inside wall of said tubular body to a temperature of 200-300° C., and a bladed rotor rotatably mounted in the cylindrical tubular body where it is set in rotation at a velocity in the range from 20 to 40 meters/second, in order to disperse said continuous stream of pumpable material to give a stream of particles,
centrifuging said particles against the heated inside wall of the turboreactor to form a thin tubular and dynamic layer, in which the particles are mechanically maintained in a state of high turbulence by the blades of said bladed rotor,
causing said thin tubular dynamic layer to advance towards the discharge opening of the turboreactor, causing it to flow substantially in contact with said heated inside wall thereof, and
feeding said turboreactor with a continuous stream of at least one digesting agent, substantially in cocurrent with said thin tubular and dynamic layer of particles and in interaction with these.
Preferably, the abovementioned digesting agent is in aqueous solution and is selected from the group comprising sodium hydroxide, calcium hydroxide, sodium metabisulphite and mixtures thereof.
The solution of digesting agent is fed to the turboreactor from the inlet because in such a way the bladed rotor provides for its efficacious atomization and centrifugation, thereby ensuring that it is introduced in a highly dispersed state into the thin turbulent dynamic layer of particles of material to be treated.
In this way, the most intimate contact possible between the particles and the digesting agent is favoured, and this makes it possible greatly to enhance the effectiveness of the treatment.
In some cases, it can turn out to be appropriate to inject the digesting agent also into other zones of the turboreactor; for this purpose, the inside wall thereof can be provided with openings for the atomization of solutions of digesting agent at various levels along the length of the cylindrical tubular body.
The quantity of digesting agent used in the process according to the invention (dry weight) is preferably between 5 and 10% by weight relative to the dry weight of the vegetable material to be treated.
The solutions of the digesting agents must have a concentration such that they give rise, in the interior of the turboreactor, to a mixture with the material to be treated, which shows a ratio between dry substance and water of between 1:3 and 1:5.
The mean residence time of the material to be treated in the interior of the turboreactor is generally between 30 and 60 seconds.
In some cases, in which the extraction of the lignin and of other substances bound to the cellulose turns out to be particularly difficult, it can prove useful to feed the product stream from the turboreactor continuously to a second turboreactor.
In such a turboreactor, in which the experimental conditions (the temperature of the inside wall, velocity of the bladed rotor) are essentially the same as above, but without any further addition of digesting agent, the completion of the reactions caused by the digesting agent occurs within a mean residence time of 5-10 minutes.
At this stage, it can prove useful to inject a small flow of steam at a pressure of 2-5 atmospheres in cocurrent with the product entering.
This has the purpose of avoiding the formation of encrustations due to hardening of the lignin.
Both in the case in which the vegetable material undergoes a single treatment in only one turboreactor and in the case in which it is subjected to two successive treatments in two turboreactors, the final product is passed to successive conventional phases of washing, separation of the cellulose fibres from the spent digesting fluid, commonly referred to by the term. "black liquor", bleaching and drying.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and characteristics of this invention will be further clarified by the description of an embodiment example of a process for the production of cellulose from vegetable material containing same, which is given below with reference to the drawings attached for indicative purposes, in which:
FIG. 1 diagrammatically shows apparatus for carrying out the process according to the invention, and
FIG. 2 diagrammatically shows a complete plant for the production of cellulose according to the process of the invention.
DETAILED DESCRIPTION OF THE INVENTION
With reference to FIG. 1, the apparatus used for the process according to the invention comprises a first unit which, in the following description, will be called turboreactor A, and a second unit which below is called turboreactor B.
The turboreactor A essentially consists of a cylindrical tubular body 1 which is closed at the opposite ends by end pieces 2, 3 and is fitted coaxially with a heating jacket 4, through which a fluid, for example heat transfer oil, is to flow in order to maintain the inside wall of the body 1 at a preset temperature.
The tubular body 1 is provided with inlet openings 5, 6 for the pumpable vegetable material to be treated and the digesting agent used respectively, as well as a discharge opening 7 for the mixture of vegetable material treated and the spent digesting agent.
In the tubular body 1, a bladed rotor 8 is rotatably mounted, whose blades 9 are arranged helically and are oriented for centrifuging and simultaneously conveying the reactants and, respectively, the products of the reaction towards the outlet.
A motor M is provided for driving the bladed rotor at variable peripheral velocities from 20 to 40 meters/second.
In the inside wall of the tubular body 1, there are openings 10 for the injection of digesting agent in atomized form.
When the reaction which has occurred in the turboreactor A needs to be completed, the discharge opening 7 of the turboreactor. A is in communication, along a pipe 11, with the inlet opening 105 of a second turboreactor B, which will not be described in detail since its structure is entirely similar to the turboreactor A described further above. The components of the turboreactor B, which are the same as those of the turboreactor A, are indicated by, the same reference numerals with 100 added.
With reference to FIG. 2, a plant for the production of cellulose according to the process of the invention comprises the turboreactor A and the turboreactor B described above, a washer L, a twin-screw press P, a dryer EB for the black liquor, a bleaching unit or bleacher BL and a dryer EF for the cellulose fibres.
EXAMPLE
A turboreactor A with a tubular cylindrical body 1 of 220 mm internal diameter, in which the bladed rotor is caused to rotate at a velocity of 1000 rpm and in which the inside wall is maintained at a controlled temperature of around 280° C., is continuously fed with a stream of ground wheat straw (dimensions of about 2 cm length) at a rate of 10 kg/h. At the same time, 30/h of a 2.5% (weight/volume) solution of NaOH are continuously fed through the orifice 6 and the openings 10.
At the inlet of the turboreactor A, the stream of ground straw is immediately dispersed mechanically into minute particles which are at once centrifuged against the inside wall of the said turboreactor, where they form a thin tubular dynamic layer.
At the same time, the aqueous sodium hydroxide solution, entering via the opening 6, is finely atomized mechanically by the blades 9 of the rotor 8, which also provide for immediate centrifugation of the extremely small droplets obtained. These are introduced in this way into the thin tubular dynamic layer of straw particles with which they can "interact".
The sodium hydroxide solution introduced in atomized form via the openings 10 further increases the interaction of the digesting agent with the straw particles.
After a residence time of about 40 seconds in the turboreactor 1, the reaction product, consisting of a mixture of cellulose fibres and of spent digesting agent, is continuously discharged from the opening 7.
The reaction product is continuously fed to the turboreactor B of 350 mm internal diameter, through the opening (105) in cocurrent with a flow of steam at a pressure of 3.5 bar and at a rate of 40 kg/h.
In the turboreactor B, the wall temperature is controlled at a value of 260° C., while the speed of the bladed rotor is maintained at a constant 700 rpm.
In this second turboreactor B, the interaction between the sodium hydroxide and the straw particles is completed, and the subsequent separation of the cellulose fibres from the black liquor is facilitated, the constituents of the straw, in particular the lignin, which tend to encrust the cellulose being maintained in a softened state owing to the flow of steam.
After a residence time of about 6 minutes, a product consisting essentially of cellulose and a black liquor consisting of a solution of sodium hydroxide containing resins, encrusting substances, lignin and the like, is continuously discharged through the orifice 107.
This product is passed to a washer L where it is washed with three parts by weight of water at a temperature of 95-100° C. and subsequently to a separator of the twin-screw press P type in which the cellulose fibres are separated from the black liquor.
The resulting yield of cellulose fibres relative to the straw fed is equal to 38%, calculated as dry material.
The black liquor can be dried in the dryer EB and used as fuel or as a raw material in the adhesives industry.
On the other hand, the cellulose fibres can be passed to a bleaching phase for treatment with hydrogen peroxide or other bleaching agents in a bleacher BL and finally dried in a drier EF.
The steam generated in the dryers EB and EF can in part be fed to the turboreactor B and to the washer L and in part be condensed and reused for preparing the digesting agent solutions.
All the abovementioned working steps following the reactions carried out in the turboreactors A and B can advantageously be carried out in continuously operating equipment.
In particular, it is possible to use, in place of the conventional dryers for the cellulose fibre (EF) and for the black liquor (EB), turbodryers of the type of the products from the same Applicant.
In the same way, it is possible to replace the conventional bleachers BL by turboreactors identical to those described above.
The traditionally used washers L can also be replaced by turbowashers.
With the use of such equipment, it is possible to operate the process of producing cellulose from vegetable raw materials in a much more profitable and flexible manner than with equipment of the state of the art.
Above all, the continuous working thus made possible assures a higher overall efficiency due to the absence of dead times during working, and higher production rates.
Moreover, the equipment used for carrying out the process according to the invention and the successive phases which lead to cellulose fibres being obtained which are ready for use in the manufacture of paper, cardboard and the like, is characterized by dimensions which are definitely reduced as compared with conventional equipment and leads to installation costs which are reduced to about one-tenth of those foreseeable for a traditional plant.
This makes more than realistic the supposition of installing a plurality of productive units corresponding to the places of production of the vegetable raw material.
In this way, the problem, described above, of the high costs connected with the transport of the raw materials derived from annual plants or vegetable wastes from the place of cultivation to the paper mill can be solved and the way to an extensive use of annual plants or vegetable wastes in the production of cellulose can thus be opened, with clear advantages from the point of view of not only economics but also protection of the environment.
A further great advantage connected with the process according to the invention is that of reduced quantities of water required for carrying it out, equal to about one tenth of that necessary for carrying out the corresponding known processes.
This is made possible owing to the intimate contact achieved between the particles of vegetable raw material and the digesting agents in the interior of the thin tubular dynamic layer which is created in the turboreactors by the effect of the intense mechanical action of the bladed rotor.
Owing to the said mechanical action, also in the presence of a reduced quantity of water, the particles are equally enabled to come homogeneously and intimately into contact with the molecules of the digesting agent.
An advantage connected with the reduced consumption of water is the very greatly reduced, or almost zero, production of effluents.
The invention thus conceived is amenable to variants and modifications, all covered by the scope of protection applying thereto. It remains to state that the fundamental critical condition of the process of this invention for the production of cellulose consists of the thermal treatment of vegetable material made pumpable in a thin and dynamic layer with at least one digesting agent, and that many variants can be applied at the level of the starting vegetable material, of the digesting agents used, of the chemico-physical parameters in play in the process and of the structural characteristics of the equipment, all as a function of particular and contingent requirements.
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A process for producing cellulose from vegetable raw materials containing same by reacting these with digesting agents is described, comprising a preliminary size reduction of said raw materials to give a pumpable material, and a heat treatment of said material, arranged in a thin layer and maintained in a state of high turbulence, with at least one digesting agent; the abovementioned treatment is preferably carried out in a turboreactor and produces a mixture of cellulose fibres and of spent digesting agent, from which cellulose fibres ready for the uses in the paper industry are obtained via subsequent washing and separation phases; the process described is particularly suitable for the production of cellulose from annual plants in high yields, in very short times and at costs substantially reduced as compared with known processes.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a light-sensitive material feeding rack for use in sending a light-sensitive material into and out from a processing tank.
2. Description of the Related Art
A light-sensitive material such as print paper is fed as it is held between a plurality of pairs of feed rollers rotatably supported by a rack disposed within a processing tank. During such feeding, a light-sensitive material pushed out by a pair of mated feed rollers is then guided by guide plates to the portion of contact between a subsequent pair of feed rollers.
The rack has an arrangement in which the guide plates can be disassembled from the rack when it is necessary to perform a maintenance operation such as cleaning. This arrangement facilitates maintenance operations conducted with respect to the interior of the rack.
However, if the guide plates are dismounted from the rack or moved from their original positions, and if they are then mounted again onto the rack to be returned to their original positions after the completion of a maintenance operation, there is a risk that the guide plates may become displaced from their optimal positions for guiding the light-sensitive material. If the guide plates are mounted at positions displaced from the optimal positions, the guide plates may interfere with the light-sensitive material and damage the surface of the material, or the light-sensitive material may be guided along a path deviated from the correct feeding path.
SUMMARY OF THE PRESENT INVENTION
In view of the above-described circumstances, it is an object of the present invention to provide a light-sensitive material feeding rack which is capable of facilitating maintenance operations for the rack and which is capable of positively guiding a light-sensitive material even after the completion of maintenance.
To this end, according to the present invention, there is provided a light-sensitive material feeding rack for feeding a light-sensitive material along a feeding path within a processing tank, comprising a rack body disposed within the processing tank; feed rollers rotatably supported by the rack body and paired for feeding the light-sensitive material held between pairs of the feed rollers; and guide means extending along the feeding path of the light-sensitive material for guiding the light-sensitive material to the light-sensitive material entrance side of the pairs of feed rollers, the guide means being rotatable about the end portion thereof that is closer to the light-sensitive material entrance side.
In the light-sensitive material feeding rack of the present invention, a light-sensitive material is fed by the guide means to the entrance side of the feed rollers.
The guide means can be rotated about the end portion thereof that is closer to the light-sensitive material entrance side of feed rollers when it is necessary to conduct a maintenance operation for the light-sensitive material feeding rack, thereby opening the interior of the rack. This arrangement facilitates an maintenance operation, e.g. cleaning, of portions of the rack located inward of the guide means.
Further, since the guide means is rotatable about the end portions thereof that is closer to the light-sensitive material entrance side of the feed rollers, this provides the following advantage when the guide means has been returned to its original position after the completion of a maintenance operation. Namely, displacement in position of the guide means is such that the end portion of the guide means that is positioned on the downstream side of the guide means with respect to the direction in which the light-sensitive material is fed is less displaced than the upstream-side end portion of the guide. A light-sensitive material which has immediately been fed from a pair of mated feed rollers moves along a relatively constant path. With such a movement of the material, therefore, even if the position of the guide means has been incorrectly determined, the guide means can be kept from coming into contact with the light-sensitive material and can guide the material without encountering any problem. However, when the light-sensitive material is immediately before it enters the subsequent pair of mated feed rollers, it moves with a relatively large extent of vibration. With such a movement of the material, therefore, if the position of the guide means is incorrect, the guide means may come into unnecessary contact with the light-sensitive material and may fail to guide it properly. According to the present invention, by virtue of the arrangement in which the guide means is rotatable about the end portion thereof that is closer to the light-sensitive material entrance side of the feed rollers, the error in position of this portion can be small even if the position of the guide means has not been determined very precisely. Accordingly, when guide means has been returned to its original position after the completion of a maintenance operation, the path along which the light-sensitive material is fed can be maintained as it is correct, thereby preventing the guide means from interfering with the light-sensitive material and also preventing the light-sensitive material from deviating from the feeding path.
In consequence, the maintenance operation for the rack can be facilitated, and the light-sensitive material can be positively guided even after the completion of maintenance operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a developing apparatus having a light-sensitive material feeding rack in accordance with a first embodiment of the present invention;
FIGS. 2 and 3 are perspective views of light-sensitive material feeding guides used in the first embodiment;
FIG. 4 is a fragmentary sectional view sectioned through the line IV--IV shown in FIG. 1;
FIG. 5 is a sectional view of a developing apparatus having a light-sensitive material feeding rack in accordance with a second embodiment of the present invention;
FIG. 6 is a perspective view of a light-sensitive material feeding guide used in the second embodiment;
FIG. 7 is a fragmentary perspective view of the light-sensitive material feeding guide shown in FIG. 6, illustrating a state in which the rack is open;
FIG. 8 is a fragmentary sectional view sectioned through the line VIII--VIII shown in FIG. 5; and
FIGS. 9 and 10 are perspective views of the light-sensitive material feeding guides used in the second embodiment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a sectional view of a developing apparatus 10 having a light-sensitive material feeding rack in accordance with a first embodiment of the present invention.
The developing apparatus 10 has a developing tank 12, a fixing tank 14, and washing tanks 16 which are successively disposed. The tanks 12 to 16 receive respective processing liquids, and a light-sensitive material 18 is processed by being successively immersed in the liquids within the developing tank 12, the fixing tank 14, and the washing tanks 16 in this order. In the illustrated example, the washing tanks 16 consist of two tanks disposed in sequence.
A light-sensitive material feeding rack 20 is submerged in the processing liquid within the developing tank 12. The light-sensitive material feeding rack 20 is provided with a pair of side plates 22, 24 disposed in parallel to each other (see FIG. 4).
A pair of feed rollers 26 extend between the pair of side plates 22, 24 on one upper side thereof. At a location above the pair of feed rollers 26, a feed roller 28 extends between the side plates 22, 24. Also extending between the side plates 22, 24 are a feed roller 30 located below the pair of feed rollers 26, a feed roller 32 located below the feed roller 30, and two feed rollers 34, 36 located at the same height below the feed roller 32.
On either side of the feed roller 30, feed rollers 38, 40, each having a diameter smaller than that of the feed roller 30, are disposed in contact with the feed roller 30 and extend between the side plates 22 and 24.
Similarly, on either side of the feed roller 32, feed rollers 42, 44, each having a diameter smaller than that of the feed roller 32, are disposed in contact with the feed roller 32 and extend between the side plates 22 and 24,
On the outer side of the feed rollers 34 and 36, feed rollers 46, 48, each having the same diameter as that of the feed roller 34 or 36, are disposed in contact with the feed rollers 34, 36, respectively, and extend between the side plates 22 and 24.
The above-stated feed rollers 26 to 48 are adapted to rotate when drive force is transmitted from a drive means via gears (none of which are shown).
A guide block 50 having a generally trapezoid section is disposed above the feed roller 30 and has its two ends fixed to the side plates 22, 24. Further, guide blocks 52, 54 are respectively disposed above the feed rollers 38, 40, and have their ends fixed to the side plates 22 and 24. These guide blocks 52, 54 are disposed at the same height as the guide block 50. The gap between the guide block 50 and the guide block 54 serves as an entrance of the light-sensitive material 18 through which it is fed to the developing tank 12. The light-sensitive material 18 is then guided from the portion of contact between the feed rollers 26 toward the portion of contact between the feed rollers 30, 40.
The gap between the guide blocks 50, 52 serves as an exit of the light-sensitive material 18 through which it is sent out. The material 18 is held between and fed by the feed rollers 30, 38, and it is then guided by the guide blocks 50, 52 so as to be fed to the portion of contact between a pair of feed rollers 56 disposed at an upper location of the side plates 22 and 24.
Intermediate guide blocks 58 and 60 are respectively disposed between the feed rollers 30, 32, and between the feed roller 32 and the feed rollers 34, 36. Two ends of each guide block 58, 60 are fixed to the side plates 22, 24.
A guide block 62 for turning back the light-sensitive material 18 is disposed at a portion of the tank 12 surrounded by the feed rollers 34, 36, 46 and 48, and the bottom surface of the developing tank 12. Two ends of the guide block 62 are fixed to the side plates 22, 24. The upper surface of the light-sensitive material turning guide block 62 is formed with a circular recess whereby the direction in which the light-sensitive material 18 has been fed is changed in such a manner that the material 18 which has been fed from the portion of contact between the feed rollers 36, 48 is guided to the portion of contact between the feed rollers 34, 46.
A light-sensitive material feeding guide 65 is disposed between the feed rollers 40 and 44 at a location corresponding to the intermediate guide block 58. The guide 65 is provided for guiding the light-sensitive material 18 from the portion of contact between the feed rollers 30, 40 to the portion of contact between the feed rollers 32, 44.
As shown in FIG. 2, the light-sensitive material feeding guide 65 has a shaft 64 and six guide plates 63, 66, 68, 70, 72, and 73 supported by the intermediate portion of the shaft 64. The shaft 64 passes through these guide plates 63 to 73 in the vicinity of one end portions thereof. The guide plates 63 to 73 are disposed at equal intervals and are fixed to the shaft 64 by means of bolts 51 which are threaded into bosses integrally projecting from the guide plates and which have their tips pressed against the shaft 64. The guide plates 63 to 73 are fixed to the shaft 64 at positions having the same rotational angle about the shaft 64.
Among the six guide plates 63 to 73, those guide plates 63, 73 disposed at longitudinal ends of the shaft 64 are formed with bent pieces 63B, 73B, respectively, which are bent in such a manner as to extend toward each other. The provision of the bent pieces 63B, 73B enables the guide 65 to positively guide the widthwise ends of the light-sensitive material 18. Further, the guide plates 66, 72 are formed with bent pieces 66B, 72B, respectively, which are bent in such a manner as to extend away from each other. The second bent pieces 66B, 72B provide an action similar to that described above. Another shaft 67 passes through the other end portions of the guide plates 63 to 73. A bolt 77 is threaded into a threaded hole formed at one end portion of the shaft 67. Thus, the guide plates 63 to 73 are fixed at identical positions when viewed in the direction of the axis of the shaft 64.
The light-sensitive material feeding guide 65, having the above-described members, is mounted onto the light-sensitive material feeding rack 20, by allowing the shaft 64 to extend between the pair of side plates 22, 24 and be supported thereby at its ends. In this condition, the shaft 64 is positioned closer to the feed roller 44 and has its ends supported by the side plates 22, 24, as shown in FIG. 4. That is, the shaft 64 is positioned at the end portion of the guide 65 that is on the downstream side of the guide with respect to the light-sensitive material 18 being fed from the portion of contact between the feed rollers 30, 40 to the portion of contact between the feed rollers 32, 44; in other words, the shaft 64 is positioned in the vicinity of the light-sensitive material 18 entrance side of the feed rollers 32, 44. When the light-sensitive material feeding rack 20 is in use within the developing tank 12, the rack 20 is fixed at a position shown in FIG. 1. At this time, the guide 65 is fixed in place by inserting a bolt 92 penetrating though the side plate 24 into an insertion hole 63A formed in the guide plate 63, as shown in FIG. 4.
The light-sensitive material feeding guide 65 has the end faces of the bent pieces 63B, 66B, 72B, and 73B of the guide plates 63, 66, 72, and 73 as well as the end faces of the guide plates 68 and 70 positioned to correspond to one surface of the light-sensitive material 18, while a face of the guide block 58 corresponds to the other surface of the material 18, so as to guide the light-sensitive material 18 to the portion of contact between the feed rollers 32, 44.
Although the light-sensitive feeding guide 65 may be manufactured by forming the guide plates 63 to 73 and the shaft into an integral structure, if the guide 65 is manufactured in this way, the structure may experience deformation after its forming, thereby causing a reduction in the intervals between the guide plates 63 to 73, and thus leading to a reduction in dimensional precision. To avoid this problem, in the illustrated embodiment, the shaft 64 and the guide plates 63 to 73 are prepared as separate component parts which are then assembled to be integrated. In this way, a sufficient level of precision in dimension is ensured.
Another light-sensitive material feeding guide 74 is disposed between the feed rollers 44, 48. As shown in FIG. 3, the guide 74 has basically the same structure as that of the guide 65, except that the end portion of the guide 74 positioned in the vicinity of the feed rollers 36, 48 is extended toward the portion of contact between these rollers 36, 48.
That is, as shown in FIG. 3, one end portions of guide plates 79 to 89 of the guide 74 through which a shaft 64 passes are formed as projections 74A that project toward the light-sensitive material 18 when the guide 74 is assembled onto the light-sensitive material feeding rack 20, so as to provide a smooth guiding of the light-sensitive material 18. The shaft 64 of the light-sensitive material feeding guide 74 is disposed in such a manner as to be closer to the feed roller 48. That is, the shaft 64 is disposed at the end portion of the guide 74 that is positioned on the downstream side of the guide with respect to the light-sensitive material 18 being fed; thus, the shaft 64 is disposed at the end portion of the guide 74 that is positioned closer to the feed roller 48. The guide 74 is mounted onto the side plates 22, 24 in a manner similar to that of the guide 65.
A further light-sensitive material feeding guide 76 is disposed between the feed rollers 38, 42. The guide 76 has the same structure as that of the guide 65. A shaft 64 of the guide 76 is disposed in such a manner as to be closer to the feed roller 38. Tat is, the shaft 64 is disposed at the end portion of the guide 76 that is positioned on the downstream side of the guide with respect to the light-sensitive material 18 being fed. The guide 76 is rotatable about that end portion. The guide 76 is fixed to the side plates 22, 24 in a manner similar to that of the guide 65.
The light-sensitive material feeding guide 76 forms a light-sensitive material feeding passage in cooperation with the guide block 58, so as to guide the light-sensitive material 18 to the portion of contact between the feed rollers 38, 30.
A still further light-sensitive material feeding guide 78 is disposed between the feed rollers 42, 46. The guide 78 has the same structure as the guide 65. A shaft 64 of the guide 78 is disposed in such a manner as to be closer to the feed roller 42, this being similar to the case of the guide 76. Similarly to the guide 76, the guide 78 is rotatable about the end portion thereof that is positioned on the downstream side of the guide with respect to the light-sensitive material 18 being fed, in other words, about the end portion of the guide 78 that is positioned closer to the light-sensitive material 18 entrance side of the feed rollers 32, 42. The light-sensitive feeding guide 78 is fixed to the side plates 22, 24 in a manner similar to that of the guide 65.
Next, the operation of the rack in accordance with this embodiment will be described.
The light-sensitive material 18 is fed into the developing tank 12 by being guided by the feed roller 28 and fed by the pair of feed rollers 26. The material 18 thus fed into the developer tank 12 descends within the tank 12 by being held between and fed by the feed rollers 30, 40, the feed rollers 32, 44, and the feed rollers 36, 48. The light-sensitive material 18 which has thus descended within the tank 12 is turned back by the light-sensitive material turning block 62, and it then ascends within the developer tank 12 by being held between and fed by the feed rollers 46, 34, the feed rollers 32, 42, and the feed rollers 38, 30. The light-sensitive material 18 which has thus ascended within the tank 12 is fed out to the fixing tank 14 by being held between the pair of feed rollers 56. By the above-said action, the light-sensitive material 18 is immersed in the liquid within the developing tank 12 to be subjected to development.
While the light-sensitive material 18 is fed by the feed rollers, it descends and then ascends within the developing tank 12 as it is guided. More specifically, it descends within the developing tank 12 as it is guided by the guide blocks 50, 54, the intermediate guide block 58 and the light-sensitive material feeding guide 65, and the intermediate guide block 60 and the light-sensitive material feeding guide 74. Then, the light-sensitive material 18 ascends within the developing tank 12 as it is guided by the intermediate guide block 60 and the light-sensitive material feeding guide 78, the intermediate guide block 58 and the light-sensitive material feeding guide 76, and the guide blocks 50 and 52.
When it is required to perform a maintenance operation of the light-sensitive material feeding rack 20, in particular, a maintenance operation of portions between the intermediate guide block 58 and a member such as the light-sensitive material feeding guide 65 or 76 as well as portions between the intermediate guide block 60 and a member such as the light-sensitive material feeding guide 74 or 78, the light-sensitive material feeding rack 20 is first taken out from the developing tank 12. The bolts 92 are removed, from the insertion holes 63A, and the light-sensitive material feeding guides 65, 74, 76, and 78 are rotated outward about the shafts 64. By this operation, a maintenance operation (e.g., cleaning) of the portions between the guides 65, 76 and the portions between the guides 74, 78 can be performed with ease.
After the completion of the maintenance operation, the light-sensitive material feeding guides 65, 74, 76, and 78 are rotated inward about the shafts 64, to return to their original positions, and are fixed to the side plate 24 by means of the bolts 92.
The light-sensitive material 18 moves describing a relatively constant locus when it has just been fed from the portion of contact between a pair of mated feed rollers. With such movement, therefore, even if the position of the light-sensitive material feeding guides 65, 74, 76, and 78 has been determined incorrectly, they can be kept from contacting the light-sensitive material 18 and can guide the material 18 without encountering any problem. However, the light-sensitive material 18 moves vibrating to a large extent immediately before it enters the next pair of mated feed rollers. With such movement, therefore, if the light-sensitive guides 65, 74, 76, and 78 are incorrectly positioned, there is a risk that the guides 65, 74, 67, and 78 may come into unnecessary contact with the light-sensitive material 18 or may fail to guide it properly.
According to this embodiment of the present invention, the light-sensitive material feeding guides 65, 74, 76, and 78 are rotated, when necessary, about the end portions of the guides that are on the downstream side of the guides with respect to the direction in which the light-sensitive material 18 is fed, thereby causing only a small error in position of those portions. Therefore, when the light-sensitive material feeding guides 65, 74, 76, and 78 have been returned to their original positions after the completion of a maintenance operation, it is possible to maintain correctly the feeding path of the light-sensitive material 18, thereby preventing any interference between the light-sensitive material 18 and the light-sensitive material feeding guides 65, 74, 76, and 78, and thus preventing deviation of the light-sensitive material 18 from the feeding path.
FIG. 5 illustrates a sectional view of a developing apparatus 110 having a light-sensitive material feeding rack in accordance with a second embodiment of the present invention. In this embodiment, members, component parts, etc. which are the same or correspond to those of the first embodiment are denoted by the same or corresponding reference numerals, and detailed explanations of those members, etc. will be omitted.
As in the case of the developing apparatus 10 explained in the first embodiment, the developing apparatus 110 has a developing tank 12, a fixing tank 14, and washing tanks 16 which are successively disposed.
A light-sensitive material feeding rack 120 is submerged in a processing liquid received in the developing tank 12. The light-sensitive feeding rack 120 has a pair of side plates 122, 124 disposed in parallel with each other (see FIG. 8).
A pair of feed rollers 126 extend between the pair of side plates 122, 124 at one upper side thereof. At a location above the pair of feed rollers 126, a feed roller 128 extends between the side plates 122, 124. Further, extending between the side plates 122, 124 are a feed roller 130 located below the pair of feed rollers 126, a feed roller 132 located below the feed roller 130, and two feed rollers 134, 136 located at the same height below the feed roller 132.
On either side of the feed roller 130, feed rollers 138, 140, each having a diameter smaller than the feed roller 130, are disposed in contact with the feed roller 130 and extend between the side plates 122, 124.
Similarly, on either side of the feed roller 132, feed rollers 142, 144, each having a diameter smaller than the feed roller 132, are disposed in contact with the feed roller 132 and extend between the side plates 122, 124.
On the outer side of the feed rollers 134, 136, feed rollers 146, 148, each having the same diameter as that of the feed roller 134 or 136, are disposed in contact with the feed rollers 134, 136, respectively, and extend between the side plates 122, 124.
The feed rollers 126 to 148 are adapted to rotate when drive force is transmitted from a drive means via gears (none of which are shown).
As shown in FIGS. 6 and 8, the feed roller 144 has four grooves 144A formed in the outer periphery of the axially intermediate portion of the roller 144 by reducing the diameter. The end portions of a rotary shaft 144B of of the feed roller 144 project through the side plates 122, 124 and are supported by bearings 123, 125 provided on the side plates 122, 124. Bosses 122A, 124A are also provided on the side plates 122, 124 in such a manner as to extend towards each other coaxially with the rotary shaft 144B of the feed roller 144.
The feed rollers 138, 124, 126, and 148 each have the same configuration as that of the feed rollers 144 and are each supported by bearings 123, 125 provided on the side plates 122, 124. Bosses 122B, 122C, 122D, 122E, 124B, 124C, 124D and 124E are also provided on the side plates 122, 124 in such a manner as to extend coaxially with rotary shafts of the feed rollers 138, 142, 146, and 148.
Guide blocks 50, 52, 54, and intermediate guide blocks 58, 60 are fixed to the side plates 122, 124. Since these blocks are the same as those of the first embodiment, explanations of those blocks will be omitted.
In this embodiment, a guide block corresponding to the guide block 62 is not provided on the bottom of the rack 120. Instead, a light-sensitive material feeding guide, described later, is provided.
A light-sensitive material feeding guide 165 is disposed between the feed rollers 140, 144 at a location corresponding to the intermediate guide block 58, so as to guide a light-sensitive material 18 fed from the portion of contact between the feed rollers 130, 140 to the portion of contact between the feed rollers 132, 144.
As shown in FIG. 6, the light-sensitive material feeding guide 165 has a shaft 164 and six guide plates 163, 166, 168, 170, 172, and 173 supported by the intermediate portion of the shaft 164. These guide plates 163 to 173 are disposed at equal intervals and are fixed to the shaft 164 by means of bolts 151 which are threaded into bosses integrally projecting from the guide plates 163 to 173 and which have their tips pressed against the shaft 164. The guide plates 163 to 173 are fixed at positions having the same rotational angle about the shaft 164.
Among the six guide plates 163 to 173, those guide plates 163, 173 disposed at the longitudinal ends of the shaft 164 are formed with bent pieces 163B and 173B, respectively, which are bent in such a manner as to extend toward each other. The provision of the bent pieces 163B, 173B enables the guide 165 to positively guide the widthwise end portions of the light-sensitive material 18. Further, the guide plates 163, 173 each have a notch 163C or 173C formed in the end portion thereof that is not the end portion at which the guide plate is fixed to the shaft 164. Each of the notches 163C, 173C is generally rectangular and has a semi-circular bottom surface.
The light-sensitive material feeding guide 165 is fixed to the light-sensitive material feeding rack 120 by inserting the bosses 122A, 124A into the notches 163C, 173C formed in the guide plates 163, 173, and by fixing the guide plate 173 to the side plate 124 by means of a bolt 192. In this condition, the bosses 122A, 124A are coaxial with the feed roller 144 and support the light-sensitive material feeding guide 165, as shown in FIG. 8. That is, in this condition, the bosses 122A, 124A are positioned at the end portion of the guide 165 that is on the downstream side of the guide with respect to the direction in which the light-sensitive material 18 is fed from the portion of contact between the rollers 130, 140 to the portion of contact between the rollers 132, 144. During the use of the light-sensitive material feeding rack 120 within the developing tank 12, the rack 120 is fixed at a position shown in FIG. 5. At this time, the guide 165 is fixed in place by inserting the bolt 192 penetrating through the side plate 124 into an insertion hole 173A formed in the guide plate 173.
The light-sensitive material feeding guide 165 has the end faces of the bent pieces 163B, 173B of the guide plates 163, 173 as well as the end faces of the guide plates 166, 168, 170, and 172 positioned to correspond to one surface of the light-sensitive material 18, while a face of the guide block 58 corresponds to the other surface of the material, so as to guide the light-sensitive material 18 to the portion of contact between the feed rollers 132, 144.
As in the case of the guide of the first embodiment, the light-sensitive material feeding guide 165 of this embodiment is formed by preparing the shaft 164 and the guide plates 163 to 173 as separate component parts, and assembling these parts to integrate them. In this way, a sufficient level of precision for diameters can be ensured.
Another light-sensitive material feeding guide 174 is disposed between the feed rollers 144, 148. As shown in FIG. 9, the guide 174 has basically the same structure as that of the guide 165, except that the end of the guide 174 positioned in the vicinity of the feed rollers 136, 148 is extended toward the portion of contact between these feed rollers 136, 148.
That is, as shown in FIG. 9, a shaft 188 passes through one end portions of guide plates 176 to 186 of the guide 174, and the other end portions of the guide plates 178 to 184 are formed as projections 178A to 184A which project toward the moving light-sensitive material 18 when the guide 174 is assembled onto the light-sensitive material feeding rack 120, so as to provide a smooth guiding of the light-sensitive material 18. The guide 174 also has notches 176C, 186C formed in such a manner as to be closer to tee feed roller 148. That is, the notches 176C, 186C are disposed at the end portion of the guide 174 that is positioned on the downstream side of the guide with respect to the light-sensitive material 18 being fed. The guide 174 is mounted onto the side plates 122, 124 by means of the bosses 122B, 124B provided on the side plates 122, 124, in a manner similar to that of the guide 165.
A further light-sensitive material feeding guide 176 is disposed between the feed rollers 138, 142. The guide 176 has the same structure as that of the light-sensitive feeding guide 165. Notches 163C, 173C of the guide 176 are formed in such a manner as to be closer to the feed roller 138. That is, the notches 163C, 173C are disposed at the end portion of the guide 176 that is positioned on the downstream side of the guide with respect to the light-sensitive material 18 being fed. The guide 176 is rotatable about the bosses 122E, 124E. The guide 176 is fixed to the side plates 122, 124 in a manner similar to that of the guide 165.
The light-sensitive feeding guide 176 forms a light-sensitive material feeding passage in cooperation with the guide block 158, so as to guide the light-sensitive material 18 to the portion of contact between the feed rollers 138, 130.
A still further light-sensitive material feeding guide 178 is disposed between the feed rollers 142, 146. The guide 178 also has the same structure as the guide 165. Notches 163C, 173C of the guide 178 are formed in such a manner as to be closer to the feed roller 142. The guide 178 is rotatable about the end portion thereof that is positioned on the downstream side of the guide with respect to the light-sensitive material 18 being fed. The guide 178 is fixed to the side plates 122, 124 in a manner similar to that of the guide 165.
In contrast with the first embodiment, according to this embodiment, a light-sensitive material feeding guide 190 is disposed at a portion surrounded by the feed rollers 134, 136, 146 and 148, as well as the bottom surface of the developing tank 12.
As shown in FIG. 10, the guide 190 has a shaft 192 and six guide plates 194 to 204 supported by the intermediate portion of the shaft 192. These guide plates 194 to 204 are disposed at equal intervals and are fixed to the shaft 192 by means of bolts 206 which are threaded into bosses integrally projecting from the guide plates 194 to 204 and which have their tips pressed against the shaft 192. The guide plates 192 to 204 are fixed at positions having the same rotational angle about the shaft 192.
Each of the guide plates 194 to 204 is formed with a circular configuration, so that the direction in which the light-sensitive material 18 has been fed is changed in such a manner that the material 18 which has been feed from rollers 136 and 148 is guided to the portion of contact between the feed rollers 134, 146.
Among the six guide plates 194 to 204, those guide plates 194, 204 disposed at end portions of the shaft 192 are formed with bent pieces 194B, 204B. These bent pieces 194B and 204B are bent in such a manner as to extend toward each other. The provision of the bent pieces enables the guide 190 to positively guide the widthwise end portions of the light-sensitive material 18.
The end portions of the guide plates 194, 204 that is not the end portions fixed to the shaft 192 are formed with notches 194C, 204C. The light-sensitive material feeding guide 190 is mounted onto the light-sensitive material feeding rack 120 by inserting the bosses 122C, 124C, which are provided on the side plates 122, 124, into the notches 194C, 204C formed in the guide plates 194, 204, and by fixing the guide plate 204 to the side plate 124 by means of a bolt 208.
In this condition, the free end portions of the guide plates 196 to 202 are inserted into grooves 146A formed in the feed roller 146.
Next, the operation of the rack in accordance with this embodiment will be described.
The light-sensitive material 18 is fed into the developing tank 12 by being guided by the feed roller 128 and fed by the pair of feed rollers 126. The material 18 which has thus fed into the developer tank 12 descends within the tank 12 by being held between and fed by the feed rollers 130, 140, the feed rollers 132, 144, and the feed rollers 136, 148. The light-sensitive material 18 which has thus descended within the tank 12 is turned back by the light-sensitive material guide 190, and it then ascends within the developer tank 12 by being held between and fed by the feed rollers 146, 134, the feed rollers 132, 142, and the feed rollers 138, 130. The light-sensitive material 18 which has thus ascended within the tank 12 is fed out to the fixing tank 14 by being held between a pair of feed rollers 56. By the above-said action, the light-sensitive material 18 is immersed in the liquid within the developing tank 12 to be subjected to development.
While the light-sensitive material 18 is fed by the feed rollers, it descends and then ascends within the developing tank 12 as it is guided. More specifically, it descends within the developing tank 12 as it is guided by the guide blocks 50, 54, the intermediate guide block 58 and the light-sensitive material feeding guide 165, and the intermediate guide block 60 and the light-sensitive material feeding guide 174. Then, the light-sensitive material 18 ascends within the developing tank 12 as it is guided by the intermediate guide block 60 and the light-sensitive material feeding guide 178, the intermediate guide block 58 and the light-sensitive material feeding guide 176, and the guide blocks 50 and 52.
When it is required to perform a maintenance operation of the light-sensitive material feeding rack 120, in particular, a maintenance operation of portions between the intermediate guide block 58 and a member such as the light-sensitive material feeding guide 165 or 176, portions between the intermediate guide block 60 and a member such as the light-sensitive material feeding guide 174 or 178, and portions between the feed rollers 134, 136, 146, 148, the light-sensitive material feeding rack 120 is first taken out from the developing tank 12. The bolts 192, 208 are removed from the insertion holes 173A, 186A, 204A, and the light-sensitive material feeding guides 165, 174, 176, 178, and 190 are rotated outward about the bosses 122A to 122E and 124A to 124E. By this operation, the maintenance operation (e.g., cleaning) of the portions, such as those between the guides 165, 176, and between the guides 174, 178, can be performed with ease.
After the completion of the maintenance operation, the light-sensitive material feeding guides 165, 174, 176, 178, and 190 are rotated inward about the bosses 122A to 122E and 124A to 124A, are returned to their original positions, and are fixed to the side plate 124 by means of the bolts 192 and 208.
The light-sensitive material 18 moves describing a relatively constant locus when it has just been fed from the portion of contact between a pair of mated feed rollers. With such movement, therefore, even if the position of the light-sensitive material feeding guides 165, 174, 176, 178, and 190 has been determined incorrectly, they can be kept from contacting the light-sensitive material 18 and can guide the material 18 without encountering any problem. However, the light-sensitive material 18 moves vibrating to a large extent immediately before entering the next pair of mated feed rollers. With such movement, therefore, if the light-sensitive guides 165, 174, 176, 178, and 190 are incorrectly positioned, there is a risk that these guides may come into unnecessary contact with the light-sensitive material 18 or may fail to guide it properly.
According to this embodiment of the present invention, the light-sensitive material feeding guides 165, 174, 176, 178, and 190 are rotated, when necessary, about the end portions of the guides that are on the downstream side thereof with respect to the direction in which the light-sensitive material is fed, thereby causing only a small error in position of those portions. Therefore, when the light-sensitive material feeding guides 165, 174, 176, 178, and 190 are returned to their original positions after the completion of a maintenance operation, it is possible to maintain correctly the feeding path of the light-sensitive material 18, thereby preventing any interference between the light-sensitive material 18 and the light-sensitive material feeding guides 165, 174, 176, 178, and 190, and preventing deviation of the light-sensitive material 18 from the feeding path.
Although in the foregoing embodiments, the light-sensitive material feeding rack is disposed within the development tank 12, the rack in accordance with the present invention may alternatively be used in a processing tank of a different type, such as a fixing or washing tank.
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A light-sensitive material feeding rack for feeding a light-sensitive material along a feeding path within a processing tank by holding the material between paired feed rollers. The rack has guide plates extending along the feeding path for guiding the material to the light-sensitive material entrance side of the paired feed rollers. These guide plates are each rotatable about the ends thereof that are closer to the light-sensitive material entrance side. When the rack is to be cleaned, the guide plates are rotated so as to open the interior of the rack, thereby facilitating the cleaning of the rack. After the completion of cleaning, the guide plates are rotated in the opposite direction to be returned to their original condition. Even after the returning of the guide plates, the positional relationship between the feed rollers and the end portions of the guide plates that are closer to the entrance side can be very precisely maintained.
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CROSS-REFERENCE TO RELATED APPLICATIONS
U.S. patent application Ser. No. 08/016,062, directed to a "Method and Systems for Unified Voice Telephone Services" and filed on even date herewith is hereby incorporated by reference.
TECHNICAL FIELD OF THE INVENTION
This invention relates in general to agent-based telephone communication systems and more particularly to a computer-based system architecture that allows integration of voice, text, image and call processing with an agent-based call center, all under control of a single, unified software control system.
BACKGROUND OF THE INVENTION
Over the years, various systems have been developed to operate in conjunction with public and private switching telephone networks to provide specialized functions that lend power, versatility and efficiency to telecommunications.
These various systems are designed to operate on data in one or more of three general categories: voice, text and image. Together, these types of data encompass all data currently desired to be processed or transmitted in communication systems.
The above-described data can be processed or communicated in ways that can be generally categorized as "mail" (also termed "store and forward"), "interactive" and "bulletin" systems. Mail systems allow a user to retrieve voice, text or images that have been exclusively addressed to the user. In such mail systems, it is typical to require the user to enter a unique password to gain access to the exclusively-addressed data. Interactive systems allow a user to control what data the interactive system delivers to the user, and, perhaps, in what order the data is delivered. Unlike mail systems, however, the data need not be exclusively-addressed, and thus can be publicly available. Lastly, bulletin systems allow a user to retrieve publicly available information in a non-interactive, system-controlled fashion.
One type of system directed to handling of data is automatic call distribution ("ACD"), wherein a pool of agents is assigned to answer calls incoming on a particular group of telephone lines. ACD systems handle these calls as they arrive, assigning them to agents in the order received and choosing the agents based on length of idle time. This algorithm of queueing is called "fair queueing." Because human agents are present, such ACD systems are interactive.
Another such system is audio text (or "audio tex"). Audio text system are designed to "play" a message stored in a memory device to a person listening on the other end of the call. These systems are generally not interactive and can be bulletin systems.
Yet another such system is a modem pool. Modem pool systems function in a manner similar to ACD systems. As a plurality of computers make incoming calls to a central pool of modems, typically attached to a single, large, general-purpose computer, the modem pool system assigns the incoming calls in a "fair queueing" manner. Such systems are also typically interactive.
Still another such system is a predictive dialer. Predictive dialers are used in outbound calling applications and typically in conjunction with a pool of agents. Predictive dialers employ statistical techniques to predict the length of time, on average, agents take to handle calls. These dialers further gather statistics regarding the average time required to successfully connect an outbound call. The dialers use these averages and data pertaining to agent availability to place calls from a list of numbers to be dialed, employing their predictive ability to maximize agent utilization. These systems can be mail, interactive or bulletin.
Another such system is voice mail. Voice mail allows callers to leave voice messages with those called. Voice mail systems typically play greeting messages recorded by the called parties, record the time and origin of received messages and allow for callers to exit the system to speak with a human, if desired. Obviously, voice mail systems are categorized as mail systems.
Another such system is facsimile ("fax"). This ubiquitous system has exploded onto the marketplace in recent years and, as is nearly universally understood, gives one the capability to send paper-borne images by telephone. Such systems are image-based and can be implemented as mail, interactive or bulletin systems.
Other image-based systems are adapted to handle graphics or moving images (video). As with fax, these graphics or moving image systems can be mail, interactive or bulletin.
Still another system to be described is automatic number identification ("ANI") systems. These systems are designed to take inbound calls and detect special signals delivered from a central office indicating the phone number of the calling party. Since the signals can uniquely identify the calling party, the call can then be routed to a specific agent or interactive voice response ("IVR") application able to handle that caller, based upon caller identification.
As useful and desirable as these individual systems are, they have always been thought of as independent systems that, at best, adhere to a common protocol for interface and data interchange, allowing them to be attached to and cooperate with, telephone systems, either separately or in combination. However, it should be understood that, in any case, these systems do not cooperate in any fashion apart from superficial connectivity via industry standard telephony connections. Some manufacturers who happen to make more than one type of system may provide a proprietary interface or protocol between systems, but these proprietary links are just that: cooperation at a connectivity level.
Computer technology has worked itself into telephony as effectively as it has in so many other areas. Accordingly, over the years, the above-described systems have moved from the analog to the digital domain, employing digital processors, memory, digital storage media, data and address buses and the like. As it is, each of these systems stands alone, each having its own computer hardware and software. A person wishing to use two systems together must live with the fact that the systems have independent hardware and software.
Another disadvantage of the separate nature of the systems is that each collects call routing and other control data, including data collected during the course of its interaction with a party during a particular call. For instance, assume a system allowing for both ACD and voice mail such that incoming callers may choose to leave a message if all agents are busy. As a particular call begins, the ACD system elicits information from the caller pertaining to the reason for the call. Using dual tone multi-frequency ("DTMF"), ANI or voice recognition, the ACD system captures and stores this information to direct the call to the proper agent or to prompt an agent ahead of time as to what is needed.
The caller, however, may grow weary of waiting and wishes to exit the ACD queue. The ACD system allows for this by providing for an exit upon receipt of a particular tone. However, upon successfully exiting the ACD queue, the caller is once again prompted to supply the very same information to the voice mail system to thereby allow the voice mail system to collect the needed information. The caller has had to give the same information twice, owing to the lack of coordination between the systems.
Of course, if the systems are supplied by the same manufacturer, proprietary interfaces and protocols may allow transfer of the information. But even if this disadvantage is overcome, the systems still duplicate hardware and software. As a particular application demands more and more functions, the problems of integrating the various necessary systems become more acute and perplexing.
Other problems abound. These systems, because they stand alone, have separate maintenance consoles and control languages. The systems must be interconnected by cables that, as the number of cables grows, increases the chances of failure. The loose connectivity of these systems limits rates of data transfer between the systems. In fact, adjunct switching matrices are frequently required to perform ancillary switching tasks that would overload the main switching system, typically a private branch exchange ("PBX").
These systems frequently offer the option of providing reports and statistics concerning their operation. These reports and statistics are frequently incompatible and difficult to integrate. Most often, there is simply no one place from which to obtain reports and statistics. Because of the duplication of hardware and software, these systems are difficult to manage, they are larger and more costly than necessary, and they consume more power and produce more heat than is optimal. In short, integration of these various systems has been a long felt need in the art, but one that, thus far, has been met with dissatisfaction.
Unfortunately, the prior art has failed to provide an effective means by which to integrate these systems under unified software control, allowing them to share information and resources among themselves in a cost and time efficient manner.
The above-mentioned U.S. patent application Ser. No. 08/016,062, entitled "Method and Systems for Unified Voice Telephone Services" and filed on Feb. 10, 1993, is directed to a unified system for handling voice, text and image data in a plurality of "functional partitions," each of which corresponds to one of the heretofore separate systems described above. That unified system is capable of interfacing with a telephone exchange via an integrated call-processing partition.
Since the mid-1970s, more and more companies have taken advantage of interactive voice response ("IVR") systems to automate, and thereby reduce the cost of, providing information to their customers, employees and others.
IVR is actually an extension of audio text systems. An IVR system allows callers to access computer-resident data such as account balances or stock prices through a standard telephone. The IVR system allows the caller to query for data using touch-tone signals, and the result is returned as spoken words. Again, it is obvious that such systems are interactive and can be mail.
These IVR systems have typically handled from 30% to 70% of incoming calls, with the remaining calls being transferred to live operators. When the calls reach the operators, the callers have generally already identified themselves by touch-tone entry of their account number as well as a security code, perhaps as part of an interactive session wherein, for instance, the caller has obtained a balance of a checking account. As previously mentioned, customers justifiably find it aggravating and time consuming to have to re-identify themselves for the agent and then wait for the agent to request information from the host database. Companies that manufacture private branch exchange/automatic call distribution ("PBX/ACD") systems have sought for years to solve this problem by developing interfaces that allow the host application to better integrate the voice, text and image data components of the call. While these measures do provide a means of solving the problem, there are several significant drawbacks to the solution.
The first problem is that the host (or workstation) application must be modified to take full advantage of the PBX/ACD. Many companies have large sums of money invested in their host application and thus, even if they had sufficient staff to make such modifications, they are disinclined to do so.
The second problem is that each PBX/ACD company has its own proprietary host communication link. While there are products, such as IBM's CallPath SwitchServer/2, that abstract differences between telephone or communication link switches, all switches do not support all of the same functions. This means that the host software must still, in many cases, be configured to communicate with each type of switch being used, often requiring different switch drivers to take advantage of each switch's functionality.
The third problem is cost. Current solutions require purchase of high-priced software for both the host computer (or workstations) as well as a high-priced software module for the PBX/ACD. Even after purchase of all this software, there remains the expense of writing host or workstation software to create a solution.
The fourth and possibly most significant problem is the complexity of the solution. One must acquire expertise in 1) the host software, 2) the PBX/ACD software, 3) the IVR software and 4) the voice mail software and then attempt to make it all work together well enough for the system to appear "seamless" to callers.
Clearly, a solution is needed that does not require any changes to the host computer or PBX software and provides a cost effective, single application software environment for controlling calls from start to finish regardless of what is required by the caller.
U.S. Pat. No. 4,797,911, which issued on Jan. 10, 1989, to Szlam et al., discloses a method and apparatus for relieving the agent of the duty of obtaining preliminary caller account information by automatically querying a host database at the beginning of a call. Szlam et al. also provide for on-line, direct updating of the caller account information in the host computer, thereby eliminating the need for consolidation of changes into the caller account file. This provides the agent with the most current information on the caller account. More particularly, Szlam et al. provide an apparatus that automatically dials the telephone number of the caller or potential caller, ascertains the status of the called number and, if the call is answered, routes the call to the next available agent and automatically obtains the current caller account information from the mainframe and displays, at the agent's terminal, the current caller account information. The apparatus also provides for automatic answering and routing of incoming calls to the next available agent along with caller account information retrieved from the mainframe.
U.S. Pat. No. 4,894,857, which issued on Jan. 16, 1990, to Szlam et al., is a continuation-in-part of the Szlam et al. patent described above and provides for a similar method and apparatus for retrofitting and extending or upgrading an existing caller account servicing system to provide for automated handling and processing of both incoming and outgoing calls. The system controller and terminals use the same command and data format structure as that already in use by the existing system and software of the mainframe. The system controller is transparent to the operation of the mainframe and the agent terminals and allows the system to be upgraded without the necessity of purchasing different software or programs for the mainframe.
As mentioned above, the prior art has taken a piecemeal approach to voice, text, image and call processing systems, preferring to treat them as separate and distinct. In limited cases, particularly as illustrated in the patents to Szlam et al., integration of data and call processing systems has been limited to superficial cooperation at a communications protocol level. The prior art has unfortunately failed to provide a seamless, fully integrated voice-, text-and image-based system specifically designed to operate in conjunction with live agents to produce thereby a calling center that is able to be configured to function as a mail, interactive or bulletin system and is adaptable to a wide range of applications without requiring modification of either hardware of software.
SUMMARY OF THE INVENTION
The present invention solves the foregoing problems and is directed to an improved call center configured as an integrated voice, text and image communication system and providing for automated processing of inbound and outbound telephone calls. A key point of novelty of the present invention is its ability to connect callers to live agents when necessary, all the while retaining unified software control of the interaction between caller and agent via an agent script. As such, the present invention is the first to treat interaction with live agents as simply another type of functional partition.
Therefore, it is a primary object of the present invention to provide an integrated telephone call handling system adapted to be coupled to (1) a telephone network to enable the system to communicate via the network, (2) an agent workstation to enable an agent to communicate with the system and (3) an agent telephone to enable the agent to communicate with a party via the system and the network. The system is controlled by a unified software system comprising a system for controlling a call between the system and the party, the unified controlling system capable of (1) transferring the call among functional partitions within the system, the functional partitions providing mechanized communication via the network and (2) directing communications between the party and a selected one of the functional partitions.
One of the most powerful advantages realized by providing such an integrated system for handling calls and data is the ability to use a unified script language to thereby allow unified scripting of a call from inception to termination, including scripting of interactions between a party and an agent. Accordingly, the present invention provides for a first script for directing interaction between the system and the party and a second script for directing interaction between the system and the agent. Thus, the present invention is the first to provide for a way of scripting interactions with a live agent, thus treating the live agent as just another functional partition. In a preferred embodiment, the first script and the second script are able to communicate information between one another, all under common control.
Another major advantage realized by integration of heretofore separate call handling functions is integration of record-keeping during a particular call. Accordingly, it is another object of the present invention to provide a system further comprising means for creating a single record containing data gathered during a single call session and means for storing data pertaining to the single call session in the single record throughout a duration of the call, the data gathered from a plurality of functional partitions within the system to thereby eliminate a need to gather a particular datum multiple times during the single call. Unified scripting facilitates creation and maintenance of the single record. The record can contain data received from the caller or data generated by the system, including its various functional partitions and any database. These single records can be cross-referenced to one another to thereby create a meta-record of an entire transaction with a particular caller, allowing auditing and reporting of the entire transaction, rather than of just single calls within the transaction.
In its preferred embodiment, the system of the present invention comprises an agent workstation coupled to the system, the workstation permitting communication between the agent and the system. This permits the agent to view portions of the call record to allow the agent to more effectively and efficiently serve the caller's needs. This also allows the agent to access data contained in a central database, existing as either part of the system itself, or as an external host database.
As previously mentioned, the system of the present invention can be configured to communicate with callers in one or more of several system modes, depending upon the particular application. First, the system can operate as a mail system, wherein the system presents information intended for delivery to a particular caller to the particular caller (store and forward). Second, the system can act as an interactive system, wherein the system presents information to a caller in a manner determined by the caller (perhaps as part of an IVR). Finally, the system can be configured as a bulletin system, wherein the system presents information to caller in a predetermined manner (perhaps as part of an audio text system).
The preferred environment for operation of the present invention is a communications system having (1) an agent for communicating with inquiring parties, (2) a database of information pertaining to accounts of the parties and (3) call completion capability for terminating calls to a plurality of different call terminations, the terminations including automated data response for obtaining information from a selected one of the accounts. In that environment, the present invention provides for a control unit for answering calls from the inquiring parties and for directing any of the calls to a selected one of the call terminations, comprising (1) means for (a) interactively communicating with one of the parties to determine which call termination is required, (b) establishing a first call termination with respect to the one of the parties and (c) transferring to the first call termination any data obtained with respect to the one of the parties. The invention further provides (2) means for continuing to monitor established communication connections to permit modification of the first call termination when the one of the parties desires connection to a second call termination and (3) means for transferring to the second call termination the any data obtained with respect to the one of the parties and any data obtained during the first call termination.
Typically, the first call termination is a data response and the second call termination is to the agent. The system further including means, associated with the agent, for providing selected account information to the agent when the agent becomes connected to the one of the parties and the communicating means includes means for providing a preselected portion of the one of the parties's account data to the agent concurrent with the transferring of the second call termination to the agent, the preselected portion including a portion of the any data obtained with respect to the one of the parties. The monitoring means further includes means for modifying a call termination at a direction of the one of the parties or any call termination.
The present invention also includes methods of operation of such systems.
In a typical application, incoming callers are provided typical account information in a VRU script that has been programed into the system. When a caller requests a live agent, such as by pressing "0" on a touchtone telephone pad, the caller is routed to an ACD that allows calls to be held pending agent availability. The ACD can provide selected call-back when an agent becomes available or at a specific future time. When an agent becomes available, the call is connected and the caller's host computer session is immediately switched to the agent's workstation screen so that the selected agent can answer the call armed with specific information pertaining to the caller.
The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter that form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and the specific embodiment disclosed may be readily used as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, and the advantages thereof, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a prior art method for servicing callers;
FIG. 2 illustrates a prior art method for automatically servicing callers;
FIG. 3 illustrates a prior art conventional call center;
FIG. 4 illustrates a call center according to the present invention; and
FIG. 5 illustrates a system architecture of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, illustrated is a prior art system for servicing of caller accounts on either an incoming or outgoing basis. The system is comprised of PBX 11 attached to subscriber public network 10. A caller account representative, or agent, will employ telephone 12, that is connected to PBX 11, and data terminal 13, that is connected to host mainframe Host 14 contains a database of caller account information.
In this system, customers calls from public network 10 are received by PBX 11 and subsequently transferred to telephone 12 so that the caller account representative may speak with the caller. The caller account representative will access caller account information from host 14 through data terminal 13.
The caller account representative may also place outgoing calls to public network 10 through PBX 11. In performing this task, the agent must manually retrieve caller account information from host 14 through terminal 13 and manually dial on telephone 12 the caller's telephone number and wait for the caller to answer. Of course, there may be a plurality of agents with data terminals connected to host 14 and telephones connected to PBX 11 in order to receive and place telephone calls to customers.
Referring next to FIG. 2, there is shown the next evolution in systems for servicing caller accounts. In this improved version, robot agent 20 is also placed between PBX 11 and host mainframe 14. Now, when an incoming call from public network 10 is received by PBX 11, it is initially transferred to robot agent 20 that controls an IVR for interacting with the caller according to a predefined script programed within robot agent 20. The result is that the caller may converse with robot agent 20 using his touchtone keypad on his telephone for responding to requests by robot agent 20. The caller is thereby allowed to access a menu of options including entering his account identification number. Robot agent 20 uses this account identification number and other information retrieved from the caller to access the caller's account in host mainframe 14. The result is that the caller, using his touchtone keypad, may access account information from host mainframe 14 through robot agent 20 without ever having to speak to a live agent.
Robot agent 20 may also have a voice recognition unit that allows a caller to simply speak his requests and responses to the voice recognition unit that uses this information when accessing host mainframe 14.
Robot agent 20 has the capability to transfer the caller to a live agent if the caller is using a rotary telephone and is thus unable to enter information with a touchtone keypad, or robot agent 20 has the ability to transfer the caller to a live agent at the caller's request, such as when the caller enters on his touchtone keypad a menu option requesting a live agent. In these instances, robot agent 20 will essentially place a transfer of the call through PBX 11 to telephone 12.
The problem with such a system is that any caller information retrieved by robot agent 20 is not passed to data terminal 13 when the call is transferred to telephone 12. The caller is then required to again provide caller account information to the live agent at data terminal 13 so that he may request the caller account information from host mainframe 14.
In another embodiment of this prior system, shown in FIG. 3, host 14 may be coupled to the system through public network 10. In this system, a call coming from public network 10 into PBX 11 will be transferred to a voice response unit ("VRU") 31 that uses host gateway 32 to connect to host 14 through public network 10 in order to access caller account information within host 14. If the caller wishes to speak to a live agent, the call will be transferred from VRU 31 through PBX 11 to one of telephones 12A, 12B or 12C at caller stations 13A, 13B or 13C, respectively. For example, the call could be transferred to telephone 12A. Simultaneously, a "short screen" of information received by VRU 31 from the caller is sent through PBX and gateway 34 to terminal 13A, that subsequently establishes a data link with host 14 through gateway 33. The agent will then use terminal 13A to access caller account information within host 14.
Outbound calls may also be placed by an agent at one of the workstations. Dialer 35 may be used to automatically call customers through public network 10, which calls will be answered by VRU 31 as previously described. If necessary, the call may be transferred to a live agent in the manner previously described.
A caller may also request that a transfer be made to voice mail 36 in order to leave a message for a particular party if a live agent is not available.
In both incoming and outgoing processes, VRU 31 may transfer a short screen of information to the data terminals while transferring the caller to one of the live agents. The data terminals will then request the full caller account information through host gateway 33.
It should be noted that the above-described systems all require several separate pieces of hardware and equipment in order to implement such a system. Additionally, once the call is transferred to a live agent, the call ends there and may not be transferred back to VRU 31 or any other function or resource such as another agent, a facsimile card, a modem, audio text, etc.
Referring next to FIG. 4, there is shown an integrated voice, text and image data automation system of the present invention providing all the functionality needed to automate processing of inbound and outbound telephone calls including connecting callers to robot agents or live agents. Call center 40 is physically connected to workstations 13A, 13B and 13C via LAN and to agent telephones 12A, 12B and 12C either directly or via an existing PBX (not shown). Call center is also shown directly connected to host computer 14, that may be a group of computers interconnected via LAN. Call center 40 does not require software changes in the host or PBX for integrations. Call center 40 is also connected to public network 10 that provides interconnections to caller telephones 41. Host 14 may be connected to call center 40 through public network 10 (connection not shown).
Referring next to FIG. 5, there is shown a typical implementation of the present invention. Applications manager 51 manages the various resources available within call center 40.
IVR 53 allows all caller calls or DNIS/DID-directed calls to enter an IVR script upon answer. This script may be a standard package or a caller defined application. As an example, a call from a caller originating within public network 10 will be received by telco interface 501 within call center Alternatively, call center 40 may be connected to public network 10 through PBX 11.
The caller call arriving at interface 501 is transferred through voice channel architecture 57 to IVR 53 for interaction with the caller. The caller may interact with IVR 53 for retrieving information on the caller's account and also access any other information that IVR 53 is configured to offer. At times, IVR 53 may request information from host 14 through architecture 57 and host interface 502. This retrieved information may then be transferred to the caller. As previously described, IVR 53 may provide a menu of options to the call, who may choose from this menu by pressing digits on his touchtone keypad.
Calling center 40 also has the capability for allowing callers to receive requested information via fax. For example, while the caller is interacting with IVR 53, the caller may request that a facsimile of desired information be faxed to a caller provided telephone number. This option may be provided by IVR 53 via a menu option selectable by the caller using his touchtone telephone keypad. In such a situation, IVR 53 will retrieve the caller requested information from host 14 in the manner previously described and transfer this information over voice channel architecture 57 to shared resources block 58 that includes the fax functionality of call center 40. At the caller's direction, IVR 53 will also transfer over architecture 57 to block 58 the telephone number of the receiving facsimile machine at the caller's premises. This transfer of information to block 58 by IVR 53 may be accomplished while IVR 53 is still conducting an interactive conversation with the caller or after IVR 53 has completed an interactive communication with the caller whereby the facsimile functionality within block 58 will fax the requested information through voice channel architecture 57 and telco interface 501 to public network 10 wherein the caller's receiving facsimile machine is located.
Call center 40 may also provide a voice mail system for allowing caller callers to leave messages to a particular person, such as a caller representative agent when no agents are available. In such an instance, IVR 53 may provide an option to the caller to be transferred to voice mail 52 in order to leave a message. This option may be selected by the caller by pressing a particular digit on his touchtone keypad. At that instance, IVR 53 will transfer the call over voice channel architecture 57 to voice mail 52, which will then interact with the caller.
If IVR 53 recognizes that the caller does not have the use of a touchtone telephone, IVR 53 may transfer the call through voice channel architecture 57 to block 58 that contains voice recognition functionality whereby the same menu options and procedures offered by IVR 53 are offered with voice recognition capabilities so that a caller may merely speak responses to inquiries as opposed to entering the responses with a touchtone keypad. A caller using a rotary phone may also be transferred to a live agent in a manner to be described.
If the caller has a computer (not shown) and wishes to interface with call center 40 using that computer, IVR 53 may transfer the call through voice channel architecture 57 to block 58 that has a modem for interfacing with the caller's computer in basically the same manner as IVR 53 interacts with the caller's person. Menu options are supplied to the caller through his computer display, and the caller enters responses using his computer keyboard.
If the caller is hearing impaired and has access to a telephone device for the deaf ("TDD"), IVR 53 will transfer the caller through voice channel architecture 57 to block 58 that also contains the capability of interacting with a TDD in the same manner that the modem interacts with a caller's computer.
Call center 40 contains the ability to transfer the caller to a live agent when one is requested, such as when the caller presses 0 on his touchtone keypad. When a live agent is requested, the caller is placed in an automatic call distribution ("ACD") smart queue within agent's controller module 56 that allows holding or selecting a call back when an agent is available or at a specific future time. Callers are provided the estimated hold time and given the option of remaining in queue or specifying a later call back. Additionally, calls may be directed to live agents using DNIS or DID to agent ACD groups with an optional prompt for account number to allow automatic host access prior to connection to an agent. Calls to specific extensions may be made and voice mail 52 may be accessed if all agents are busy or there is a ring no-answer when an agent is requested. A "short screen" containing data obtained by the initial IVR script may be displayed for the agent while the host is retrieving the full record. The call center then makes a voice, text and image data connection to the live agent.
The call center supports dialing out from caller lists using a pacing algorithm. When an answer occurs, an agent is selected, and an IVR script displays a "short screen" and requests the full record from the host system.
An agent may transfer a call to another agent or supervisor. This is handled by the call center IVR script in the same manner as a transfer from the initial IVR script to the ACD queue, establishing a voice, text and image data session for the recipient of the call.
The call center supports transferring calls to other remote locations by selecting an outbound trunk line and dialing another location using a DNIS that activates an IVR script on the receiving end of the call. The caller's identification is passed to the receiving end IVR script that, in turn, establishes a host session for a local agent. The initial call center location then holds up the voice connection until the call is completed.
The call center supports conferencing-in another agent or supervisor, with voice, text and image data available to both operators.
A live agent uses workstation 13 connected to call center 40 through workstation interface 504 and optional 317X controller 505, if needed. Workstation 13 is used to access host 14.
The live agent also uses telephone 12 that is connected to call center 40 with phones/PBX interface 503. The phones may be directly connected to interface 503 or through optional PBX 11.
If a caller requests a live agent, IVR 53 will transfer the call through voice channel architecture 57 to agent's controller module 56 to be placed in an ACD queue. Once a live agent is available, the caller will be switched through voice channel architecture 57 to interface 503 and phone 12. At that time, agent's controller module 56 may send a short screen of information through architecture 57 and interface 504 to workstation 13 in order that the live agent may have immediate access to the caller's account number and other brief information that has been given to IVR 53 by the caller. Call center 40 will then retrieve the full caller account information from host 1 that will be downloaded to workstation 13. While these last two tasks are being performed, the live agent is already speaking to the caller through telephone 12.
If required, the live agent may transfer the caller to any of the previously described functions, including IVR 53, voice mail 52 and fax 58 in order to further service the caller's needs. Call center 40 contains the capability of perpetually transferring the caller to any of the functions within call center 40. As the call is transferred, caller account information is also transferred to the destination thus obviating the need to repeatedly ask the caller for the information.
Workstation 13 may be placed into a normal mode through workstation 504, architecture 57 and host interface 502 whereby workstation 13 interacts with host 14 in a normal host session. In this instance, phone 12 operates as a normal PBX extension. In a campaign mode, the live agent's workstation 13 and phone 12 are driven by an IVR script contained in call center 40. Once a live agent logs into workstation 13 in a campaign mode, call center 40 makes a telephone call through interface 503 to telephone 12 providing a permanent connection between call center 40 and telephone 12. The agent then stands by for transfers of caller callers to workstation 13 and phone 12.
Call center 40 also supports dialing outbound from caller lists using a pacing algorithm within predictive dialing module 55. In this process, predictive dialing module 55 begins dialing outbound over interface 501 to public network 10. As calls are answered, a call progress monitor within predictive dialing module 55 determines the status of the outgoing line such as ringing, busy signals, out-of-service signals and answers. This continues until a live caller is reached whereby predictive dialing module 55 determines the availability of any live agents attached to call center 40. If no live agents are available, the call may be transferred to IVR 53 to interact with the caller in the manner previously described. Or, the caller may be placed in an ACD queue within agent's module 56 that allows holding or selecting a call back when an agent is available or at a specific future time, as previously described.
If and when a live agent becomes available, call center 40 makes a voice connection to the live agent through architecture 57, interface 503 and phone 12. A data connection to the live agent is made through workstation interface 504 to workstation 13. As previously described, an IVR script within IVR 53 transfers a "short screen" of caller information to workstation 13 and requests the full record through host interface 502 from host 14 for subsequent transfer to workstation 13. The live agent may then interact with the caller and subsequently transfer the caller to any of the other function modules within call center 40. A live agent may also transfer a call to another live agent or supervisor through interface 503 and interface 504. The already retrieved data is then transferred to the new workstation where the audio portion of the call has been transferred.
Call center 40 also supports transferring calls to remote locations by selecting an outbound trunk line through interface 501 and dialing another location using a DNIS that activates an IVR script on the receiving end of the call. The caller's identification is passed to the receiving end IVR script, that, in turn, establishes a host session for a local agent. The initial call center's location then holds up the voice connection until the call is completed.
The call center supports two methods of providing PBX functionality to the agents. For small groups of up to 48 stations, 2,500 telephone instruments can be connected directly to the call center. Very basic PBX service is supported, including station-to-station calls, station-to-trunk calls, trunk-to-station calls and call transfers.
For larger groups, or where full-feature PBX support is required, the call center connects digitally via T1/E1 transmission lines to many popular PBX systems. When agents wish to enter a call center ACD group, they log on into a campaign and a connection is "mailed up" through the PBX, allowing the call center to control campaign call switching.
The call center supports digital connectivity to the telephone network via standard T1 transmission lines in the U.S. and E1 internationally. ISDN primary rate protocol is supported and is certified in many countries. Additionally, loop-start analog connections are supported.
Call center 40 also supports conferencing-in another agent or supervisor on a call, with voice, text and image data available to both operators.
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.
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An integrated telephone call handling system and method are disclosed. The system comprises a unified software control for controlling a call between the system and a party, the unified control capable of transferring the call among functional partitions within the system, the functional partitions providing mechanized communication via the network and capable of directing communications between the party and a selected one of the functional partitions. The unified control includes a unified script language to allow unified scripting of a call from inception to termination, including scripting of interaction between the party and an agent.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of co-pending U.S. application Ser. No. 14/404,565, filed Nov. 28, 2014, the disclosure of which is incorporated herein by reference. This application claims priority benefits under 35 U.S.C. §1.119 to Korean Patent Applications No. 10-2012-0103136 filed Sep. 18, 2012 and No. 10-2012-0128126 filed Nov. 13, 2012.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention is for various types of surface signs printed on the surface of the road for signage purpose, more specifically, the surface sign would be in a form that appears to be elevated vertically making it easy for the driver to recognize the sign which can enhance readability, and it draws the drivers gaze to the road helping the driver practice safer driving.
[0004] 2. Description of Related Art
[0005] There are many printed surface signs on the road today. Such surface signs make it possible for drivers to know the direction for key points of traffic, when to change lanes before turning either right or left, and various information regarding warnings. In such surface road signs which are generally text that have been simply stretched lengthwise, far off horizontal lines give the feeling of being wider than close up horizontal lines, and vertical lines and lane markers and are parallel to the road making it difficult for the driver to recognize, therefore it is near impossible to recognize these two types of vertical lines, therefore resulting in the disadvantage of reduced readability. Accordingly, in order for the driver to become familiar with reading surface signs, the signage has to be printed several times for the message to be repeated enough, and since there are many traffic conditions where the driver is not narrowly focusing straight ahead what results is various warnings are not being recognized by the driver. Accordingly, this causes the driver to inaccurately recognize the words, and it also confuses the driver into thinking that the words are moving which leads to the necessity for a surface sign that can naturally catch the attention of the driver.
PRIOR TECHNOLOGY REFERENCES
Patent References
[0006] (Patent Reference 1) Korea Public Patent No. 10-0763512 (Registration No.) 2007 Sep. 27
BRIEF SUMMARY OF THE INVENTION
Technical Problem Solving
[0007] Accordingly, the purpose of this invention is to provide surface signs with an optical illusion effect presenting signage in a way that appears to have been vertically elevated to the driver enhancing the readability of the text.
[0008] Also, from the standpoint of the driver it has the appearance of moving on the road drawing the gaze of the driver to the sign, and providing surface signs with an optical illusion effect that can call attention to the sign which can help safe driving as it causes the driver to pay attention to warnings better.
[0009] Since this invention is printed onto the road surface creating surface signs using words or shapes that provide information to a far off driver the above surface sign from the standard distance between the above driver and the above surface sign a standard distance between the above driver and the above surface sign, where the roadside prints are formed longer than the wayside prints for random waysides and roadsides reflected at the same distances form in the periphery of the above driver, which is the feature of this invention.
[0010] Also, this invention has the feature of the painted length of the above surface sign, ‘y,’ where y=((X−Y)/(A−b))b for ‘b’ the random length of the roadside established from the point the furthest down of the above surface sign that is reflected in the field of vision of the above driver.
[0011] Also, a third features of this invention is that when the distance between the above driver and the above surface sign is ‘X’ and the above painted scope of the surface sign is ‘S’, then the formed angle of the above surface sign θ, is θ=2 tan −1 ((S/2)/X).
Beneficial Effect
[0012] In case the driver is at a distance from the surface sign( 1 ) the surface sign( 1 ) will appear as if it is laying flat on the road, but the shorter the standard distance used in the surface sign( 1 ) in the diagram, the surface sign( 1 ) will gradually elevate, and when the driver is in position the surface sign( 1 ) will become visible to the driver as if it were in its vertical form on the surface of the road, therefore this invention boosts the effect of the readability of the text.
[0013] Also, this invention would have the effect of aiding in safer driving because from the standpoint of the driver if the surface sign( 1 ) is elevated it becomes something that appears to be moving while lying flat on the road which could draw the driver's attention of the because of the human tendency recognize moving objects quicker than stationary ones.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a schematic view showing the surface signs with an optical illusion effect according to the implementation example of this invention.
[0015] FIG. 2 is conceptual view showing the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention.
[0016] FIG. 3 is a conceptual view showing the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention.
[0017] FIG. 4 is a conceptual view showing the left side angle of the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention.
[0018] FIG. 5 is a conceptual view showing the length ratio formula of the underside and topside of the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention.
[0019] FIG. 6 is the floor plan of the print example of the length of the painted surface signs with an optical illusion effect according to the daily standard length.
DETAILED DESCRIPTION OF THE INVENTION
[0020] Below described in detail are the surface signs with an optical illusion effect of this invention according to the attached figures.
[0021] FIG. 1 is a schematic view showing the surface signs with an optical illusion effect according to the implementation example of this invention, FIG. 2 is conceptual view showing the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention, FIG. 3 is a conceptual view showing the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention, FIG. 4 is a conceptual view showing the left side angle of the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention, FIG. 5 is a conceptual view showing the length ratio formula of the underside and topside of the computational formula of the length of the painted surface signs with an optical illusion effect according to the implementation example of this invention, and FIG. 6 is the floor plan of the print example of the length of the painted surface signs with an optical illusion effect according to the daily standard length.
[0022] By printing copy or shapes on the road in school zones, children protection zones, and copy and information about major intersections, and various guidance copy and shapes, this invention's surface signs with an optical illusion effect gives 3-D shape to surface signs( 1 ) within the field of view of the driver who is behind the wheel of the car, calling attention to the hazards the driver may face and improving the readability of the copy.
[0023] In order to do this, this invention as described in diagrams 1 through 5 , has a surface sign( 1 ) from the standard distance between the driver and the surface sign, where the roadside prints are formed longer than the wayside prints for random waysides and roadsides reflected at the same distances form in the periphery of the above driver. In more detail, when the height of the field of vision for the driver has been established as Am, and the height of the surface sign( 1 ) that can be seen in 3-D has been established as Bm, the printed length of the surface sign( 1 ) according to the distance between the driver and the surface sign( 1 ) uses a rule that has similar figures as a triangle and follows the formula below. Here, the distance between the driver and the surface sign( 1 ) means the furthest away distance from the driver to the surface sign( 1 ), and the height of the surface sign( 1 ) means the total length of the surface sign( 1 ) reflected in the field of view of the driver from the point the furthest up to the point the furthest down.
[0000]
X
:
A
=
Y
:
B
AY
=
BX
Y
=
B
A
X
Mathematical
Formula
1
[0024] The height of the field of view of the driver of a passenger car was established as 1.3 m, and the height of the surface sign( 1 ) seen three dimensionally was described in the case of being established at a height of 39 cm, but these are matters that can be selected by the person from the scope that applies the above formula, therefore the height of the field of view of the driver and the height of the surface sign( 1 ) in this invention is not fixed at a numerical value.
[0025] If the printed length of the surface sign( 1 ) according to the length of the distance between the driver and the surface sign( 1 ) according to the mathematical formula is 30 m,
[0000]
Y
=
0.39
1.3
30
=
9
Mathematical
Formula
2
[0000] then it becomes 9 m. Using the same method the printed length of the surface sign( 1 ) for distances of 15 m, 20 m, and 25 m between the driver and the surface sign( 1 ) would be 4.5 m, 6 m, and 7.5 m, respectively.
[0026] Also, as described in FIG. 3 , even the length that is shown in the same interval in the field of view of the driver, the printed length of this become longer the further up you go, but the distance of the point of ‘y’ as expressed on the actual surface of the height of the random point of b as seen three dimensionally in surface sign( 1 ) follows the following formula. Here, the random point ‘b’ means the random vertical length that is established from the lowest point of the surface sign( 1 ).
[0000]
y
+
(
X
-
Y
)
:
A
=
y
:
b
Ay
=
by
+
(
X
-
Y
)
b
(
A
-
b
)
y
=
(
X
-
Y
)
b
y
=
X
-
Y
A
-
b
b
Mathematical
Formula
3
[0000] Meaning, in order to see the row of the uppermost part and the lowermost part, the lower part of the uppermost row will be shown at a point of 29 cm, and the upper part of the lowermost row will be shown at a point of 10 cm, therefore each would be indicated
[0000]
y
=
30
-
9
1.3
-
0.29
0.29
=
6.03
y
=
30
-
9
1.3
-
0.1
0.1
=
1.75
Mathematical
Formula
4
[0000] at points of 6.03 m and 1.75 m. Accordingly, the upper part of the lowermost row would be indicated at a point of 9 m, and the print length would be 2.97 m, and with the print length of the lowermost row as 1.75 m, it would result in a ratio of about 1.7 times. The means that the print distance of the surface sign( 1 ) should be printed even more elongated the further you go from lower to upper for it all to be seen as the same length in the driver's field of view.
[0027] Also, that which can be known from the length of ‘y’ for the point ‘b’ is that if one wants to view both the horizontal and vertical at lengths of 10 cm, then as the length of the vertical described in the actual surface is about 1.75 m from the lower part of the surface sign( 1 ), and about 2.97 m in the upper part then the roadside length is 17˜30 times the wayside length.
[0028] Also, in the above, the upper and lower lengths of the surface sign( 1 ) according to the field of view of the driver were mentioned, so the right and left side angle of the surface sign( 1 ) according to the driver's field of view will be described.
[0029] When the distance between the driver and the surface sign( 1 ) as seen in FIG. 4 is Xm, and the range of printing of the surface sign( 1 ) is established, then the right and left side angle ‘θ’ is expressed in the following formula.
[0000]
θ
=
2
tan
-
1
S
2
X
Mathematical
Formula
5
[0030] This means that if the distance between the surface sign( 1 ) is 30 m, and the range of printing is 3.5 m, then the right and left side angle of the surface sign( 1 )
[0000]
θ
=
2
tan
-
1
3.5
2
30
=
6.68
Mathematical
Formula
6
[0000] becomes 6.68 m. In the same way, the criteria for the distance of 15 m, 20 m, and 25 m, between the driver and the surface sign( 1 ) each have a right and left side angle of the surface sign( 1 ) of 13.31, 10 and 8.01. This way, when establishing the right and left side angle of the surface sign( 1 ) according to the distance between the driver and the surface sign( 1 ) m , the field of view of the driver from the relevant distance makes the edge of uppermost right and left side and the edge of the lowermost right and left side appears at the same location, therefore the letters do not appear to be uneven.
[0031] The right and left side angle of this surface sign( 1 ) are matters that can be determined based on the range selected by the person that were applied according to the standard distance between the surface sign( 1 ) and the driver, the range of printing of the surface sign( 1 ), therefore this is not fixed at a numerical value.
[0032] For example, the above was described for when printing a surface sign( 1 ) on a standard road that is 3.5 m wide, but when printing on a range where the lanes are 3.15 m wide, the criteria distance of 15 m, 20 m, 25 m and 30 m would be replaced with left and right side angles that are 12 degrees, 9 degree, 7.2 degrees and 6 degrees, respectively.
[0033] The left and right angles of the surface sign( 1 ) are applied to each letter when printing, but the random vertical line that connects from the uppermost point to the lowermost point, for example, in case of the vowel “I”, the angle forming the left side version and the right side version would be printed in different ways from each other. When the vowel “I” is formed as a whole from the upper part of the surface sign( 1 ) to the lower part, when considering the left side version of the vowel “I” is at a distance of 1 m from the square center of the surface sign( 1 ) and the right side version of the vowel “I” is at a distance of 1.1 m from the square center of the surface sign, then the line dividing the left side and right side versions of the vowel “I” and the angle that is formed is
[0000]
Left
=
tan
-
1
1
30
=
1.91
Righ
=
tan
-
1
1.1
30
=
2.1
Mathematical
Formula
7
[0000] resulting in an angle of 0.19 formed by the left and right side of the vowel “I” that has a width of 10 cm.
[0034] If you substitute this in mathematical formula 5,
[0000]
θ
=
2
tan
-
1
0.1
2
30
=
0.19
Mathematical
Formula
8
[0035] This means it follows the range formula of the surface sign( 1 ) according to the field of view of the driver.
[0036] Accordingly, with the adding of the angles to each other that are formed from the separate letters in a fan-shape the formation of the final left and right side angle the left and right side angle of the surface sign( 1 ) that follows the driver's field of view, then it means that the meaning of the left and right side angle of the surface sign( 1 ) as defined in the terms of this invention is the angle that is formed from among the printed left and right side peripheral sides.
[0037] However, as above, for the furthest length s2 m of the upper side from the driver by the closest length lower side from the driver of the random vertical line of the vowel “I” that goes from the uppermost point of the surface sign( 1 ) to the lowermost point, this can be deduced as follows using the similar figures as a triangle as described in FIG. 5 .
[0000]
X
:
s
2
=
X
-
Y
:
s
1
(
X
-
Y
)
s
2
=
Xs
1
s
2
=
X
X
-
Y
s
1
Mathematical
Formula
9
[0038] Here, as above the printed length of surface sign( 1 ) of standard distances of 15 m, 20 m, 25, and 39 m, respectively, for the driver's field of view height of 1.3 m were each calculated in lengths of 4.5 m, 6 m, 7.5 m, and 9 m, therefore this was plugged into ‘X’ and ‘Y’, and when considering the length of the side of vowel “I” by 10 cm, the length of vowel “I” s2 was 14.29 cm,
[0000]
s
2
=
15
15
-
4.5
0.1
=
0.14285
s
2
=
20
20
-
6
0.1
=
0.14285
s
2
=
25
25
-
7.5
0.1
=
0.14285
s
2
=
30
30
-
9
0.1
=
0.14285
Mathematical
Formula
10
[0000] the same in all cases. Likewise, in accordance with the implementation of this invention, the upper side length of the lower side letters or shapes that appear as equal in width, regardless of the distance between the driver and the surface sign( 1 ) 1.43 times would be deemed appropriate, and this would be because the gap between driver and the surface sign ( 1 ) would narrow and instead of the left and right side angle of the vowel “I” getting larger the printing length of the surface sign( 1 ) would be just as narrow.
[0039] But, even in cases such as this, within the range of application of the formula above the above numerical value can be selected by the person in charge of the application, and according to the field of view of the driver, in case the length of the surface sign( 1 ) is varied the length of the upper side can also be varied of course, therefore this invention is not limited to the numerical value.
[0040] Examples about the particulars of the composition that makes up this invention of surface signs with an optical illusion effect are described in FIG. 6 . In FIG. 6 it could be seen among the embodiments of the present invention, with the reduction of the surface sign( 1 ) that was printed on the actual road for the case of a distance of 20 m between surface sign( 1 ) and the driver, a greater width was formed for the roadside to the far side from the drive rather than to the close side of the driver, also each roadside was formed to reach the mutually acute angles, and also, the print length of the upper line was formed in a way that was longer than the lower line.
[0041] Yet, in cases of trucks and buses where the field of view is higher than that of a passenger car, just as can inferred in FIGS. 1 and 2 it still works but when the location of the driver is further from the surface sign( 1 ), and likewise drivers of trucks and buses will be able to view surface sign of the 3-D formation from an even further location.
[0042] For the invention of surface sign( 1 ) with an optical illusion effect that was described in case the location of the driver is further away from the surface sign( 1 ), the surface sign( 1 ) will appear as if it is lying flat on the road, the narrower the gap to the standard distance used in the diagram of surface sign( 1 ) the more the surface sign( 1 ) would elevate, and when the driver comes into position at a standard distance used in the diagram of surface sign( 1 ), the surface sign( 1 ) would appear to the driver as seeming to be elevated erect, therefore it would aid in safer driving because from the standpoint of the driver if the surface sign( 1 ) is elevated becoming something that looks like it is moving while lying flat on the road this could draw the attention of the because of the human characteristics that more quickly recognize moving objects rather than stationary ones.
EXPLANATION OF MARKS
[0000]
Surface sign: 1
|
Disclosed is a surface sign that is seen by the driver as raised vertically improving the readability by the driver, and as for the surface signs with an optical illusion effect that can aid the driver in driving safely due to the tendency of being able to capture the gaze of the driver printing onto the road surface creating surface signs that provides information to a far off above driver using copy or shapes, from the standard distance between the above driver and the above surface sign, where the roadside prints are formed longer than the wayside prints for random waysides and roadsides reflected at the same distances form in the periphery of the above driver, and the surface of the road is painted in order for the two nearby roadsides to form a mutually acute angle.
| 4
|
This application claims priority from Provisional Application No. 60/163,229, filed Nov. 3, 1999.
BACKGROUND OF THE INVENTION
This invention relates to compositions of matter classified in the art of chemistry as fluoropolymers, more specifically to copolymers of vinylidene fluoride (VDF) and hexafluoropropylene (HFP) and still more specifically to such copolymers having very low or no crystallinity and to processes for their preparation and use. The copolymers at all levels of HFP content remain highly flexible, thermoplastic copolymers which show low surface tack even at high HFP levels.
Fluoropolymers and copolymers of VDF, collectively VDF-based polymers wherein the VDF portion is greater than the total molecular percent of comonomers, are well known and widely used. Among the variety of fluoropolymers based upon tetrafluoroethylene, chlorotrifluoroethylene, and other speciality fluorine-containing monomers, the VDF polymers are unique offering the widest possible range of processing options to obtain articles having the beneficial attributes associated with improved chemical resistance and surface properties associated with the high concentration of carbon fluorine bonds. Thus, among the wide spectrum of fluoropolymers, the VDF polymers may be melted in typical processing equipment for thermoplastic resin for extrusion or molding or combinations such as extrusion-blown film and molding into tanks.
This versatility in processing options is related to the linear polymer chain structure and the presence of the highly polar-CF 2 -groups alternating along the VDF polymer chain. The microstructure of the polymer chain and morphology of these polymers reflects these two factors in many interesting ways as described in Polymeric Materials Encyclopedia, 1996, Vol II, CRC Press; Vinylidene Fluoride-Based Thermoplastics (Overview and Commercial Aspects), J. S. Humphrey, pp. 8585 to 8588; Vinylidene Fluoride-Based Thermoplastics (applications), J. S. Humphrey and E. J. Bartoszek, pp. 8588-8591; Vinylidene Fluoride-Based Thermoplastics (Blends with Other Polymers), J. S. Humphrey and X. Drujon, pp. 8591-8593; Vinylidene Fluoride-Based Thermoplastics (Homopolymerization and Copolymerization), J. S. Humphrey and X. Drujon, pp. 8593-8596.
The balance between amorphous and crystalline regions, the nature and extent of the crystalline regions, and the interphase between these regions affects the mechanical properties significantly, and hence, the ultimate applications for a given resin composition.
At one end of the spectrum there are totally amorphous thermoplastic polymers and at the other S extreme the highly crystalline polymers. The microstructure of the polymer chain determines the flexibility (or alternately the stiffness) at a given temperature. This mechanical behavior is controlled by the type and amount of the crystalline phase (if any) and the dynamics of the molecular motion along the chain such that at some temperature the polymer undergoes a second order change in response to applied stresses, the so-called glass transition temperature (Tg). Above the Tg the polymer chain has molecular motions which are free to rotate, stretch, etc. and thereby absorb the energy input. Below the Tg the molecular motions are frozen and the stresses may lead to brittle fracture or glass-like behavior.
The immediate invention is concerned more with the morphology and crystalline/amorphous.ratio of the VDF polymers and the ultimate end uses. It is therefore important to understand the background of the present invention in the context of the teaching how crystalline and amorphous content fit into the range of polymers which are classed as thermoplastic, elastomer-modified thermoplastic, or elastomeric resins. In this particular invention, the key attribute is related to highly flexible resins related to the latter two categories. This invention produces a variety of VDF-HFP resins, which are differentiated quite clearly from prior art with respect to the low level of crystallinity compared to resins of the otherwise same nominal monomer ratio composition produced by standard teachings. Thus, the present invention relates to a novel fluoro-thermoplastic having a unique combination of properties including excellent flexibility, low temperature processability, high clarity,solution stability and room temperature film forming capability from aqueous dispersions.
PRIOR ART
U.S. Pat. No. 3,051,677 describes batch emulsion and continuous emulsion processes for copolymerization of vinylidene fluoride and hexafluoropropylene (HFP) in the range of 30 to 70 weight percent of hexafluoropropylene monomer and 70 to 30 weight percent vinylidene fluoride monomer. The copolymers described in this reference have relatively high crystallinity as is confirmed by the properties described in the document for the products exemplified. Analogous materials from a batch process are described by Moggi, et. al. in Polymer Bulletin, Vol. 7 pp. 115-122 (1982).
U.S. Pat. No. 3,178,399 describes both batch and semi-continuous emulsion processes for preparing HFP-VDF copolymers having between 85 and 99 mole percent VDF and 1 and 15 mole percent HFP (approximately 2 to 30 weight percent HFP and 70 to 98 weight percent VDF). Once again, the copolymers produced have relatively high internal crystallinity and this fact is evidenced by the physical data provided for those copolymers actually exemplified. This patent discloses that Tensile X Reversible Elongation was increased as the overall HFP proportion decreased in the copolymer. This implies that crystallinity increases as HFP content decreases.
U.S. Pat. No. 5,093,427 describes HFP-VDF copolymers, with the other extreme crystalline melting behavior, containing from about 1 to 20 weight percent HFP wherein, based on the synthetic method described, a polymer containing significant portions of homopolymer and other copolymer portions having a high proportion of HFP in the copolymer results. Thus, compositions of the copolymers described in this reference are significantly different from the copolymers contemplated by the present invention.
Indonesian Patent Application W-980105, published Nov. 26, 1998 as number 020.295A equivalent to WO 98/38242 and to U.S. patent application Ser. No. 09/031,014, the contents of which have been included in CIP Application 09/641,015 discloses an emulsion process for producing HFP-VDF copolymers having highly homogenous distribution of the comonomers in individual claims and from chain to chain thereby having reduced extractable content and improved solution clarity over HFP-VDF copolymers prepared according to the techniques of the preceding references. These materials differ from the copolymers of the present invention because the products of this patent application are limited to lower percentages of HFP content, the solubility and solution stability properties as well as the reduced melting points are attributed to the homogeneous distribution of the comonomers and no discussion of the crystallinity or lack thereof of the polymers described and whether or not it might be related to any of the properties observed for those polymers is provided.
In Polymer, Vol. 27, p. 905 (1986) and Vol. 28, p. 224 (1987), Moggi, et al. Report synthesis of HFP-VDF copolymers and studies of various physical properties and how these properties may be correlated to certain internal structural features such as crystallinity, monomer sequencing in individual molecules and the like. The limited synthesis information indicates that the polymers formed were analogous to those prepared according to the previous references except for U.S. patent application Ser. No. 09/031,014 and the limited physical data provided is consistent with this interpretation and that the polymers described had a high degree of crystallinity.
Although it is well established in the prior art to reduce crystallinity by means of adding higher amounts of HFP to the copolymer, there is no prior art suggesting how to produce as low crystallinity as is provided by the present invention at any given nominal proportion of HFP. Thus, the copolymers disclosed herein have measurably lower crystallinity at any given HFP level than copolymers with the same nominal HFP content produced in accordance with processes enabled by any of the above listed references.
SUMMARY OF THE INVENTION
The invention provides in its first composition aspect a vinylidene fluoride, hexafluoropropylene copolymer having from about 1 to about 66 weight percent hexafluoropropylene content and having low crystallinity.
By a vinylidene fluoride hexafluoropropylene copolymer having from about 1 to about 66 weight percent hexafluoropropylene content having low crystallinity is meant that such copolymers have measurably lower crystallinity than copolymers produced according to the prior art references, which provide sufficient details for a reproductive synthesis of the materials described therein. Thus, the copolymers having 36% by weight or greater HFP content have the heats of fusion calculated from any endotherms detected in a differential scanning calorimeter (DSC) scan (described below), of about 0 J/g and for copolymers having less than 36 weight % HFP content any endotherm detected in a DSC scan as described below is at least about 1.5 J/g less than the endotherm detected for copolymers of substantially (±1.00 wt %) similar HFP content for copolymers produced according to the prior art listed above. Thus, the copolymers having from greater than 0 to 28.5 wt % HFP content have an endotherm on melting which is defined by the relationship:
Δ H =56.49−1.854(HFP wt %)
and the copolymers having from greater than 28.5 up to less than 36 weight % HFP content have an endotherm on melting which is defined by the relationship:
Δ H =54.81−1.53(HFP wt %).
In addition, the copolymers of from greater than 0 to 30 wt % HFP also have lower DSC melting points at a given HFP content than any of the copolymers of the same HFP content described in any of the references cited above and the melting point for a copolymer having a particular HFP content in the greater than 0 to 30 wt % HFP range is defined by the relationship:
Melt Temp. (° C.)=162.16−3.192(HFP wt %).
Copolymers having greater than 30 wt % HFP produced according to such prior art, as will be illustrated in the examples below, all exhibit exotherms in their DSC scans run as described below significantly greater than 0/J/g. Those having lower than 30% HFP content all have higher crystallinity as defined by higher ΔH of melting determined by DSC than those of this invention.
The DSC scan measuring the crystalline content is performed according to ASTM D 451-97 using a Perkin Elmer 7 DSC apparatus with an Intercooler II attachment. The instrument is equipped with a dry box with an N 2 purge through the dry box. Specimens of 9 to 10 mg are used and crimped in aluminum pans.
For samples with a low degree of crystallinity, the DSC run is begun at −50° C. followed by a 10° C./min ramp to 180° C.
For samples with an HFP content lower than 30 wt. % and, thus, a higher degree of crystallinity, the DSC run is performed in a three step cycle. The cycle is begun at −50° C. followed by a 10° C./min ramp to 180° C. with a 10 minute hold. The sample is then cooled at a rate of 10° C./min to −50° C. and then unheated at the 10° C./min rate to 180° C.
In comparison with other previously known copolymers of VF2/HFP produced by the above cited references, the reduced crystalline content of VF2/HFP at a given HFP level provides a unique combination of properties among which are those offering the following advantages:
(i) Reduced tack: allows ease of handling and better field performance;
(ii) Improved miscibility with other polymers, particularly with different esters of polyacrylates and polymethacrylates;
(iii) Lower melting temperature: allows easier manufacturing for typical molding processes;
(iv) Higher elongation at yield point: allows better performance;
(v) Lower stress at yield point: allows ease of process and manufacturing due to lower modulus;
(vi) Enhanced blendability: lower crystallinity: allows more intimate blending with other polymers because of reduction in size and in volume fraction of hard domains;
(vii) Clearer solution/haze free solution: reduction in size and in volume fraction of hard domains caused by reduced crystallinity, results in enhanced salvation of polymer chain which consequently retards the gelation of the polymer solution;
(viii) Improved optical clarity of polymer film.and plaque sheets;
(ix) Improved elastomeric properties;
(x) Longer shelf stability of solution: better solubility due to reduction of crystalline domains, results in enhanced salvation of polymer chain which consequently retards the gelation of polymer solution.
Surprisingly, as the crystallinity of the HFP copolymers decreases, it has been found that the Tg increases and still more surprisingly, It has been found that when blended with acrylic polymers, for the copolymers of the present invention, the Tg for the mixture actually increases. This is highly unexpected because normally a mixture of polymers shows lower Tg than pure polymer.
For example, two copolymers of the present invention were mixed in equal parts by weight with three different polyacrylate esters and the Tg values for each mixture determined and compared with the Tg values for identically proportioned mixture of a standard commercially available VDF/HFP copolymer which had a ΔH of melting of 37.2 (KYNAR® Flex 2750, available from ATOFINA Chemicals, Inc., Philadelphia, Pa. which contains about 15.5 wt % HFP). All three copolymers had a Tg of about −25±2° C. Copolymer sample 1 (sample 1) of the present invention had about 16.5 wt % HFP content and a ΔH of melting of 30.4 while copolymer sample 2 (sample2) of the present invention had about 14.1 wt % HFP content and a ΔH of melting of 26.7. A blend of 50 wt % polymethylmethacrylate with the KYNAR Flex had, as expected, a Tg of 24.2° C., while the analogous mixture with sample 1 had Tg of 34.3° C. and the analogous mixture with sample 2 had Tg of 40.8° C. A blend of 50 wt % polyethylmethacrylate with the KYNAR Flex had, as expected, a Tg of 17.8° C., while the analogous mixture with sample 1 had Tg of 26.3° C. and the analogous mixture with sample 2 had Tg of 30° C. A blend of 50 wt % polybutylmethacrylate with the KYNAR Flex had, as expected, a Tg of 11.7° C., while the analogous blend with sample 1 had Tg of 18.6° C. and the analogous blend with sample 2 had Tg of 23.1° C.
HFP content was alternatively determined by 19 F NMR using the following methods.
In preparation for the NMR analysis, VDF/HFP copolymer samples were dissolved in a 5 mm diameter NMR tube. Samples of less than 10 wt % HFP were dissolved in DMSO-d6 at 86° C., while samples of more than 10 wt % HFP were dissolved in acetone-d6 at 50° C. An amount of copolymer, 2 to 4 mg, was placed in a tube and enough solvent was added to fill the tube to 5.5 cm (about 0.75 ml of solvent). A heating block was used to bring the samples to temperature. The samples were heated for at least one hour, until the solid was dissolved and there was no gel present, but in the case of DMSO-d6, for a time no longer than 8 hours in order to avoid degradation. Tubes were inverted to check for gel.
Spectra were acquired on either a Bruker DMX or a Varian Mercury 300 spectrometer operated at 80° C. in the case of DMSO-d6 solvent or at 50° C. in the case of acetone-d6 solvent. Specific parameters for the instruments were as follows:
Bruckner DMX
Varian Mercury 300
19 F signal frequency
281.9 MHz
282.3 MHz
pulse width
45° at 2.5 us
300 at 2.5 us
recycle delay
5s
5s
linear prediction
not needed*
first 12 point are
back predicted using
1024 points and 64
coefficients**
probe
5 mm high
5 mm Nalorac zspec
temp H/F
1 H decoupling***
yes
no
sweep width
125 kHz
100 kHz
acquisition time
1.05 s
0.3 s
*No fluorine background observed on this instrument.
**This will be instrument dependent, depending on severity of background.
***This is inverse gated decoupling on the Bruker to
Spectra were analyzed according to the signal assignments described in Pianca et al., Polymer, vol. 28, 224-230 (February 1987). As a check on the accuracy of the NMR acquisitions, the integrals of the CF3's and the CF's were compared to see if they were in a ratio of 3 to 1.
The synthetic technique described herein also provides a method for preparing a high solids small particle size latex of the copolymers of the invention. This high solids small particle latex which because of its low crystallinity offers the following applied use properties in addition to those mentioned above:
(i) lower minimum film forming temperature (MFFT) which means that the resin is able to form continuous film at lower temperatures, e.g. at room temperature where the substrate may be heat sensitive.
(ii) Longer latex stability giving a longer shelf life;
(iii) Higher concentration of polymer in latex which provides lower cost per unit weight of polymer for transportation and storage as well as better film formation characteristics;
(iv) Improved optical properties: superior to prior art in terms of clarity. It is important in many coating applications to have clear film forming resin.
Copolymers produced according to the prior art are those produced by the methods enabled by those references listed above.
The tangible embodiments of the first composition aspect of the invention are white or light colored solids having physical and chemical characteristics tending to confirm the molecular structure assigned herein.
The aforementioned chemical and physical characteristics taken together with the method of synthesis and standard analytical technique measurements, such as dynamic mechanical analytical, infrared and nuclear magnetic resonance spectroscopic and differential scanning calorimetric measurements further positively confirm the aforesaid structure for the first composition aspect of the invention.
The tangible embodiments of the first composition aspect of the invention possess the inherent applied use characteristics of being useful in formulating high performance coatings, films and foams, as encapsulants, in fiber optic applications, and as thermoplastic polymers having UV and chemical. resistance when fabricated into shaped objects including wire and cable insulation, pipes and other extruded or molded objects.
Special mention is made of embodiments of the first composition aspect of the invention wherein the hexafluoropropylene residue content is greater than 5 weight %, preferably greater than 10 weight %, still more preferably greater than 15 weight % and still more preferably greater than 30 weight %.
The invention provides in a second composition aspect, an object having at least one surface and having a coating comprising at least one embodiment of the first composition aspect of the invention on said surface.
The invention provides in a third composition aspect of the invention, a formed object comprising at least one embodiment of the first composition aspect of the invention.
The invention provides in a fourth composition aspect, an embodiment of the first composition aspect of the invention prepared by a process as described hereinafter.
DETAILED DESCRIPTION
The manner of making and using the embodiments of the invention will now be illustrated with reference to specific embodiments thereof.
The vinylidene fluoride, hexafluoropropylene copolymers of the first composition aspect of the invention are conveniently made by an emulsion polymerization process, but suspension and solution processes may also be used. In an emulsion polymerization process, a reactor is charged with deionized water, water soluble surfactant capable of emulsifying the reactor mass during polymerization and the reactor and its contents are deoxygenated while stirring. The reactor and contents are heated to the desired temperature and vinylidene fluoride, hexafluoropropylene and, optionally, chain transfer agent to control copolymer molecular weight are added. When the desired reaction pressure is reached, initiator to start and maintain the reaction is added. To obtain the VDF/HFP copolymers of the present invention, the initial charge of VDF and HFP monomers is such that the weight ratio of HFP to VDF is an exact first ratio which is from three to five times the weight ratio of HFP to VDF to be fed during the reaction. HFP and VDF are fed during the reaction in a proportion such that the total amount of HFP added over the entire course of the reaction is approximately equal to the proportionate amount of HFP desired in the final copolymer. The VDF/HFP ratios are, thus, different in the initial charge and in the continuous feed. The process uses total amounts of VDF and HFP, monomers such that the amount of HFP incorporated in the final copolymer is up to about 66 wt % of the combined total weight of the monomers.
To determine the exact first ratio for a particular reaction to provide the optimum low crystallinity at any desired HFP ratio at a desired reaction temperature and pressure, one of skill in the art will understand how to perform a few pilot scale run varying the initial HFP concentration in the desired range to select the proper exact ratio keeping other reaction conditions constant.
The reactor is a pressurized polymerization reactor preferrably a horizontal polymerization reaction equipped with a stirrer and heat control means. The temperature of the polymerization can vary depending on the characteristics of the initiator used, but it is typically between 30° and 130° C., and most conveniently it is between 50° and 120° C. The temperature is not limited to this range, however, and might be higher or lower if a high-temperature or low-temperature initiator is used. The pressure of the polymerization is typically between 20 and 80 bar, but it can be higher if the equipment permits operation at higher pressure. The pressure is most conveniently between 40 and 60 bar.
Surfactants used in the polymerization are water-soluble, halogenated surfactants, especially fluorinated surfactants such as the ammonium, substituted ammonium, quarternary ammonium, or alkali metal salts of perfluorinated or partially fluorinated alkyl carboxylates, the perfluorinated or partially fluorinated monoalkyl phosphate esters, the perfluorinated or partially fluorinated alkyl ether or polyether carboxylates, the perfluorinated or partially fluorinated alkyl sulfonates, and the perfluorinated or partially fluorinated alkyl sulfates. Some specific, but not limiting examples are the salts of the acids described in U.S. Pat. No. 2,559,752 of the formula X(CF 2 ) n COOM, wherein X is hydrogen or fluorine, M is an alkali metal, ammonium, substituted ammonium (e.g., alkylamine of 1 to 4 carbon atoms), or quaternary ammonium ion, and n is an integer from 6 to 20; sulfuric acid esters of polyfluoroalkanols of the formula X(CF 2 ) n CH 2 OSO 3 M, where X and M are as above; and salts of the acids of the formula CF 3 (CF 2 ) n (CX 2 ) m SO 3 M, where X and M are as above; n is an integer from 3 to 7, and m is an integer from 0 to 2, such as in potassium perfluorooctyl sulfonate. The surfactant charge is from 0.05% to 2% by weight on the total monomer weight used, and most preferably the surfactant charge is from 0.1% to 1.0% by weight.
A paraffin antifoulant may be employed, if desired, although it is not preferred, and any long-chain, saturated, hydrocarbon wax or oil may be used. Reactor loadings of the paraffin may be from 0.01% to 0.3% by weight on the total monomer weight used.
After the reactor has been charged with deionized water, surfactant, and any optional paraffin antifoulant, the reactor is either purged with nitrogen or evacuated to remove oxygen. The reactor is brought to temperature, and chain-transfer agent may optionally be added. The reactor is then pressurized with a mixture of vinylidene fluoride and hexafluoropropylene.
Chain-transfer agents which may be used are well-known in the polymerization of fluorinated monomers. Alcohols, carbonate esters, ketones, carboxylate esters, and ethers are oxygenated compounds which serve as chain-transfer agents. Specific, but not limiting examples, are isopropyl alcohol, such as described in U.S. Pat. No. 4,360,652, acetone, such as described in U.S. Pat. No. 3,857,827, and ethyl acetate, as described in the published Unexamined Application (Kokai) JP 58065711. Other classes of compounds which serve as chain-transfer agents in the polymerization of fluorinated monomers are halocarbons and hydrohalocarbons such as chlorocarbons, hydrochlorocarbons, chlorofluorocarbons, and hydrochlorofluorocarbons all having 1 to 6 carbon atoms; specific, but not limiting examples are trichlorofluoromethane, such as described in U.S. Pat. No. 4,569,978, and 1,1-dichloro-2,2,2-trifluoroethane. Chain-transfer agents may be added all at once at the beginning of the reaction, in portions throughout the reaction, or continuously as the reaction progresses. The amount of chain-transfer agent and mode of addition which is used depends on the activity of the agent and the desired molecular weight characteristics of the product. The amount of chain-transfer agent used is from 0.05% to 5% by weight on the total monomer weight used, and preferably it is from 0.1 to 2% by weight.
The reactor is pressurized by adding vinylidene fluoride and hexafluoropropylene in a definite ratio (first exact ratio) such that the hexafluoropropylene ratio in the VDF/HFP mixture initially charged ranges from about 3 to about 5 times the ratio of hexafluoropropylene fed into the reactor during the reaction. The exact ratio can be selected by a series of controlled laboratory runs as described above.
The reaction can be started and maintained by the addition of any suitable initiator known for the polymerization of fluorinated monomers including inorganic peroxides, “redox” combinations of oxidizing and reducing agents, and organic peroxides. Examples of typical inorganic peroxides are the ammonium or alkali metal salts of persulfates, which have useful activity in the 65° C. to 105° C. temperature range. “Redox” systems can operate at even lower temperatures and examples include combinations of oxidants such as hydrogen peroxide, t-butyl hydroperoxide, cumene hydroperoxide, or persulfate, and reductants such as. reduced metal salts, iron (II) salts being a particular example, optionally combined with activators such as sodium formaldehyde sulfoxylate or ascorbic acid. Among the organic peroxides which can be used for the polymerization are the classes of dialkyl peroxides, peroxyesters, and peroxydicarbonates. Exemplary of dialkyl peroxides is di-t-butyl peroxide, of peroxyesters are t-butyl peroxypivalate and t-amyl peroxypivalate, and of peroxydicarbonates are di (n-propyl) peroxydicarbonate, diisopropyl peroxydicarbonate, di (sec-butyl) peroxydicarbonate, and di (2-ethylhexyl) peroxydicarbonate, and di (2-ethylhexyl) peroxydicarbonate. The use of diisopropyl peroxydicarbonate for vinylidene fluoride polymerization and copolymerization with other fluorinated monomers is taught in U.S. Pat. No. 3,475,396, and its use in making vinylidene fluoride/hexafluoropropylene copolymers is further illustrated in U.S. Pat. No. 4,360,652. The use of di (n-propyl) peroxydicarbonate in vinylidene fluoride polymerizations is described in the Published Unexamined Application (Kokai) JP 58065711. The quantity of an initiator required for a polymerization is related to its activity and the temperature used for the polymerization. The total amount of initiator used is generally between 0.05% to 2.5% by weight on the total monomer weight used. Typically, sufficient initiator is added at the beginning to start the reaction and then additional initiator may be optionally added to maintain the polymerization at a convenient rate. The initiator may be added in pure form, in solution, in suspension, or in emulsion, depending upon the initiator chosen. As a particular example, peroxydicarbnates are conveniently added in the form of an aqueous dispersion.
As the reaction progresses, a mixture of vinylidene fluoride and hexafluoropropylene monomers is fed in a definite ratio (second effective ratio) so as to maintain reaction pressure. The proportion of hexafluoropropylene in the second effective ratio used corresponds to the monomer unit ratio desired in the final composition of the copolymer, and it can range up to 66% of the combined weight of the monomers being fed continuously throughout the reaction. The feed of vinylidene fluoride, hexafluoropropylene, and optionally initiator and chain-transfer agent is continued until the desired solid content is obtained.
Upon reaching the desired solids level in the reactor, the feed of monomers is discontinued, but the feed of initiator is continued to consume residual monomers, To minimize compositional drift at this stage, after the reactor pressure drops by 10 to 20 bar from the continuous reaction pressure, a portion of VDF is added to bring reactor pressure back up to the initial set point and initiator feed continues until the reactor pressure falls about 15 to 25 bar. After a delay time of about 10 to 20 minutes then the reactor is cooled as quickly as possible. After reaching ambient temperatures (200 to 35° C.), the unreacted monomers are vented and the latex produced by the reaction is drained into a suitable receiving vessel. To obtain dry resin, the latex is coagulated by conventional methods, the coagulum is separated and the separated coagulum may be washed. To provide powder, the coagulum is dried.
For the coagulation step, several well-known methods can be used including freezing, the addition of acids or salts, or mechanical shear with optional heating. The powder, if desired, can be further processed into pellets or other convenient resin forms.
One of skill in the art will recognize that small quantities of a third monomer known to be copolymerizable with VDF(up to about 10% by weight of the HFP level) may also be included in the above described synthesis to provide VDF based terpolymers also having low crystallinity. Such known copolymerizable monomers may, for example, be selected from among C(2-8) alkenes containing at least one fluorine atom besides HFP, an alkyl vinyl ether containing at least one fluorine atom, an aliphatic or cyclic C(3-6) ketone containing fluorinated α-α, positions and non-fluorinated C(2-4) unsaturated hydrocarbons, C(3-6) alkyl vinyl ethers or C(4-6) vinyl esters.
Among the applied uses for the resin is in paint bases for coatings. It will be understood by one of skill in the art that such paint bases will conventionally include a portion of an acrylic resin and that formation of paints varnishes and related coating materials and coatings therefrom may be accomplished by standard methods well known to those of skill in the art
The following examples further illustrate the best mode contemplated by the inventors for the practice of their invention and should be considered as illustrative and not in limitation thereof.
EXAMPLES 1 THROUGH 9
Preparation of and Comparison of the Internal Crystallinity of VDF/HFP Copolymers
Copolymers of VDF and HFP were prepared by the method described above (Examples 1,7,8, Application Examples), by the method described in U.S. Pat. No. 3,051,677 (Examples 2,3,6, Comparative Examples), U.S. Pat. No. 3,178,399 (Examples 4,5, Comparative Examples). Table I shows the weight % HFP fed initially and during the steady state reaction (S.S.), the method employed to isolate the resin from the reaction latex (acid coagulation or not) and the internal crystallinity found by DSC. Also included in Table 1 is a comparison of the internal crystallinity found in a commercially obtained sample of the fluoroelastoner Viton A (Example 9).
The crystalline content is an important feature in semi-crystalline polymers. It is known that the crystalline content in copolymers of VF2/HFP is related to the HFP content of final product. The measured crystalline content (ΔH of melting by DSC) of the VF2/HPF copolymer examples are tabulated in Table 1. Inspection of Table 1 indicates that the copolymers of the present invention have zero crystallinity at high HFP content (30 to 60%) whereas the copolymers of the prior art contain at least some crystallinity.
TABLE 1
Acid
feeding rate
Coagula-
DSC
Steady
tion
Δ
Example
Polymer
initial
State
HCl.
H (melt)
#
Type
HFP wt %
HFP wt %
wt %
J/g
1
Application
66.7
35.8
—
0
example
2
Comparative
56.6
38.3
1.5
0.485
example
3
Comparative
50.0
36.3
0.8
5.043
example
4
Comparative
39.4
38.1
0.9
6.681
example
5
Comparative
49.8
45.8
0.9
0.889
example
6
Comparative
50.0
45.0
1.1
1.107
example
7
Application
66.8
45.5
1.9
0
example
8
Application
75.1
45.9
1.9
0
example
9
Viton A
40%
—
—
0.286
Commercial
(nominal
grade
content in
polymer)
EXAMPLES 10 THROUGH 21
Additional examples of VDF/HFP copolymers prepared by the method of this application (Examples 14, 18, 20, 21), by the method of U.S. 3,178,399 (Examples 11, 16) by the method of U.S. 5,093,247 (Examples 10, 12, 15, 19) and of Indonesian Patent Application W 980105 (Examples 13, 17). The HFP content, the melting points and the ΔH of melting are tabulated in Table 2.
When copolymers of this invention are synthesized with HFP level below 30%, the copolymers are semi-crystalline. The crystalline and peak melting temperatures of VF2/HFP copolymer examples with HFP content with less than 30% are presented in Table 2, Inspection of Table 2 shows that at the same HFP level, the copolymers of the present invention have lower crystallinity that the copolymers prepared according to the above prior art. The difference between crystalline content of copolymers of this innovation and those copolymers of prior art at the same HFP content, is indicative of the differences between the molecular structures of these copolymers.
initial/
steady
ΔH
Example
HFP
state
(melt)
No.
wt %
HFP
Tm° C.
J/g
10 (comp)
10.3
0.53
138.4
48.8
11 (comp)
11.3
1.06
134.0
35.4
12 (comp)
14.1
0.52
131.4
28.7
13 (comp)
13.4
2.53
123.0
29.7
14 (Appln)
14.2
3.59
118.8
25.7
15 (comp)
15.6
0.00
139.2
28.2
16 (comp)
15.4
1.06
119.8
26.4
17 (comp)
16.5
2.20
111.5
25.1
18 (Appln)
15.4
5.00
112.8
23.5
19 (comp)
17.4
2.09
107.9
24.5
20 (Appln)
20.9
3.37
91.5
18.5
21 (Appln)
25.6
6.77
83.0
9.5
Brief description of the figures: FIGS. 1, 2 and 3 respectively illustrate the differences in Heat of Fushion, Crystallinity and Melting Temperature for the present polymers versus the prior art.
The subject matter which applicants regard as their invention is particularly pointed out and distinctly claimed as follows:
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New and novel copolymers of vinylidene fluoride and hexafluoropropylene having lower or no crystallinity together with processes for their manufacture and use are disclosed.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 USC 119(e)(1) of U.S. Provisional Patent Application Ser. No. 60/302,246 filed Jun. 29, 2001.
FIELD OF THE INVENTION
This invention relates to packaging of optical components and, more particularly, to alignment of such components relative to other components.
BACKGROUND
People currently align connectors to modules but typically do it via either an active optical alignment scheme (where they emit light into or from individual devices) or use very small numbers of devices where an accurate pick & place machine can get integration alignment. For example, using one laser where there is no concern regarding rotational alignment.
The processes typically used for alignment of connectors requires the individual devices be illuminated and then the fiber(s) are scanned across the optical device with the output light from the end of the fiber monitored for the intensity of light output. This process is repeated and the fiber light output is continuously monitored as fibers are moved in several dimensions to allow accurate alignment. An example of this technique is described in, for example, IBM Micro News, Volume 6, Number 3, Third Quarter 2000.
Such techniques are costly, since requiring illuminating devices necessitates the use of significant capital equipment to power up each device, to monitor the output powers, etc. Moreover, because the techniques are active device techniques, they run the risk of damaging the devices.
SUMMARY
We have devised a passive technique for aligning a connector containing an array of optical fibers with an optical module containing an array of optical devices prior to attachment. Furthermore, these techniques can be used, but are not limited to, for the following alignments: aligning an array of optical fibers with another array of optical fibers; aligning an array of optical fibers with an optical chip; and aligning a micro-lens with an optical chip. These techniques are not limited to any particular optical devices, the devices could be lasers, cameras, detectors, modulators, micro-electronic mechanical systems (MEMS) or other devices.
The advantages and features described herein are a few of the many advantages and features available from representative embodiments and are presented only to assist in understanding the invention. It should be understood that they are not to be considered limitations on the invention as defined by the claims, or limitations on equivalents to the claims. For instance, some of these advantages are mutually contradictory, in that they cannot be simultaneously present in a single embodiment. Similarly, some advantages are applicable to one aspect of the invention, and inapplicable to others. Thus, this summary of features and advantages should not be considered dispositive in determining equivalence. Additional features and advantages of the invention will become apparent in the following description, from the drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows example features of a chip array to be aligned with the features on an optical coupler;
FIG. 2 shows example features on an optical coupler to be aligned with the features on the chip array of FIG. 1 ;
FIG. 3 shows an example photo mask standard for aligning the features of FIG. 1 with the features of FIG. 2 ;
FIG. 4 shows the photo mask of FIG. 3 relative to the images from FIGS. 1 and 2 ;
FIG. 5 illustrate the steps involved in the alignment process;
FIG. 6 is a photograph of an alignment apparatus constructed for operation in accordance with the invention; and
FIGS. 7A and 7B show, in generic form, alternative arrangements constructed for operation in accordance with the invention
DETAILED DESCRIPTION
In the optical device fields, alignment of connector pieces onto modules is crucial to proper operation.
We have devised a simple, passive deterministic method toward alignment of components for array based transmitter, receiver or transceiver packaging.
Our approach uses an element having features common to each of the devices to be aligned as a central standard. Each of the devices can then be passively aligned to the standard which, in turn, causes the pieces to be in alignment relative to each other. As a result, the pieces will be aligned relative to each other when they are brought together.
The packaging alignment techniques allows the devices to be optimally coupled with an optical coupler.
FIG. 1 shows example features, in this case lasers and detectors, that need to be aligned with the features on an optical coupler (shown in FIG. 2 ). Shown in FIG. 1 is a chip array 100 . chip array 100 has a laser array 110 and a detector array 120 . FIG. 2 illustrates an exemplary optical coupler 200 . Optical coupler 200 has feature array 210 that match with the laser array 110 , and feature array 220 that match with detector array 120 .
As shown in FIG. 3 , the approach creates a photo mask consisting of a properly aligned superposition of the two sets of features to be aligned. An example photo mask 300 for the features of FIGS. 1 and 2 is shown in FIG. 3 . Namely, set 310 having feature array 210 superimposed with the laser array 110 , and set 320 having feature array 220 superimposed with detector array 120 .
FIG. 4 shows the photo mask 300 placed between the two images from FIGS. 1 and 2 , namely chip array 100 and optical coupler 200 where it can be readily seen that both items features are contained on the photo mask in proper alignment.
This photo mask 300 thus serves as the alignment standard. By comparing the Photo Mask 300 with the actual devices and the optical coupler the offset between each device and the corresponding optical couplers can be visually determined at once with high accuracy. Therefore, without actually turning devices on, the loss figures of the optical path can be determined. In addition, alignment using the mask may be accomplished utilizing one or both sides of the photo mask 300 .
In overview, the actual alignment process proceeds as follows using high accuracy, low back-lash XYZ stages, with continuing reference to FIG. 5 .
Shown in FIG. 5 is an exemplary method of alignment. It is understood that these individual steps may be done in any order and/or may delete or add steps of the method depending on the implementation desired Shown in block 500 is the alignment process of a connector assembly or optical coupler chip 504 with a photo mask 502 utilizing a camera 501 . Shown in block 510 is the alignment process of an optical device chip with a photo mask 502 utilizing camera 501 . These alignments may be done individually or at the same time depending on the implementation. The camera 501 may be replaced with a laser, microlens, or any other device that can be used in the assistance of aligning the optical device chip 511 with the fixed mask 502 .
In one example, the device chip 511 is held on one end of a stage and a coupler or connector assembly 504 to which the devices are to be aligned is held in the other end of the stage. The mask 502 is placed in between in a position that will remain fixed throughout the alignment process or, in certain variants, can be removed and replaced with high accuracy.
The device chip 511 is then viewed through the mask using a zooming viewing scope or camera or any other device that can be used in alignment procedures. The device chip 511 is then moved out of the way using the XYZ stage, so that it can be accurately replaced later. After that the optical coupler chip 504 having a fiber array 503 is aligned in a similar manner with the fixed mask 502 using a zooming viewing scope from the other side. Again, the mask can be utilized on one or both sides. Depending on the implementation, the order of alignment may be reversed as shown in FIG. 5 . Shown in FIG. 5 is the optical coupler or connector assembly 504 being aligned with mask 502 prior to alignment of device chip 511 . Again either one side or both sides of the mask can be used in this alignment process as well as alignment at the same time or individually, as shown in block 500 and block 510 . Shown in block 500 is mask feature 505 and optical coupler feature 506 that are brought into an alignment position 507 . Shown in block 510 is mask feature 505 and optical device chip feature 508 that are brought into an alignment position 509 . Block 520 illustrates alignment of the optical device chip 511 with optical coupler chip 504 . Again, any optical component may utilize this technique of alignment. For example, the optical components given in this description as examples, specifically aligning a connector containing an array of optical fibers with an optical module containing an array of optical devices prior to attachment, may readily be replaced with aligning an array of optical fibers with another array of optical fibers; aligning an array of optical fibers with an optical chip; and aligning a micro-lens with an optical chip.
The photo mask 502 is then removed as shown in block 530 and, optionally, depending upon the separation distance between the two, the device chip 511 is moved away from the optical coupler 504 .
The device is then axially adjusted relative to the optical coupler position to optimize the coupling efficiency. This adjustment and coupling is shown in block 540 .
Advantageously, it should thus be recognized that the whole process is simple and deterministic.
Moreover, by using a simple deterministic approach, transceiver packaging cost and complexity is reduced.
In particular, the approach proceeds as follows.
A filter mask, which contains features, which resemble both the optical fiber array and the optical device array, is created or, if previously created, attached to the center of the XYZ stage. In the example in FIGS. 1-3 above, the optical device array contains both lasers and detectors (though it could contain a myriad of other devices), which have different sizes and orientations. The fiber array has yet a third size and shape in this example. Thus, the filter mask has all three of those features on it to act as an absolute positioning standard to which all of the pieced can be aligned.
The mask has a series of elements, which correspond to the elements on both the optical fiber array (also known as the optical coupler) and to the optical chip array (i.e. the laser and detector arrays).
Once the mask standard is positioned, alignment can begin.
The optical chip array and optical fiber array/connector assembly are mounted on a high precision, reproducible, low-backlash stage. The optical chip array is then moved away to accommodate a camera or, if there is enough space, the camera is merely interposed between the optical chip array and the standard.
The optical fiber array is then brought close to the mask and the camera is used to look through the mask at the optical fiber array.
The fiber array/connector assembly is moved around in a plane parallel to the mask, as well as for roll, pitch and yaw, until the fiber elements align to the corresponding elements on the filter mask as observed using the camera. Once alignment is achieved, the position of the fiber array/connector assembly is noted.
The fiber array/connector assembly is then moved aside on a high precision, reproducible, low-backlash stage (so that later it can be repositioned to its previously noted position above). The optical chip assembly is then positioned near the filter mask. As was done for the optical fiber array, a camera is then brought in and used to look through the mask at the optical device chip. The optical device chip assembly is then moved around in a plane parallel to the mask, as well as for roll, pitch and yaw, until the optical elements on the chip align to the corresponding elements on the mask standard as observed using the camera.
Once alignment is achieved, the position of the optical chip assembly is optionally noted.
It should be appreciated that, although the alignment was described in a particular order, the chip array could have been aligned first. Alternatively, the first component could be aligned to the standard before the second component is even mounted.
In any case, once the two have each been aligned relative to the mask standard, the camera is moved aside and the fiber array/connector assembly is repositioned to its aligned location. At this point, the optical device assembly and the fiber array/connector assembly are aligned accurately in ‘X’, ‘Y’, and Rotational dimensions as well as in tilt.
Next, the filter element is moved aside from the central region between the fiber array/connector assembly and the optical chip assembly.
The two aligned pieces are then brought together in the ‘Z’ dimension until they are in contact and secured together.
FIG. 6 is a photograph of an assembly station 600 used for the alignment process described herein. Through use of this station to align various pieces including fiber bundles, optical chips and connector assemblies, we have achieved an accuracy of, as low as, 20 nanometers of tolerance.
In other alternative variants, the same approach can be used with a single camera so long as the camera can be accurately and reproducibly be moved from one position to another.
In still other alternative variants, another device, such as a laser, a photodetector (detector) a non-coherent light source, etc. can be used in place of the camera as the device used to check alignment between a given component and the standard, such as the photo mask.
FIG. 7A shows, in generic form, such an arrangement. One of the components 700 to be aligned is mounted on a moveable high precision stage 702 . Another of the components 704 to be aligned is also mounted on a moveable high precision stage 706 . The standard 708 is located between the two components 700 , 704 . As shown in FIG. 7A , the arrangement is constructed so that at least one of the components to be aligned is moved out of the way so that the device 710 that is used to check alignment of the other component can be moved in its place. Alternatively, for example as shown in FIG. 7B , if spacing permits, the device 710 can be interposed between the standard 708 and a component to be aligned. The alignment then proceeds as described herein, first for that component and then for the other component.
It is to be understood that these techniques are not limited to alignment of any particular optical devices or combinations thereof, the devices could be lasers, cameras, detectors, modulators, micro-electronic mechanical systems (MEMS) or other devices.
In summary, by using a passive deterministic approach to alignment advantages not present in the prior art can be achieved. For example, by not illuminating the individual devices, we can perform alignment 1) more quickly, and 2) with lower cost of capital equipment for each assembly station.
By making a purely passive system, the cost of capital equipment is minimal (essentially the cost of the translation stages and camera(s), lasers or other optical devices used in the alignment process. In addition, setup and insertion of the module components to prepare for alignment can also occur much more rapidly when module components are passively aligned than when they are actively aligned, thereby reducing labor costs.
It should therefore be understood that the above description is only representative of illustrative embodiments. For the convenience of the reader, the above description has focused on a representative sample of all possible embodiments, a sample that teaches the principles of the invention. The description has not attempted to exhaustively enumerate all possible variations. That alternate embodiments may not have been presented for a specific portion of the invention, or that further undescribed alternate embodiments may be available for a portion, is not to be considered a disclaimer of those alternate embodiments. One of ordinary skill will appreciate that many of those undescribed embodiments incorporate the same principles of the invention and others are equivalent.
|
A method involves aligning each of two optical components to be joined relative to a common standard, removing the common standard, and joining each of two optical components to each other in alignment.
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FIELD OF THE INVENTION
The present invention relates to the field of Networked systems management, and more specifically, to a system and method for providing autonomic management of a networked system.
BACKGROUND
Complexity and brittleness are present problems in the run-time behavior management within a storage system. Complexity arises from the level of details required to specify policies. These details are non-trivial and require a thorough understanding and expertise of the system internal. More precisely, it is difficult for administrators and system builders to choose which combination of system parameters to observe from a large set of possible observables; determine appropriate threshold values after considering the interaction of a large set of system variables; and select a specific corrective action from the large set of competing options. As the number of users, storage devices, storage management actions and service level agreements increase, it becomes computationally exhaustive for a system administrator and storage management tool developers to consider all the alternatives.
With regards to brittleness, it is difficult for vendors to provide pre-packaged transformation code within their products because this code becomes brittle with respect to changing system configurations, user workloads and department/business constraints. Thus, it is difficult for the storage management vendors to envision all of the potential use case scenarios ahead of time, and thus, many of the current storage management solutions provide workflow environments which, in turn, pass the responsibility of transforming high level QoS goals (via workflow scripts) to an organization's system administrators and infra-structure planners.
What is needed, is a solution which provides for autonomic management in storage systems, in which the resulting problems associated with complexity and brittleness are overcome.
SUMMARY OF THE INVENTION
According to the present invention, there is provided a network management system to provide autonomic management of a networked system using an action-centric approach. The network management system includes a policy specification logic block to maintain a policy specification associated with the managed system. In addition, the network management system includes a reasoning logic block to provide for the determining of action rules using a combination of logic and information obtained from the policy specification. Also, the network management system includes a learning logic block to couple the policy specification logic block with the reasoning logic block to improve an understanding of a managed system. The learning is continuous and provides for autonomic evolvement of the system in which reliance on manual input from a user is lessened.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a system model in which autonomic management of a storage system using an action-centric approach is provided, according to an exemplary embodiment of the invention.
FIG. 2 is a block diagram of the logical blocks included within a system manager, wherein the system manager is utilized to dynamically manage a computer system's behavior, according to an exemplary embodiment of the invention.
FIG. 3 is a method of performing reasoning within a system manager, according to an exemplary embodiment of the invention.
FIG. 4 illustrates an N-dimensional behavior space.
FIG. 5 shows vector addition based on Blackwell's theorem, where a recursive algorithm based on Blackwell's theorem is utilized to combine vectors.
FIG. 6 is a block diagram of a system manager and its interaction with its functionality, according to an exemplary embodiment of the invention.
FIG. 7 illustrates a method, of executing an action-centric approach for specification, reasoning and self-learning in a managed system, according to an exemplary embodiment of the invention.
DETAILED DESCRIPTION
The invention will be described primarily as a system and method to provide autonomic management in a storage system, using an action-centric approach. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details.
Those skilled in the art will recognize that an apparatus, such as a data processing system, including a CPU, memory, I/O, program storage, a connecting bus and other appropriate components could be programmed or otherwise designed to facilitate the practice of the invention. Such a system would include appropriate program means for executing the operations of the invention.
An article of manufacture, such as a pre-recorded disk or other similar computer program product for use with a data processing system, could include a storage medium and program means recorded thereon for directing the data processing system to facilitate the practice of the method of the invention. Such apparatus and articles of manufacture also fall within the spirit and scope of the invention.
FIG. 1 illustrates a system model 10 to provide autonomic management of a storage system 12 using an action-centric approach, according to an exemplary embodiment of the invention.
System model 10 includes system manager 14 . System manager 14 provides for tuning the managed system 12 according to the goals specified by an administrator.
Managed system 12 includes a set of Resources <R> 16 , which are used to service requests from applications. Examples of resources 16 include the processor, network, memory and storage. Also, the managed system 12 includes, a set of Observables <O> 18 . The set of observables 18 represent the properties (e.g., throughput, latency, reliability, availability, security) of the managed system 12 as visible to the application. The Goals of the managed system 12 are expressed as thresholds on the values of <R> 16 or <O> 18 .
A stream of incoming requests to managed system 12 can be characterized along several dimensions. For example, in a storage system, typical dimensions are the read/write ratio, the access pattern (sequential/random), the block size of requests, etc. In the exemplary embodiment, the capturing of information along various dimensions (e.g., block size of requests, etc.) is utilized to determine the Workload characteristics <W> of the incoming stream.
To achieve goals associated with managed system 12 , system manager 14 either invokes services or tunes configuration parameters within managed system 12 as a result of status information (e.g., workload characteristics, resource information from resources 16 , observables information from observables 18 , etc.) received from monitors 22 . The service invocations and parameter changes define the set of adaptive actions <A> 20 that managed system 12 can perform.
In an exemplary embodiment, actions <A> 20 are first-class entities. They have an impact on behavior dimensions, including resources 16 and observables 18 . The quantitative effect of an action depends on current workload characteristics, resource utilization levels and observable values in managed system 12 . Actions 20 have well-defined and standardized functions (based on SMI-S
FIG. 2 is a block diagram 24 of the logical blocks included within a system manager 14 , according to an exemplary embodiment of the invention. Block diagram 24 includes policy specification logic 26 , reasoning logic 28 and learning logic 30 .
Policy Specification
The policy specification logic 26 maintains a policy specification associated with managed system 12 is maintained. The policy specification can be made up multiple policies. A policy specification maintained by policy specification logic 26 , according to an exemplary embodiment of the invention, treats actions as software-objects, and an administrator simply defines properties of actions (rather than the complex “how to” details of existing approaches).
The policy specification logic 26 provides an action-centric (in contrast to event-centric) approach, where actions 20 are represented as software objects. The policy specification defines attributes of these objects. The policy specification does not define how managed system 12 should react when goals are not met. Properties of actions 20 are defined, and by reasoning, system manger 14 derives the precise behavior on-the-fly.
In an exemplary embodiment, attributes of actions 20 fall under two categories, including meta attributes and base attributes.
Meta Attributes
Meta attributes allow system manager 14 to reason with regards to tradeoffs involved in choosing an action, and to decide which action to invoke among several available options in actions 20 . Meta attributes provide information along two dimensions:
Effects of invoking the action; they are specified as a set of behavior implications. A behavior implication consists of a behavior impact vector that describes how the action impacts managed system 12 resources <R> 16 and/or observables <O> 18 . Preconditions upon which the “effectiveness” of the action depends.
These are predicates in terms of workload conditions <W> or limits on resources <R> 16 .
Base Attributes
This group of attributes specifies how exactly to invoke an action that has been chosen through the use of meta-attributes. This involves selecting the values of parameters to invoke the action with while conforming to restrictions on those values.
In addition, to the meta attributes category and the base specification category, the policy specification also includes certain exceptions.
TABLE 1
Template for Policy Specification of an Object
Action-object <A>
{
[Observable Implications]
// Observable dimensions the action
affects
[Resource Implications]
// Resources that the action affects
[Pre-conditions]
// Dependencies of the action on low-
level state
[Workload Dependency]
[Resource Dependency]
[Base Specification]
// Functions for invoking the
action
[Exception handling]
// Error-events
}
According to an exemplary embodiment of the invention, table 1 provides a template for the specification of an object in the policy specification.
TABLE 2
Policy specification grammar
specification := <entry> <specification> | <entry>
entry := <name> <behavior_implications> <preconditions> <usage>
name := <string-value>
resource := cpu | memory | network | storage
behavior_implications := <behavior_implication>
<behavior_implications> | <behavior_implication>
behavior_implication := <dimension> <impact>
impact := up | none
dimension := latency | throughput | reliability | availability
preconditions := <precondition> <preconditions> | null
precondition := <workload-characteristic> | <resource-precondition>
workload-characteristic := rw-ratio <rw-ratio-value> | access-pattern
<access-pattern-value> | request-block-size <integer-value-inclusive> |
request-rate <integer-value-inclusive>
rw-ratio-value := mostly-reads | mostly-writes | reads-writes | *
access-pattern-value := sequential | random | *
resource-precondition := <resource> <value>
value := <interval-value> | <list-value>
interval-value := <float-value> to <float-value> | <integer-value>
to <integer-value>
list-value := <list-value>*<list-item>
list-item := <float-value> | <integer-value>
integer-value-inclusive := <integer-value> | *
TABLE 3
Prefetch knob definition
<action name = prefetch>
<behavior_implications>
<implication dimension = memory impact = down>
<implication dimension = storage impact = none>
</behavior_implications>
<preconditions>
<precond dimension = access-pattern value = sequential>
<precond dimension = memory value = 20-60>
</preconditions>
</action>
Table 3 provides an exemplary definition of a prefetch know using the grammar of Table 2, according to an exemplary embodiment of the invention.
Reasoning
Reasoning logic 28 provides for the determining of action rules “on-the-fly” using a combination of logic and base attributes. System manager 14 is alert-driven, and invokes the reasoning procedure only when managed system 12 indicates that one or more goals are violated. Managed system 12 indicates violation of one or more goals through generating an alert. System manager 14 uses the knowledge base built based on the policy specification for reasoning and decides to invoke one or more actions 20 to bring managed system 12 back to a state in which all goals are met.
FIG. 3 is a method 32 of performing reasoning within the reasoning logic 28 of system manager 14 , according to an exemplary embodiment of the invention. At block 34 , method 32 begins.
At block 36 , behavior goals associated with managed system 12 are identified. The behavior goals are specified by the Administrator responsible for running the system. These goals are similar to service level agreements (SLA) and define constraints on the observed behavior of managed system 12 . Examples of behavior goals include: latency less than 5 msec, throughput greater than 100 MBPs, system down-time less than 5 minutes a year, etc.
At block 38 , the workload characteristics of managed system 12 are determined.
At block 40 , the resources utilized by managed system 12 are determined.
At block 42 , a determination is made as to whether the behavior goals identified at block 36 are being met. If no, then method 32 returns to block 36 .
Returning to block 42 . If yes, then at block 44 , a trigger initiating the reasoning logic 28 within system manager 14 is initiated.
At block 46 , identify a reference configuration associated with managed system 12 . The reference configuration is a previous configuration for managed system 12 in which the identified behavior goals (see step 36 ) were being met.
At block 48 , compare the identified reference configuration with the current configuration of managed system 12 to identify the system characteristics (e.g., workload, resources, environment, goals, etc.) or combination of system characteristics caused the identified behavior goals (see step 36 ) not to be met. This comparison helps to provide understanding for change(s) at the behavior-level and state-level.
Examples of some system characteristics include, but are not limited to the following:
a. Resources utilization (percentage) [c 1 ]: This accounts for failures, resource-addition and application activity-bounds. b. Application request-characteristics [c 2 ] c. Assigned goals [c 3 ] d. Environment [c 4 ]: This accounts for dependencies with other components within the system. This aspect is a part of future work as the current-work concentrates on stand-alone systems.
In most cases, the combined-effect of [c 2 ] & [c 4 ] will reflect in [c].
TABLE 4
System characteristic file-system parameters
Resources utilization (percentage) [c 1 ]
Storage sub-system
Network
Memory
CPU
Application request-characteristics [c 2 ]
Access-characteristics
Request block size
Request rate
Skew/Locality
Async operations
Pathname translation operations
Read/write ratio
Assigned goals [c 3 ]
Throughput
Latency
Availability
Security
At block 50 , the policy specification maintained by policy specification logic 26 is searched to locate adaptation-objects whose attributes match the system characteristics or combination of system characteristics identified at block 48 . The search results in a shortlist of all the adaptation-objects that affect parameters in c 1 , c 2 & c 4 .
The policy specification search is based on a simple table-based approach: For each of the parameters in c 1 , c 2 & c 4 , the adaptation-objects are arranged in the form of a table. i.e. the objects that affect the desired set of resources, application-characteristics and environment. A join operation is used to select objects that affect parameters in two or more categories.
At block 52 the shortlist is filtered based on the adaptation-objects pre-conditions. Pre-conditions are the requirements on system-state and workload characteristics which ensure that the action will be effective (if invoked). For example, in the case of prefetch action, the preconditions are the workload being sequential and memory being available.
At block 54 , a list including adaptation-objects that partially or completely affect the goals that are not being met, is generated.
Performing Higher-Order Operations on Actions
FIG. 4 illustrates an N-dimensional behavior space 56 . The dimensions of goals (c 3 ) is used to decide the combination of Adaptation-objects that needs to be invoked and their corresponding degree change.
Returning to FIG. 3 .
At block 58 , a decision as to the combination of adaptation-object that need to be invoked and their corresponding degree change, is made. The shortlist adaptation objects and an estimate of the behavior dimensions affected, are provided to the dimension of goals (c 3 ) (See FIG. 4 above). The behavior dimensions are derived by a combination of the policy specification content and self-learning.
The operations within block 58 , can be explained in terms of vector-space operations. The vector space represents an n-dimensional behavior space as shown in FIG. 4 . Each adaptation-object is represented as a unit vector, within an n-dimensional behavior space. The direction of the vector is an estimate of the behavior dimensions that it affects. The length signifies degree change for the base-invocation of the adaptation-object.
A determination is made as to the combination of the unit vectors (see FIG. 4 ) and their associated length.
FIG. 5 is a diagram 59 showing vector addition based on Blackwell's theorem, where a recursive algorithm based on Blackwell's theorem is utilized to combine vectors.
A target vector 60 starting from the current-state 62 to the desired-state 64 , is generated.
The unit vector whose cosine angle with the target vector 60 is greatest, is selected. The step size of the vector is k, where ‘k’ signifies the degree of instability of the system. (k<the length of target vector). Repeat the generation of the target vector 60 and the selection of the unit vector whose cosine angle with the target vector is greatest. In the exemplary embodiment, the steps of repeating the generation of the target vector are repeated until the unit vector (with step size k) equals the target vector. During each iteration the algorithm is selecting the best possible action for the given state (e.g., local optimization based on the current state).
Using the Base Specification to Decide on How to Invoke the Action
At block 66 , once a decision has been made as to which one or more actions to invoke, a determination is made as to the quantitative changes required along each of the behavior dimensions (resources and observables). An incremental approach is utilized to decide what parameter values to set for the action. For example, the action with a unit change of parameter value in one direction is invoked. If the implications of this step are as expected, then the action is repeatedly invoked, with increasing values of the parameter until the system reaches a satisfying state. If not, then direction of change to the action parameter value is reversed and the actions within block 66 are repeated.
Thus, the reasoning module is invoked when the system indicates that one or more goals of managed system 12 have been violated.
At block 68 , method 32 ends.
Learning
Returning to FIG. 2 . Learning logic 30 provides a methodology for coupling learning with policy specifications (policy specification logic 26 ) and reasoning (reasoning logic 28 ). Learning logic 30 is utilized to refine the knowledge base with measured values and thresholds. Existing approaches, such as those for machine-learning (e.g., neural networks, decision trees, K-NN, etc.) are leveraged. The existing approaches have been used for classification and are used here to learn from responses to earlier decisions.
Learning is systematically done at multiple levels, including a meta specification level (see meta attributes above), a base specification level (see base attributes above), a level covering relations between actions and a level in which learning from the administrator is achieved.
Meta Specification Level
An administrator may provide incomplete or imprecise information regarding the implications of an action. For instance, they may fail to specify values of one or more precondition dimensions for which the action does not have the mentioned impact. The system learns during regular operation about these additional preconditions, and modifies the policy specification accordingly.
As another instance of learning, the framework allows the administrator to specify hints that would guide the system in reasoning. For instance, in the scenario where more than one action may be invoked in order to correct the system's state, the administrator could specify (based on their prior experience) which action to invoke under specific workload conditions. This can be implemented by using a decision tree to specify workload conditions, where the leaves of the tree contain the administrator's choice of action to invoke.
Base Specification Level
The system can learn from incremental invocation. In order to decide the values of parameters to invoke an action with, in addition to the incremental approach, the action agent can use a neural network-based approach to learn from previous invocations what the approximate value of the parameters should be. It can then follow the incremental approach from that point.
Relations Between Actions and Learning from the Administrator
In addition to learning the attributes of the actions, patterns can also be derived by recording the relationships between action invocation and trying to derive patterns (e.g., Action A and B are always invoked together, Action C and D nullify each other, etc.).
Learning can also be achieved through monitoring an administrator. When the administrator invokes an action in response to a goal not being met, the system creates a record and records details such as the resource levels, workload characteristics, the value of the goals and the intended action. This record is used to create a “case” and uses existing approaches for Case-based Reasoning (CBR).
FIG. 6 is a block diagram 70 of a system manager 14 and its interaction with its functionality (e.g., monitors, actuators, etc.), according to an exemplary embodiment of the invention. The decision making module 72 is implemented through interaction between several component agents. These component agents are described briefly below.
The system agent 74 coordinates communication between all other agents and monitors in the system in order to get the input about action attributes from the administrator and to provide autonomic functionality based on the policy specification. The administrator of the system interacts directly with the system agent 74 as do the monitors and actuators. The system agent 74 uses a poll-model for getting system state. It periodically polls the monitors and updates its state variables. It then checks to see if any goals are violated. If so, then it invokes the decision-making process to rectify the situation.
The input agent 76 is responsible for converting the policy specification provided by the user into some representation in persistent storage. The input agent 76 currently parses the XML specification provided and populates database tables. Storing the action attributes in this form allows for easy retrieval of information when needed as well as for easy update by the manager while learning.
The decision Agent 72 decides which among several possible actions the manager should invoke. To accomplish this, the decision agent 72 uses the meta specification to reason between actions and chooses one or more actions to be invoked in order to return the system to a state where all the goals are met. If no such action exists, then it returns an empty set.
The action agent 78 takes the set of one or more actions generated by the decision agent, and utilizes the base specification to determine the values of the parameters with which to invoke the actions with.
FIG. 7 illustrates a method 86 , of executing an action-centric approach for specification, reasoning and self-learning in managed system 12 , according to an exemplary embodiment of the invention.
At block 88 , method 86 begins.
At block 90 , an administrator of the system sends an XML file containing the specification of action attributes to the system agent 74 .
At block 92 , the system agent 74 in turn passes the request to the input agent 76 , which parses the file and creates persistent logical structures. This is done once when managed system 12 is started, and needs to be invoked again only when the action attributes need to be changed, which happens infrequently.
At block 94 the system agent 74 checks the state of the system built from information gathered by monitors. In the exemplary embodiment, this checking is done on a periodic basis by the system agent 74 . The periodic basis is a unit of time configurable by an administrator and/or software.
At block 96 , the system agent 74 compares the current values of resources and observables with the desired ranges specified in the goals.
At block 98 , a determination is made as to whether any of managed system 12 goals are not met. If no, then method 86 ends.
Returning to block 98 . If yes, then at block 100 , a change analysis to generate an appropriate request is initiated. When one or more goals are not met, the system performs a change analysis, where it summarizes the minimum number changes needed in the values of resources and/or observables in order to bring the system to a state where all goals are met.
At block 102 , the summary of the change analysis of block 100 is recorded and sent as a resolution request to decision agent 72 .
At block 104 , decision agent 72 reasons between actions and chooses an action or a set of actions that need to be invoked.
At block 106 , the action agent 78 then takes this set of actions and the current and target states of the system, and chooses the values of the parameters to be associated with the identified action(s), based on the usage semantics given in the base specification.
At block 108 , the system agent 74 invokes the actions, based on the parameter values chosen by the action agent 78 at block 106 .
At block 110 , method 86 ends.
Thus, a system and method to provide autonomic management in a storage system, using an action-centric approach has been described. Although the present invention has been described with reference to specific exemplary embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the invention. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.
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According to the present invention, there is provided a SAN management system to provide autonomic management of a storage system using an action-centric approach. The SAN management system includes a policy specification logic block to maintain a policy specification associated with the managed system. In addition, the SAN management system includes a reasoning logic block to provide for the determining of action rules using a combination of logic and information obtained from the policy specification. Also, the SAN management system includes a learning logic block to couple the policy specification logic block with the reasoning logic block to improve an understanding of a managed system. The learning is continuous and provides for autonomic evolvement of the system in which reliance on manual input from a user is lessened.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of the following provisional application: U.S. Ser. No. 60/349,526, filed Jan. 18, 2002, under 35 USC 119(e)(i).
FIELD OF INVENTION
The present invention relates to the field of poultry processing equipment, particularly rotational hub and belt assemblies for de-feathering or plucking devices.
BACKGROUND OF THE ART
Poultry processing industries commonly use automated lines to kill, eviscerate, pluck and further process birds. Rotational devices are generally employed to facilitate continuity of process and to minimize labor. One of the most common poultry processing machines is a plucker or de-featherer. For many years devices incorporating a number of pliable fingers have been utilized to beat and pull the feathers from bird carcasses.
In processing facilities, multiple finger-type plucking devices are used in sequence to fully pluck a carcass. Typical plucking processes incorporate opposing pairs of finger-typed pluckers which are sufficiently spaced apart to maneuver a bird carcass therebetween. Initial plucking is completed with a pair of spaced-apart finger-type pluckers having a plurality of rigid, spaced-apart fingers. Subsequent plucking of fine feathers is accomplished by passing the bird between opposed pairs of pluckers having multiple pliable fingers. Automated plucking devices are generally used to suspend and move the bird carcass along a line of opposed pairs of pluckers which depiliate the carcass of all feathers from course to fine as the carcass travels along the processing line.
Typically, the pluckers of a processing line are powered by a motor which provides rotational force to each plucker via a chain or belt drive assembly. Early assemblies utilized a single motor connected to each plucker hub. This method facilitated accurate control of individual hub speed which is necessary to mesh opposing pairs of hubs and to synchronize sequential hubs. Due to the high cost of purchasing and maintaining individual motors, eventually hubs were spaced-apart in sequence so that a single motor could be used to drive multiple pluckers. Single drive hub assemblies eliminated multiple motors but had several inherent problems.
Either a V-belt or flat belt is used to transfer the rotational force from the motor to each sequentially aligned hub. Hub drives incorporate a smooth pulley commonly used for drive belt applications. The drive belts frequently have to be adjusted to maintain the desired, and necessary pressure and friction between the belt and pulleys to drive the multiple pickers. Problems exist in that the smooth belts stretch and constant maintenance and attention is required to control the drive force. Friction from belt slippage also accelerates wear and tear on hub assemblies, belts and motors.
Efforts to remediate the stated deficiencies resulted in a drive assembly which utilized drive chains and hub sprockets rather than belts and pulleys. This improvement resulted in constant and consistent force transferal from the drive source to the hub assemblies. However, it is common that the poultry being processed, or the shackles from which bird carcasses are suspended, become entangled or otherwise disrupt the plucker assembly. When, for instance, a shackle becomes entangled in single plucker, continual force of the drive source will cause the chain to shear the sprocket of that plucker. Further, problems in the plucking process can result in the jumping, or unwanted movement of the chain in relation to the sequence of hub gear assemblies. Often, hub gears are made of hardened plastic in an effort to minimize the cost incurred by shearing of sprocket teeth. These inexpensive systems are prone to failure and require significant maintenance due, in large part, to the intrusion of dirt, feathers and fecal matter into the moving parts.
Prior to Applicant's invention, the state of the art in the industry was either the “V” or flat belt technology, or the chain and gear assembly described above. Both of these assemblies require constant maintenance and adjustment. Because of belt slippage and the friction imparted on a hub assembly by the belt, hubs wear very quickly and must be rebuilt or replaced on a regular basis. Gear and chain drives require constant maintenance and because of shackle entanglement in pluckers result in the shearing of teeth from the sprocket. Further, Applicant's invention incorporates seals adjacent each bearing which significantly limits the intrusion of foreign matter into the workings of the hub assembly. The presence of the seals, along with the configuration of pulleys and belts, limits required maintenance and component replacement.
SUMMARY OF THE INVENTION
The present invention provides a poultry processing machine, particularly a hub and belt assembly such as a feather plucking device that facilitates timed rotation of driven members while diminishing wear and breakage commonly associated with such equipment. More particularly the device is a poultry processing apparatus which comprises a hub having a flange portion, a boss portion, a pulley end and a central bore extending therethrough. A hub plate, attachable to the hub, has a flange portion and a hub plate shaft bore alignable with the central bore of the hub. A drive shaft is mounted transversely through the central bore and hub plate shaft bore; the drive shaft further is provided with a pulley end and a spaced-apart drive end. A first bearing is positioned on the drive shaft at the hub plate and a second bearing is positioned on the drive shaft at the junction of the flange portion and boss portion. A seal is preferably positioned adjacent each bearing and at the hub plate to effectively prevent foreign matter from wearing the drive shaft and bearings.
A drive belt is operatively connected to a pulley fastened to the drive shaft at the pulley end and to a spaced-apart drive source. A poultry defeathering device, such as pliable rubber fingers, is attached to the drive shaft at the drive end and rotation of the drive belt about the pulley spins the drive shaft in the first bearing, second bearing and third bearing within the hub housing thereby operatively rotating the poultry de-feathering device.
Designed primarily for ganged sets of plucking arms, the hub and belt system utilizes a heat dissipating hub housing journalled to a drive shaft, preferably with at least two independent sealed bearings, and a timing belt which allows operators to alternate time opposed pairs of plucker arms to avoid entanglement of the process poultry, hangers and the plucking heads.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective side view of one embodiment of the inventive device.
FIG. 2 is a perspective view of one inventive hub assembly.
FIG. 3 is a sectional view of the inventive hub assembly taken along line 3 of FIG. 2 .
FIG. 4 is a perspective view of another embodiment of the inventive hub assembly.
FIG. 5 is a perspective view of another embodiment of the inventive hub assembly.
FIG. 6 is a perspective view of yet another embodiment of the inventive hub assembly.
FIG. 7 is a perspective view of another embodiment of the inventive hub assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention provides an assembly for efficiently rotating a gang of poultry processing equipment. A preferred embodiment of a hub 101 and belt 147 assembly for rotating processing equipment is generally shown in FIG. 1 .
Referring now to FIGS. 1 , 2 and 3 , the hub 101 of the present invention includes a hub housing 103 having a flange portion 105 , a boss portion 107 projecting laterally from one side of the flange portion 105 terminating at a pulley end 111 , and a central bore 109 extending through the flange 105 and boss 107 along the general axis of the hub. Generally, the flange portion 105 is provided with a plurality of circumferentially oriented mounting holes 113 for attaching the hub 101 to a machine cabinet 125 with screws or threaded bolts 115 . A separate hub plate 117 is mountable to the hub housing 103 at the flange portion 105 opposite the boss portion 107 . The hub plate 117 has a shaft bore 119 aligned with the central bore 109 and is further provided with a plurality of circumferentially oriented hub plate mounting holes 121 alignable with the mounting holes 113 of the flange portion 105 . It is preferred that the hub housing 103 and huh plate 117 are manufactured of material which rapidly and efficiently dissipates heat such as aluminum.
Multiple outer bearing races 129 are formed within the central bore 109 , preferably at the pulley end 111 of the boss portion 107 , at the hub plate 117 attachment position and adjacent the junction of the flange portion 105 and boss portion 107 . A drive shaft 131 is positioned through the central bore 109 of the hub 101 and the hub plate shaft bore 119 . Multiple inner bearing races 132 are provided on the drive shaft 131 coincident with the outer bearing races 129 of the central bore 109 and the hub plate shaft bore 119 . Sealed bearings 135 and 137 are fitted at each inner race 132 and outer race 129 thereby fastening the drive shaft 131 axially through the central bore 109 and hub plate shaft bore 119 while allowing the drive shaft 131 to freely rotate within the hub 101 . It is preferred that a first bearing 135 is positioned at the pulley end 111 of the hub housing 103 , a second bearing 137 positioned substantially near the junction of the flange portion 105 and boss portion 107 . Additional bearing positions may be used depending on the size and application of the hub assembly.
Hub seals 139 are positioned on the drive shaft 131 adjacent each bearing 135 and 137 . It is preferred that a seal 139 is also positioned adjacent the hub plate 117 to prevent dirt and debris from invading the juncture of the drive shaft 131 and the hub plate 117 . The combination of three seals 139 provides a near hermetic seal which eliminates invasion of feathers, feather parts, dirt, fecal matter and the like into the hub assembly.
The separate hub plate 117 has an insert flange 123 which has an outer circumference equal to the circumference of a machine cabinet opening 127 where the hub 101 it to be attached. This insert flange 123 provides a loose seal between the hub 101 and the machine cabinet 125 and further diminishes vibration and wear common in rotating processing equipment. The placement of a seal 139 on the drive shaft 131 at the insert flange 123 will significantly limit internal wear caused by the dust, feathers and debris inherent with the depilating process.
A pulley 141 is fastened, via a pulley attachment device 143 at a pulley end 133 of the drive shaft 131 adjacent the pulley end 111 of the hub housing 103 . The pulley 141 is provided with a plurality of spaced-apart timing serrations 145 . A timing belt 147 , which is provided with a plurality of spaced apart serrations 149 which mate to the pulley serrations 145 , connects the drive shaft 131 to a drive mechanism 151 . The use of the timing belt 147 and serrated pulley 141 eliminates belt slippage common with poultry processing equipment powered with a flat or V-shaped belt. A second type of timing belt 147 , as shown in FIG. 4 , may be used in place of the serrated belt.
As best shown in FIGS. 5 and 7 , the pulley 141 can be exchanged with a common pulley for use of a flat or V-shaped belt if desired, or in necessary situations such as when a timing belt is not available. If preferred, a user can exchange the pulley 141 with a gear 163 which can be driven with a chain 165 as shown in FIG. 6 . Therefore, while the preferred embodiment is described above, the instant invention provides a triple drive option because a user can drive the rotational device using a timing belt 147 , flat 162 or V belt 167 , or chain 165 by alternating the drive shaft 131 attachment with a serrated pulley 141 , common “V”, pulley 169 or flat pulley 161 .
A finger plate bore 156 is formed in a drive end 134 of the drive shaft 131 opposite the pulley end 133 . For a defeathering device, a finger plate 155 is bolted into the finger plate bore 156 . The finger plate 155 can be provided with a plurality of plucking fingers, e.g., plucking finger 171 , as is common in the industry.
As best shown in FIG. 1 , the hub end belt assembly is suited to power a series of driven rotational defeatherers. The drive mechanism 151 and a belt return hub 159 are positioned at opposite ends of a series of substantially aligied hubs 101 . A timing belt 147 encircles the drive mechanism 151 and return hub 159 and alternates above and below each sequential hub pulley 141 . It is preferred that at least one spring-loaded tension arm and idler pulley 153 is provided at at least one hub 101 to independently release belt tension should the finger plate 155 , or any part of the plucker assembly, become jammed.
The series of hub and belt assemblies preferably utilizes a timing belt having two sides, each side provided with spaced-apart protruding serrations, and wherein the belt is alternated above and below each of the aligned pulleys.
Additional variations and embodiments other than those specifically enumerated may be made to the hub and belt assembly without departing from the spirit and scope of the disclosed invention. Therefore, it is intended that the invention not be limited to this disclosed embodiment, but only by the scope of the appended claims.
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This invention relates to a hub and belt assembly for driving a poultry de-feathering machine and more particularly to a multiple bearing heat dissipating hub driven by a serrated timing belt. The hub assembly incorporates seals along a drive shaft to reduce wear caused by dirt. The timing belt synchronizes multiple picking hubs and reduces the friction driving required. The combination of a heat dissipating hub and the placement of seals along the drive shaft within the hub minimize maintenance and replacement.
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FIELD OF THE INVENTION
The present invention relates to game apparatus and more particularly table height game apparatus of the type wherein a slider, such as a disc or puck, is hand-propelled to slide along an elongated surface from a launch area to a target area. One example of this type of game apparatus is table shuffleboard.
BACKGROUND OF THE INVENTION
Table level games involving the skillful hand sliding of a projectile disc or puck have achieved popularity as amusement devices and are commonly available in coin operated versions in public amusement places as well as for home recreational use. Table level shuffleboard is one of the more popular of this class of game. While some table surface games, for example as shown in U.S. Pat. No. 1,731,353, have in the past, introduced a continuous curving top surface for a spinning top and other games, e.g., those shown in U.S. Pat. Nos. 1,906,025; 2,900,189; provide shallow elongated throughs for sliding a puck; and still another, U.S. Pat. No. 3,482,837 introduced a flexible deformable surface for a rolling disc, the vast majority of the shuffle board games have taken pains to provide, and often provide adjusting apparatus for the insuring of, a true horizontal and flatness to the sliding surface.
SUMMARY OF THE INVENTION
The present invention is directed to a more challenging game apparatus of the type wherein projectiles, discs or pucks, are hand-propelled to slide over an elongated upper surface from a launch area to a target area and wherein instead of providing a flat surface or a longitudinal channelled surface, a non-flexible sliding surface is provided which is contoured to as to present the sliding projectile as it travels along the length of the slide surface with successive surface areas of smoothly varying pitches.
This arrangement requires the player to more skillfully control his aim and speed so as to adjust to the undulating contour surface.
BRIEF DESCRIPTION OF THE DRAWING
In the accompanying drawing, like numerals refer to like elements, and:
FIG. 1 is a perspective view of a game apparatus constructed in accordance with the present invention;
FIG. 2 is a top view of the apparatus of FIG. 1;
FIG. 3 is a side elevational view of the playing surface area of the apparatus of FIG. 2 (as seen partly in section and partly broken away), as seen from the line 3--3 of FIG. 2.
FIG. 4 is a perspective view of a subassembly of the apparatus of FIGS. 1-3, illustrating one manner of constructing the apparatus.
FIG. 5 is a sectional view of the apparatus of FIGS. 1 and 2 as seen from the line 5--5 of FIG. 3;
FIG. 6 is a sectional view of the apparatus of FIGS. 1-5 as seen from the line 6--6 of FIG. 5; and
FIGS. 7 and 8 are each sectional views of the apparatus as seen from respectively the lines 7--7 and 8--8 of FIG. 6.
DETAILED DESCRIPTION
Referring to the drawings and especially FIG. 1 thereof, there is depicted a game apparatus 10 which incorporates the principles of the present invention. The apparatus 10 is of the countertop or table height type, by which is meant a height which enables a player to stand adjacent to the apparatus and to hand propel a slider such as the disc or puck 12 by moving and releasing it on the surface so that it will glide or slide after being released from a launch area to a target area.
The apparatus 10 includes an upper playing unit 14 supported on legs 16 at the desired height. As best seen in FIG. 2 the playing unit 14 includes an elongated, rectangular and horizontal base 18 about whose periphery are mounted walls 20, 21, 22, 23 which serve to contain the sliders such as the disc 12 on the playing unit. These periphery walls 20-23 include a pair of parallel side walls 20, 21 and two end walls 22, 23.
Above the base 18 and within the rectangular area bounded by the walls 20, 22 is a smooth and hard playing surface 30 which bears conventional shuffleboard indicia defining the launch/target areas 29, 29'. The areas 29, 29', of course, each serve as the launch area for one team and the target area for the other team. The surface 30, in accordance with the present invention, is fixed, that is, it is a non-flexible surface which is contoured in a regular manner so as to present a succession of smoothly flowing hills and valleys of a low pitch or slope, to a longitudinally traveling disc moving from a launch area to a target area.
As best shown in FIG. 2 the surface 20 projects into a horizontal rectangle on the base 18 and is raised over that surface somewhat by side walls 34 and 36 (FIGS. 4-7) and end walls 38 and 40 (FIGS. 3 and 5). The raised surface 30 is spaced from the interior surfaces of walls 20-23 to form a "gutter" zone into which discs such as the disc 12 may fall.
As best seen in FIGS. 1 and 3, the intersections of the surface 30 and the side walls 32 and 34 are curves 31 and 32 which preferably are mirror images of one another.
In descriptive geometry germs, the surface 30 can be generated by moving a line segment parallel to the vertical plane along a pair of generally horizontal curving lines such as 31 and 32. The line segment in the disclosed embodiment is, as is preferred, a straight line segment (although a slightly curving line might be substituted to add a further element of complexity). It should be noted that the transverse pitch of the surface 30 is continuously varying as one moves in the longitudinal direction and changes from one direction (left to right in FIG. 1 at area 29) to another direction (right to left at area 29').
In play, the apparatus 10 is used in the same manner as a conventional table level shuffleboard game and the same rules may be followed. However, the ability of the player is tested more as he must adjust the speed and angle of launching his discs to overcome the effects of the varying pitch of the fixed contours of the surface 30. This requires an additional level of skill and this presents a greater challenge to the player.
Note should be taken that surface 30 of the apparatus 10 is symmetrical about its center point so that it presents the same contour when viewed from either end. Thus a team playing either end of the table is presented with the same surface configuration.
The surface 30 can be formed in a practical manner by first providing a pair of side walls 32, 34 of the shaped depicted and then providing end walls 38, 40 of the shape shown in FIGS. 4 and 5 and, to provide rigidity, a number of cross members such as central member 50 (FIGS. 4 and 7) and a pair of intermediate cross members 51, 52 (FIGS. 4 and 5 and FIGS. 4 and 6). (Note that each of the cross members 50, 51, 52, and end walls 38 and 40 have a straight line upper surface.)
A game apparatus similar to the described preferred embodiment was actually constructed and for concreteness of this disclosure but not for purposes of limitation of the invention dimensions of this particular unit will be detailed. In overall horizontal size this embodiment's surface 30 measured eight feet by two feet with the units 38, 51, 50, 52 and 40 being two feet in length and being spaced, on centers, two feet apart along the length of the base 18. The units 38 and 40 had side end heights of 61/4 inch and 11/2 inch, while the units 51 and 52 had end edge heights of 31/2 and 11/2 inches. The central unit 50 was 4 inches in height.
A preferred way of forming the mirror image units 34, 36 or 51, 52 or 38, 40 is to cut sandwiched pieces of plywood at the same time and to simply turn one end for end.
On this frame work a sheet of thin but stiff material, such as pressboard, can then be bent or deformed over the top surface and secured in any convenient manner, such as with mastic, to form the surface 30. It should be noted that such a sheet would not be, prior to forming, of a rectangular shape but would be irregular in outline. Of course, a larger than needed sheet could be used and the overlapping margins removed.
Alternatively, the surface 30 may be formed by any other convenient manner, for example, by using lightweight concrete (vermiculite agrigate) and a suitable reinforcing media (such as expanded mesh) in a suitably shaped form. Or reinformed plastic cast in forms, such as fiber glass as in the manner for making fiberglass boat hulls. Numberous other materials and construction techniques could also be substituted.
Although the present invention has been described in terms of a symmetrical table level shuffleboard game, at least in their broader aspects, the principles of the invention can be applied to other games that involve the sliding of a disc along an elongated surface such as the currently popular coin operated baseball (and like) shuffleboard games wherein the target area comprises sensors which are triggered by the disc.
Although a specific preferred embodiment has been disclosed in detail, the present invention can take many forms and it is the intention to claim the present invention in all of the aspects and, in at least the broader claims, with such a scope as to encompass the invention in such a manner as consistent with the contribution to this art.
For example, although as disclosed in the presently preferred embodiment the playing surface is completely surrounded with a gutter, the invention has been reduced to practice in a version which employs an upstanding sidewall adjacent the periphery of the playing surface and against which pucks may be deflected during play. It is therefore the intent of at least the broadest of the appended claims to also cover this variation as well as intermediate variations, such as would employ a gutter over a part of the periphery of the playing surface and a deflection wall over the remainder.
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A game apparatus of the table level type wherein projectiles, e.g., pucks or discs, are hand-propelled to slide over an elongated surface from a launch area to a target area, is disclosed, which employs an elongated slide surface which is formed into a fixed contour so as to present the sliding projectile, as it travels along the length of the slide surface, with surfaces of varying pitches.
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This application is a 371 of PCT/EP01/01347, filed Feb. 8, 2001.
BACKGROUND OF THE INVENTION
The invention relates to a parallel spinning process and to spinning machines equipped therewith, in particular for filaments, e.g. for textile or industrial applications, made from polymers such as polyester or polyamide, in each case having a thread interlacing device between two godets.
Spinning machines for conventional POY (partially oriented yarn) spinning processes are usually equipped with two separately driven, speed-regulated godets over which a plurality of threads (four, six or eight, depending on the winder) are guided in an S-shaped threadline in order to regulate the thread tension between the thread lubrication point and the take-up device. In this threadline, the freshly spun sheets of filaments are first guided in a parallel manner next to one another to the corresponding thread lubricating devices and are each combined there to give a cohesive thread, and then the threads are guided, grouped closely next to one another, over the aforesaid godets. The thread sheet is then fed to the winder, opened out again and turned through 90° to correspond to the desired bobbin width. In order to achieve better cohesion of the thread, pneumatically operated devices for tangling the threads, so-called tangle jets or interlacers, are frequently used. This is advantageously carried out between the godets: on the one hand, the thread tension can still be regulated, and on the other hand it is easier to insert the thread through the narrow thread gap.
In contrast to this crossed threadline (the extrusion axis is turned through 90° with respect to the winder axis), no simple solution or in fact no solution at all has been found for the arrangement of interlacers and handling between the godets in the parallel spinning process, such as in U.S. Pat. No. 3,902,853.
More modern parallel spinning processes have hitherto mainly been designed as SHSS (super-high-speed spinning, Lurgi Zimmer) or HOY (high oriented yarn) processes, in which the line runs directly, i.e. without godets, to regulate the thread tension, in a parallel and perpendicular manner out of the spinnerets to the winder. This low-cost, compact design is not entirely advantageous, however: as well as the process engineering disadvantages regarding the uniformity of the threads, the bobbin building and the limited range of titres, the threading in and feeding at the start of the spinning process in these space-saving types of short spinning machines is very time-consuming and highly inconvenient.
For POY spinning processes, parallel spinning machines have hitherto usually been equipped with two very expensive long godets, such as, for example, according to WO 96/09425, between which the tangle jets are accommodated. Here too, the threading-in and feeding is tedious and inconvenient, and moreover the feeding requires a certain amount of space simply for reasons of safety.
A further POY spinning process in which a small pair of godets is provided for each thread was presented in Paris by Barmag at the ITMA in June 1999. In this design, interlacers cannot be accommodated between the small godets. Although this solution is substantially less expensive than the long godet version, the fact that the function of regulating the thread tension is insufficiently fulfilled in this arrangement with small godets, given the small angle of wrap of less than 90°, means, however, that separate drives and speed regulation are logically omitted. Thus, there are considerable process-related disadvantages to counter the low investment costs: an inadequate angle of wrap, no regulation of the speed or thread tension, a lack of entangling between the godets and a considerable space requirement when setting up the machine for the time-consuming threading-in and feeding.
Thus, for POY spinning processes in parallel spinning machines, the object is to find a device for regulating the thread tension and for thread interlacing which is easy to operate and has better performance.
According to the invention, this object is achieved by the process and the device according to the claims.
In the arrangement of godets and interlacers according to the invention, the object is achieved at the same time as surprisingly operator-friendly handling and complete fulfillment of the desired functions. The new concept provides major process and handling advantages which mean that the higher investment quickly pays for itself over the operating time: a very large angle of wrap of more than 180° is achievable, as is thread interlacing between the godets and the use of speed-regulated drives to control the thread tension. Furthermore, the automatic threading into the tangle jets and over the godets, which is a surprising solution for handling, improves the effectiveness of the machines as a result of shorter feeding times.
SUMMARY OF THE INVENTION
In the proposed arrangement according to the invention, two godets ( 2 ; 3 ) are used for each thread ( 1 ) in such a way that in the operating state of the machine an angle of wrap of from at least 85° to a maximum of 200°, but preferably from 175° to 185°, is formed by each thread ( 1 ) at the godets ( 2 ; 3 ). The godets ( 2 ) are referred to in the description below as “lower” godets and the godets ( 3 ) are referred to as “upper” godets.
DETAILED DESCRIPTION
During the feeding phase, all the upper godets ( 3 ), which are combined on a movable godet unit ( 4 ) and are also driven jointly, are then moved downwards so that each individual thread ( 1 ) firstly coming from the upper thread guide ( 5 ) can be inserted, while being bent slightly at the lower godet ( 2 ), into the associated thread guide of the triangular traversing unit ( 6 ) (cf. FIG. 1 ). Once this has been carried out for all the threads ( 1 ), the godet unit ( 4 ), together with the upper godets ( 3 ), is moved upwards along a curved or preferably arcuate path ( 7 ) in order to avoid collision with the lower godets ( 2 ), and at the same time each individual thread ( 1 ) is threaded into the associated interlacer ( 8 ) (cf. FIG. 3 ).
In the end position for the operating state (cf. FIG. 3 ), an S-shaped threadline is formed for each thread, with in each case an angle of wrap of the godets ( 2 ; 3 ) of greater than 180° and with the interlacers ( 8 ) arranged between the godets ( 2 ; 3 ), which makes it possible to regulate the thread tension without difficulty. The lower godets ( 2 ) and the upper godets ( 3 ) are in each case combined in drive terms. This configuration of the godets ( 2 ; 3 ) in groups facilitates low-cost drives via toothed belts ( 9 ; 12 ) to provide low-cost driving and control means via electronic speed control. The entire arrangement here is accommodated in a housing ( 10 ) having a sliding door ( 11 ), which is only opened for feeding, so enabling excess processing aid blown off the thread ( 1 ) during tangling to be removed by simple suction.
In a further embodiment of the invention, the intention is to simplify the threading-in operation further by moving the traversing thread guides ( 6 )—combined in a horizontally movable thread guide unit (not illustrated)—in such a way that each individual thread ( 1 ) is firstly threaded in, in each case precisely perpendicularly, and then all the threads ( 1 ) are drawn together in such a way that the first contact with the lower godets ( 2 ) takes place simultaneously for all the threads ( 1 ). The operation thereafter is as already described above: the upper godets ( 3 ) are moved upwards and threading into the respective interlacers ( 8 ) is carried out automatically. This is done by pivoting the individual upper godets ( 3 ), which are combined in groups in the godet unit ( 4 ), by means of a parallel pivot gear mechanism ( 14 ), preferably consisting of at least two pivot levers ( 15 ) and a pneumatic drive, along a curved path ( 7 ), this curved path ( 7 ) preferably corresponding to an arc (cf. FIGS. 1 to 4 ).
BRIEF DESCRIPTION OF THE DRAWINGS
The description below will be made with reference to illustrative drawings:
FIG. 1 shows the threadline, in plan view onto the godets, in the feeding mode,
FIG. 2 shows a plan view onto belt drives in the feeding mode with the threadline,
FIG. 3 shows the threadline, in plan view onto the godets, in the operating mode,
FIG. 4 also shows the plan view onto the godets and belt drives in the operating mode, and
FIG. 5 shows a section through an illustrative parallel spinning facility in a back-to-back arrangement.
FIG. 1 shows the upper godets ( 3 ) moved downwards in the feeding mode, still below the lower godets ( 2 ), which sit immovably on the spinning face ( 13 ). The entire arrangement of the godets ( 2 ; 3 ) here is accommodated in a housing ( 10 ) having a sliding door ( 11 ) which is opened for feeding. In the feeding mode illustrated here, each individual thread ( 1 ), coming firstly from the upper thread guide ( 5 ), is bent slightly past the lower godet ( 2 ) and inserted into the associated thread guide of the triangular traversing unit ( 6 ) without touching the upper godets ( 3 ) or the intermingling device ( 8 ) in the process.
FIG. 2 shows a plan view onto the belt drives in the feeding mode with the threadline indicated. The upper godets ( 3 ), here indicated merely by a dashed line, are all combined on a pivotable godet unit ( 4 ) and have been pivoted downwards by means of a parallel pivot gear mechanism ( 14 ) consisting of two pivot levers ( 15 ) and a pneumatic drive (not illustrated here) along a curved path ( 7 ) corresponding to an arc. The upper godets ( 3 ) and the lower godets ( 2 ) are in each case combined into groups and are in each case driven jointly via a toothed belt ( 9 , top, or 12 , bottom). The comb-shaped belt paths over the numerous deflector rollers ( 17 ) are necessary to prevent the drives from colliding with one another.
FIG. 3 then shows a plan view onto the godets and the threadline in the operating mode, with angles of wrap of greater than 180°. Once all the threads ( 1 ) have been threaded in, according to the description referring to FIG. 1 , the godet unit ( 4 ) (not illustrated here), together with the upper godets ( 3 ), is moved upwards along a curved or arcuate path ( 7 ) in order to avoid colliding with the lower godets ( 2 ), and at the same time each individual thread ( 1 ) is threaded into the associated interlacer ( 8 ), as drawn in the end position illustrated. The sliding door ( 11 ) can then be slid in front of the housing ( 10 ).
FIG. 4 again shows a plan view onto the belt drives, this time in the operating mode. The illustration is shown with the threadline indicated. The upper godets ( 3 ) have all been pivoted upwards on their pivotable godet unit ( 4 ) by means of the parallel pivot gear mechanism ( 14 ), consisting of two pivot levers ( 15 ) and a pneumatic drive (not illustrated), along a curved path ( 7 ). The two toothed belts ( 9 , top, or 12 , bottom) for the two groups of godets and the belt path over the deflector rollers ( 17 ) can be seen more clearly here.
FIG. 5 shows, for a general view, a section through an illustrative parallel spinning facility in a back-to-back arrangement with two winders ( 16 );
On the left in the drawing, the situation at the time of feeding is shown: the thread ( 1 ), coming from the upper thread guide ( 5 ), is inserted into the thread guide of the triangular traversing unit ( 6 ) by means of a feed gun ( 18 ). The godet unit ( 4 ), together with the upper godets ( 3 ), has been pivoted downwards in advance by means of the parallel pivot gear mechanism ( 14 ) consisting of two pivot levers ( 15 ). The arrangement of the godet unit ( 4 ), spatially offset with respect to the spinning face ( 13 ), is clearly visible, while the godets ( 2 ; 3 ) themselves all lie in the thread plane.
On the right, the operating mode is illustrated: the thread ( 1 ), coming from the upper thread guide ( 5 ), runs in a plane over the godets ( 2 ; 3 ) into the thread guide of the triangular traversing unit ( 6 ) to the winder ( 16 ). The godet unit ( 4 ) here has been pivoted upwards.
LIST OF REFERENCES
1 . Thread
2 . Lower godet
3 . Upper godet
4 . Movable godet unit
5 . Upper thread guide
6 . Thread guide of the triangular traversing unit
7 . Curved or arcuate path
8 . Interlacer; thread interlacing device; tangle jet
9 . Toothed belt, top
10 . Housing
11 . Sliding door
12 . Toothed belt, bottom
13 . Spinning face; mounting unit for the lower godets
14 . Parallel pivot gear mechanism
15 . Pivot lever
16 . Winder
17 . Deflector rollers
18 . Feeding gun
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A parallel spinning process, in particular for filaments, e.g. for textile or industrial applications, made from polymers such as, for example, PET or PA, in each case having a thread interlacing device between two godets for each individual thread, the godets being moved in relation to one another during the piercing or feeding operation in such a way that each individual thread is automatically threaded into its interlacing device associated therewith, and the angle of wrap in the operating mode is at least from 85° to at most 200°, preferably from 175° to 185°.
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This is a continuation of U.S. patent application Ser. No. 10/301,455, filed Nov. 21, 2002 now U.S. Pat. No. 6,832,473.
BACKGROUND
This disclosure relates generally to a method and system for regenerating and/or desulfating NO x adsorbers and/or regenerating particulate filters.
In general, diesel engines generally emit less nitrogen oxides (NOx) than a gasoline engine under most conditions, but because diesel engines mostly or exclusively operate on a high air to fuel ratio, the chemistry of the exhaust gas does not favor NOx reduction, because of the excess of oxidizing species. Thus, the reduction of nitrogen oxides, e.g., nitric oxide (NO), nitrogen dioxide (NO 2 ), and nitrous oxide (N 2 O), in exhaust gas is a widely addressed problem as a result of environmental concerns and mandated government emissions regulations, particularly in the transportation industry. One proposed solution is the use of a three-way conversion catalyst, which can be employed to treat the exhaust gases. Such three-way conversion catalysts, contain precious metals such as platinum, palladium, and rhodium, and can promote the oxidation of unburned hydrocarbons and carbon monoxide , and the reduction of nitrogen oxides in exhaust gas provided that the engine is operated around a balanced stoichiometry for combustion (also referred to as “combustion stoichiometry”). The balanced combustion stoichiometry is typically at an air to fuel ratio between about 14.4 to about 14.7.
However, fuel economy and global carbon dioxide emission concerns have made engine operation under lean-burn conditions desirable in order to realize a benefit in fuel economy. Under such lean-burn conditions, the air-to-fuel ratio may be greater than the balanced combustion stoichiometry, i.e., greater than about 14.7 and may be between about 19 to about 35. When lean-burn conditions are employed, three-way conversion catalysts are generally efficient in oxidizing the unburned hydrocarbons and carbon monoxide s, but are generally inefficient in the reduction of nitrogen oxides.
One approach for treating nitrogen oxides in exhaust gases is to incorporate a NO x adsorber, also referred to as a “lean-NO x trap,” in the exhaust lines. The NO x adsorber promotes the catalytic oxidation of nitrogen oxides by catalytic metal components effective for such oxidation, such as precious metals. The formation of NO 2 is generally followed by the formation of a nitrate when the NO 2 is adsorbed onto the catalyst surface. The NO 2 is thus “trapped”, i.e., stored, on the catalyst surface in the nitrate form. The system can be periodically operated under fuel-rich combustion to regenerate the NO x adsorber. During this period of fuel-rich combustion, the absence of oxygen and the presence of a reducing agent promote the release and subsequent reduction of the stored nitrogen oxides. However, this period of fuel-rich combustion may also result in a significant fuel penalty.
As previously mentioned, exhaust gas streams can further comprise particulate matter such as carbon-containing particles or soot. A particulate filter, commonly used with compression ignition engines, can be used to prevent the carbon particles or the soot from exiting a tailpipe. The particulate filter may be a stand-alone device separate and distinct from devices employing catalytic elements for removing undesirable NO x gaseous components. Carbon particles can be trapped in the particulate filter and then periodically burned to regenerate the filter.
Regeneration of particulate filters can be accomplished by the use of auxiliary devices such as a burner or other heating element. For example, an air-fuel nozzle and an ignition device can be used and operated, when desired, to heat the exhaust gases and the particulate filter to a combustion temperature of the trapped particulate matter. In this manner, the trapped particulate matter can be burned from the filter surfaces to permit a continuous flow of the exhaust gases. Alternatively, an electric heater can be used to generate the heat to initiate the combustion of the trapped particulates. However, these approaches are limited by their energy efficiency, durability, and cost.
BRIEF SUMMARY
Disclosed herein is a system for regenerating and/or desulfating a NOx adsorber and/or a system for regenerating a particulate filter. The system comprises regeneration system comprising an exhaust conduit in fluid communication with an exhaust fluid from an engine, wherein the exhaust conduit comprises a first oxidation catalyst, a NOx adsorber, and a second oxidation catalyst coupled to a particulate filter; a fuel source in fluid communication with a reformer, wherein the reformer is adapted to generate a hydrogen and carbon monoxide containing fluid from a fuel supplied by the fuel source; a regeneration conduit in fluid communication with the exhaust conduit and the reformer; and valve means disposed in the regeneration conduit for selectively controlling and directing the hydrogen and carbon monoxide containing fluid from the reformer to the first oxidation catalyst, the coupled second oxidation catalyst and particulate filter, the NOx adsorber, or a combination thereof.
In accordance with another embodiment, a regeneration system comprises an exhaust conduit in fluid communication with an exhaust fluid from an engine, wherein the exhaust conduit comprises a first oxidation catalyst, a second oxidation catalyst coupled to a NOx adsorber, and a third oxidation catalyst coupled to a particulate filter; a fuel source in fluid communication with a reformer, wherein the reformer is adapted to generate a hydrogen and carbon monoxide containing fluid from a fuel supplied by the fuel source; a regeneration conduit in fluid communication with the exhaust conduit and the reformer; and valve means disposed in the regeneration conduit for selectively controlling and directing the hydrogen and carbon dioxide containing fluid from the reformer to the first oxidation catalyst, the second oxidation catalyst coupled to the NOx adsorber, and the third oxidation catalyst coupled to the particulate filter, or a combination thereof.
A process for regenerating and desulfating a NO x adsorber and/or a regenerating a particulate filter comprises periodically supplying a fuel to a reformer; converting said fuel to a hydrogen and carbon monoxide containing fluid; selectively feeding the hydrogen and carbon monoxide containing fluid into an oxidation catalyst or into a NOx adsorber, or into the oxidation catalyst and the NOx adsorber catalyst; and generating an exotherm in the oxidation catalyst and heating an exhaust fluid passing therethrough to a temperature effective to regenerate a particulate filter disposed downstream from the oxidation catalyst or reducing nitrogen oxides adsorbed by the NOx adsorber or generating the exotherm in the oxidation catalyst and heating the exhaust fluid to the temperature effective to regenerate the particulate filter downstream from the oxidation catalyst and reducing the nitrogen oxides trapped by the NOx adsorber.
The above-described and other features will be appreciated and understood by those skilled in the art from the following detailed description, drawings, and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the figures, which are exemplary embodiments and wherein like elements are numbered alike:
FIG. 1 is a schematic view of a regeneration and/or desulfating system for light duty diesel architecture;
FIG. 2 is a schematic view of a regeneration and/or desulfating system for heavy duty diesel architecture;
FIG. 3 a schematic view of a system for regenerating a NOx adsorber in accordance with a third embodiment;
FIG. 4 is a schematic view of a system for regenerating a NOx adsorber in accordance with a fourth embodiment;
FIG. 5 is a schematic view of a system for regenerating a NOx adsorber in accordance with a fifth embodiment;
FIG. 6 is a schematic view of a system for regenerating a NOx adsorber in accordance with a sixth embodiment; and
FIG. 7 is a schematic view of a system for regenerating a NOx adsorber in accordance with a seventh embodiment.
DETAILED DESCRIPTION
Referring now to FIG. 1 , a system, generally designated 10 , for regenerating a particulate filter and/or for regenerating and/or desulfating a NOx adsorber is shown. System 10 depicts a preferred architecture for light-duty diesel architecture applications, e.g., passenger cars. The system 10 generally comprises a fuel source 12 in fluid communication with an inlet 14 of a reformer 16 . An outlet 18 of the reformer 16 is fluidly connected to a reformer conduit 20 . The general flow of reformate from the reformer 16 is indicated by an arrow labeled reformate flow direction. Valves 22 , 24 , and 26 are disposed in the reformer conduit 20 to selectively provide fluid communication from the reformer 16 to an exhaust conduit 28 . Disposed in serial fluid communication within the exhaust conduit 28 are an oxidation catalyst 30 , an NOx adsorber 32 , and an oxidation catalyst 34 coupled to a particulate filter 36 . Valve 22 provides controlled fluid communication from the reformer 16 to the oxidation catalyst 30 . Valve 24 provides controlled fluid communication from the reformer 16 to the NOx adsorber 32 . Valve 26 provides controlled fluid communication from the reformer 16 to the coupled oxidation catalyst 34 and particulate filter 36 . For light-duty applications, the general directional flow of exhaust fluid from an engine (as shown by an arrow labeled exhaust flow direction) is through the oxidation catalyst 30 , the NOx adsorber 32 , and then the coupled oxidation catalyst 34 and particulate filter 36 . The fluid passing through the exhaust conduit 28 is then discharged into the external environment.
FIG. 2 illustrates system 50 , which provides architecture for heavy-duty diesel architecture applications, e.g., over the highway tractors, trucks, and the like. In system 50 , the oxidation catalyst 30 , the NO x adsorber 32 , and the coupled oxidation catalyst 34 and particulate filter 36 are disposed in serial fluid communication within the exhaust conduit 28 . Thus, the general directional flow of exhaust fluid (as shown by an arrow labeled exhaust flow direction) from the engine to the external environment is through the coupled oxidation catalyst 34 and particulate filter 36 , then through the oxidation catalyst 30 , and then through the NO x adsorber 32 .
Fuel source 12 preferably includes hydrocarbon fuels, including, but not limited to, liquid fuels, such as gasoline, diesel, ethanol, methanol, kerosene, and others; gaseous fuels, such as natural gas, propane, butane, and others; and alternative fuels, such as hydrogen, biofuels, dimethyl ether, and others; and mixtures of at least one of the foregoing fuels. The selection of fuel source 12 is based upon application, expense, availability, and environmental issues relating to fuel source 12 .
Reformer 16 generates a reformate gas from the fuel source 12 . The reformate includes hydrogen, carbon monoxide , and other byproducts that may include carbon dioxide. Reformer 16 may be configured for partial oxidation, steam reforming, or dry reforming. Preferably, reformer 16 is configured for partial oxidation.
Partial oxidation reformers are based on sub-stoichiometric combustion to achieve the temperatures necessary to reform the hydrocarbon fuel. Decomposition of fuel to primarily hydrogen and carbon monoxide occurs through thermal reactions at temperatures of about 700° C. to about 1,000° C. Catalysts can be used with partial oxidation systems (catalytic partial oxidation) to promote conversion of various sulfur-free fuels, such as ethanol, into a synthetic gas. The use of the catalyst can result in acceleration of the reforming reactions and can provide this effect at lower reaction temperatures than those that would otherwise be required in the absence of a catalyst. An example of the partial oxidation reforming reaction is as follows:
CH 4 +½O 2 →CO+2H 2 +heat
In contrast, steam configured reformers react fuel and steam (H 2 O) in heated tubes filled with catalysts to convert hydrocarbons in the fuel into primarily hydrogen and carbon monoxide . An example of the steam reforming reaction is as follows:
CH 4 +H 2 O→CO+4H 2
Dry reforming systems form hydrogen and carbon monoxide in the absence of water, for example, by using carbon dioxide. An example of the dry reforming reaction is depicted in the following reaction:
CH 4 +CO 2 →2CO+2H 2
Reformer 16 preferably comprises a catalyst and a substrate. The catalyst can be washcoated, imbibed, impregnated, physisorbed, chemisorbed, precipitated, or otherwise applied to the substrate. Possible catalyst materials include metals, such as platinum, palladium, rhodium, iridium, osmium, ruthenium, and the like, and oxides, mixtures, and alloys comprising at least one of the foregoing metals.
The reformer substrate is preferably capable of operating at temperatures up to about 1,200° C.; capable of withstanding reducing and oxidizing environments containing, for example, hydrocarbons, hydrogen, carbon monoxide , water, oxygen, sulfur and sulfur-containing compounds, combustion radicals, such as hydrogen and hydroxyl ions, and the like, and carbon particulate matter; and has sufficient surface area and structural integrity to support the desired catalyst.
Materials that can be used as the reformer substrate include alumina, zirconia, cordierite, silicon carbide, metals (e.g., stainless steel, aluminum, and the like), as well as oxides, alloys, cermets, and mixtures comprising at least one of the foregoing materials, with alumina, zirconia, and mixtures comprising alumina and/or zirconia preferred.
Although the reformer substrate can have any size or geometry, the size and geometry are preferably chosen to optimize the surface area in the given catalytic converter design parameters. The reformer substrate can have an open cell foam structure, or an extruded honeycomb cell geometry, with the cells being any multi-sided or rounded shape, with substantially square, hexagonal, octagonal or similar geometries preferred due to increased surface area and structural integrity. The substrate is formed into a cell structure with a plurality of cells arranged in a honeycomb pattern using a foam process, and the like.
The oxidation catalyst, 30 or 34 , preferably comprises a catalytic metal including, but not limited to, platinum, palladium, ruthenium, rhodium, osmium, iridium, gold, silver, aluminum, gallium, indium, tin, titanium, and other metals, as well as oxides, alloys, salts, and mixtures comprising at least one of the foregoing metals. Moreover, the catalyst utilized for the oxidation catalyst 30 or 34 may also be employed as the catalyst in the NO x adsorber 32 and particulate filter 36 .
The NO x adsorber 32 generally comprises a porous support, a catalytic metal component, and one or more NO x trapping materials. Suitable NOx trapping materials include alkali metals, alkaline earth metals, and the like, and combinations comprising at least one of the foregoing. The catalytic metal component and NO x trapping materials can be washcoated, imbibed, impregnated, physisorbed, chemisorbed, precipitated, or otherwise applied onto and/or within the porous support.
The porous support can comprise any material designed for use in a spark ignition or diesel engine environment. Preferably, the porous support is selected to be capable of operating at temperatures up to about 1,200° C.; capable of withstanding exposure to hydrocarbons, nitrogen oxides, carbon monoxide , carbon dioxide, sulfur and/or sulfur oxides; and has sufficient surface area and structural integrity to support the desired catalyst. Some possible materials include zirconium toughened alumina, cordierite, silicon carbide, metallic foils, alumina sponges, porous glasses, and the like, and mixtures comprising at least one of the foregoing materials, with zirconium toughened alumina preferred.
Although the porous support can have any size or geometry, the size and geometry are preferably chosen to optimize surface area in the given catalytic converter design parameters. Generally, the porous support has a honeycomb geometry, with the combs being any multi-sided or rounded shape, with substantially square, triangular, hexagonal, or similar geometries preferred due to ease of manufacturing and increased surface area.
The porous support further comprises one or more other support materials suitable for use at the high operation temperatures associated with an internal combustion engine (e.g., up to about 1,200° C.). Such materials include, but are not limited to, aluminates (e.g., hexaaluminates), alumina, and the like, as well as combinations comprising at least one of the foregoing, with gamma-alumina, theta-alumina, delta-alumina, and combinations thereof being preferred.
The catalytic metal component comprises precious metals, such as, platinum, rhodium, palladium, ruthenium, iridium and osmium, as well as alloys and combinations comprising at least one of the foregoing metals. Where the catalytic metal component is a combination of rhodium with one or more other metals, the other metals, e.g., palladium, platinum, and the like, are typically present in an amount less than the rhodium. More particularly, with a a platinum/rhodium combination, the catalytic metal component can comprise up to about 95 wt % rhodium and up to about 30 wt % platinum; with about 70 wt % to about 85 wt % rhodium and about 2.5 wt % to about 20 wt % platinum preferred; and about 70 wt % to about 80 wt % rhodium and about 5 wt % to about 10 wt % platinum especially preferred, weight percent based on the total weight of the alloy.
In addition to the catalytic metal component, the porous support may be further loaded with one or more NO x trapping materials, such as alkali metals, alkaline earth metal, and mixtures comprising at least one of the foregoing metals. Suitable trapping materials include barium, lithium, potassium, magnesium, sodium, cesium, strontium, and combinations comprising at least one of the foregoing, with a mixture of barium and potassium being preferred.
The particulate filter 36 generally comprises a shell, an insulation material, and a filter element. The insulation material substantially covers the filter element, and the shell substantially covers the insulation material.
Possible materials for the shell include ferrous materials, such as ferritic stainless steels. Ferritic stainless steels include stainless steels such as the 400-Series, for example, SS-409, SS-439, and SS-441, and alloys, and combinations comprising at least one of the foregoing stainless steels, with grade SS-409 generally preferred.
The insulation material comprises materials such as fiberglass, intumescent materials, non-intumescent materials, ceramic mats, and/or mica based materials, including combinations comprising at least one of the foregoing insulation materials, and the like.
The filter element can comprise one or more monoliths, substrates, supports, and the like, comprising a ceramic, metallic, cermet, and carbides, silicides, nitrides, such as silicon carbide, silicon nitride, and the like, or composite material, and the like, and combinations comprising at least one of the foregoing materials. Such materials preferably possess a sufficient porosity to permit passage of reformate through the monolith walls, and yet filter out a substantial portion, if not all of the particulate matter present in the exhaust.
Preferably, the filter element includes a catalyst material such as precious metals such as platinum, palladium, rhodium, nickel, iron, cobalt, molybdenum, tungsten, vanadium, niobium, tantalum, their oxides and sulfides, and combinations comprising at least one of the foregoing precious metals and the like. Further, the filter element can optionally include a washcoat material such as aluminum oxide, silicon oxide, zirconium oxide, titanium oxide, cerium oxide, combinations comprising at least one of the following washcoat materials, and the like.
In operation of system 10 , 50 , the reformer 16 converts the fuel from the fuel source 12 to produce a reformate including, among other products, hydrogen and carbon monoxide gases. In a preferred embodiment, the reformer is a partial oxidation reformer. The reformate as it exits the reformer 16 is preferably at a temperature of about 1,000° C. or less. Depending on the particular system architecture, the system may include an optional heat exchanger to reduce the reformate temperature to a temperature effective to cause regeneration and or desulfurization of the particulate component, e.g., NOx adsorber 32 , particulate filter 36 , and the like. The heated reformate can then be used to regenerate and desulfate NO x adsorber 32 and/or regenerate the particulate filter 36 . For example, in system 10 , when valve 24 is open (valves 22 , 26 closed), hydrogen and carbon monoxide from the reformer 16 can be fed directly to the exhaust fluid stream entering the NO x adsorber 32 . The heated reformate allows the NOx adsorber to be regenerated using hydrogen and carbon monoxide . Preferably, the reformate is at a temperature of about 200° C. to about 600° C. as it enters the NOx adsorber 32 , with about a temperature of about 300° C. to about 500° C. even more preferred, with a temperature at about 400° C. most preferred. Valve 24 can be programmed to provide intermittent flow, i.e., a pulse, of hydrogen and carbon monoxide into NO x adsorber 32 . Valve 24 allows hydrogen and carbon monoxide to flow to NO x adsorber 32 as needed for regeneration, which can also reduce the amount of fuel consumed during regeneration, when compared to other regeneration processes that use direct injection of fuel as the reducing agent. (In system 50 , valve 26 is opened and valves 22 , 24 are closed to provide a similar regeneration of the NOx adsorber contained therein.) Additionally, the hydrogen and carbon monoxide can be used for desulfurization purposes. For example, in system 10 when valve 22 is opened hydrogen and carbon monoxide from reformer 16 is fed to oxidation catalyst 30 . Reaction of the hydrogen with the oxidation catalyst creates an exotherm, which heats the exhaust fluid flowing into the NOx adsorber 32 . The exotherm is preferably sufficient to heat the exhaust fluid to a temperature effective to remove sulfur from NO x adsorber 32 . Preferably, the exhaust fluid as it enters the NOx adsorber 32 is at a temperature of about 60° C. to about 1,000° C., and with about 260° C._to about 460° C. more preferred. Likewise, in system 50 , valve 24 is opened instead of, or in combination with valve 26 to regenerate the oxidation catalyst.
The hydrogen gas generated in the reformer 16 can also be used to regenerate the particulate filter 36 . As previously mentioned, the particulate filter 36 is coupled to an oxidation catalyst 34 , which contains a catalyst material and creates an exotherm. The exotherm preferably raises the temperature to a temperature less than or equal to about 550° C., and with less than or equal to about 500° C. more preferred. The heat generated initiates combustion of trapped particulates in the particulate filter 36 .
Other possible system architectures are schematically illustrated in FIGS. 3-6 , wherein opening and closing selected valves can be used to periodically regenerate and/or desulfurize the various components of the system. FIG. 3 illustrates system 70 , wherein the NO x adsorber 32 , the coupled oxidation catalyst 34 and particulate filter 36 , and the oxidation catalyst 30 , are serially disposed in the exhaust conduit 28 . In this embodiment, exhaust from an engine flows through the serially disposed components, wherein the reformer 16 can be used to selectively regenerate the NOx adsorber 32 and/or particulate filter 36 and/or desulfurized the NOx adsorber 32
FIGS. 4-7 schematically illustrate various system architectures 80 , 90 , 100 , 110 , wherein additional valves 40 and 42 are employed to direct the exhaust flow into a selected one of a duplicate component to provide system redundancy. Reformate is selectively injected into the selected system component by opening the appropriate valve. In this manner, regeneration can occur for the selected system component.
The valves 22 , 24 , and 26 are preferably in electrical communication with an on-board computer. The computer can be programmed such that the NOx adsorber 32 can be regenerated and/or desulfated, or the particulate filter 36 can be regenerated as need. For example, in system 10 , the computer can be programmed to open and/or close any of the valves 22 , 24 , and/or 26 based upon operating conditions such as idle speed or load, exhaust temperature, pressure differential across the diesel particulate filter, or it can be a time based program. One skilled in the art will appreciate that embodiments of the above mentioned systems could be used for processes that include desulfurization and regeneration of a NO X adsorber, regeneration of a particulate filter, and the like.
Advantageously, the system provides on-demand regeneration capabilities for the oxidation catalyst 30 or 34 , the NOx adsorber 32 , and/or the particulate filter 36 . Additional chemicals do not have to be carried on-board, since reformer 16 can readily produce hydrogen and carbon monoxide , as needed. Further, the use of hydrogen and carbon monoxide also increases NO x performance at lower temperatures as well as particulate filter regeneration at lower exhaust temperatures. Another advantage may be an increase in fuel efficiency when compared to rich-combustion reduction of a NO x adsorber. Yet another advantage may be reducing platinum and rhodium loading of the NO x adsorber, which may lead to substantial cost savings.
While the disclosure has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this disclosure, but that the disclosure will include all embodiments falling within the scope of the appended claims.
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An active system for regenerating a NOx adsorber and a particulate filter, the system includes a fuel source, a reformer for generating hydrogen and carbon monoxide in fluid communication with the fuel source, a first valve, a second valve, and a third valve in fluid communication with the reformer, an oxidation catalyst, a NOx adsorber located downstream from the oxidation catalyst, a particulate filter located downstream from the NOx adsorber; and wherein the first valve, the second valve, and the third valve control fluid flow from the reformer to the oxidation catalyst, the NOx adsorber, and the particulate filter.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a display system for displaying multimedia document information containing a character, a graph, a picture image and the like (hereinafter simply referred to as "document information") on a display device, and more particularly to a display system suited for interactive document processing.
2. Description of the Prior Art
A conventional multimedia display system includes an image memory having a storage capacity corresponding to one page of a document, and the whole information, including characters, graphs and picture images written on one page, is stored in the image memory in the form of dot information. When characters, a graph and a picture image in a rectangular region (namely, a window) are to be displayed, dot information in the region is taken out of the image memory, and is transferred to a bit-map memory.
In the above system, the image memory is required to have a storage capacity of about 500 KB in order to be able to store therein information on one page of size A4, or to have a storage capacity of about 1 MB in order to be able to store therein information on one page of size A3. That is, an expensive memory is required.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a multimedia display system which can efficiently and economically display document information containing characters, graphs and picture images, without using a large-capacity image memory.
In order to attain the above object, according to the present invention, there is provided a multimedia display system in which information in a window is not stored in an image memory having a storage capacity corresponding to one page of a document, but is directly written in a bit-map memory.
FIG. 1 is a diagrammatic view showing the fundamental thought of the present invention. Referring to FIG. 1, a document 1 contains character information 2, a graph 3 and a picture image 4. It will be needless to say that these different kinds of media may overlap each other. When information in a partial region (namely, a window) 5 of the document 1 is displayed, only document information in the window 5 is converted by a code/image converter 6 into dot information, which is directly written in a bit-map refresh memory 8 of a display device.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view showing the fundamental thought of the present invention.
FIG. 2 is a block diagram showing the hardware of an embodiment of a multimedia display system according to the present invention.
FIG. 3 is a block diagram showing the circuit configuration of an example of the transfer controller shown in FIG. 2.
FIG. 4 is a view for explaining a window management table.
FIG. 5 is a view for explaining a search table.
FIG. 6 is a view for explaining the inner structure of a document file device.
FIG. 7 is a view for explaining some of commands used in the present invention.
FIG. 8 is a flow chart showing the processing procedure for each command.
FIG. 9 is a flow chart showing a procedure for updating a window management table.
FIG. 10 is a flow chart showing in detail the procedure of the document display processing shown in FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Now, explanation will be made of an embodiment of a multimedia display system according to the present invention, by reference to FIG. 2. In FIG. 2, reference numeral 10 designates a processor such as a microprocessor, 14 designates an input keyboard for inputting commands and parameters, 18 designates a main memory for storing therein programs and tables, 20 designates a picture image memory for temporarily storing therein picture image data, 22 designates a font memory for storing therein character fonts, 24 designates a bit-map refresh memory of a display device, 26 designates a display device, 30 designates a file device for storing therein document information, 12 designates an input-keyboard controller, 16 designates a transfer controller for controlling data transfer between memories, and 28 designates a file-device controller.
The transfer controller 16 in the above embodiment may be formed of a device which is described in Japanese Patent Application No. 61075/1982. An example of such a device is shown in FIG. 3. Referring to FIG. 3, a block 2000 bounded by a broken line indicates a memory control device which is a main part of the transfer controller 16. The memory control device 2,000 is connected between a central processing unit (CPU) 10 and a memory 3,000, and is connected to the CPU 10 through an address bus 115, a data bus 110 and a control bus 65. In a multimedia display system according to the present invention, the memory 3,000 is used as a bit-map memory.
The memory control device 2,000 includes a controller 2,100, an address controller 2,300, an operation processor 2,800, a read/write switch 2,400, an address switch 2,200, and read/write buffers 2,500, 2,600 and 2,700.
The address switch 2,200 operates as follows. When a mode signal 135 delivered from the controller 2,100 indicates a first mode (in which the memory 3,000 is used as the main memory of the CPU 10), data supplied to the address switch 2,200 through the address bus 115 is sent, as address data, to the memory 3,000. When the mode signal 135 indicates a second mode (in which the memory 3,000 is used for processing a graph and a picture image), data supplied from the address controller 2,300 to the address switch 2,200 is sent, as address data, to the memory 3,000.
The read/write switch 2,400 operates as follows. When the mode signal 135 from the controller 2,100 indicates the first mode, a read/write signal 45a supplied to the switch 2,400 through a control bus 65 is sent to the read/write buffer 2,500. Then, for a reading operation, data is fetched from the memory 3,000 in the read/write buffer 2,500 at a first period of a timing signal, and the data thus fetched is sent to the CPU 10 at a second period of the timing signal. For a writing operation, the above processing is reversed, to send data from the CPU 10 to the memory 3,000 through the buffer 2,500. When the mode signal 135 indicates the second mode, a read signal 45b 1 supplied from the controller 2,100 to the read/write switch 2,400 is sent to the read/write buffer 2,500. Then, the read signal 45b issues a read command once every four periods of a synchronizing signal 40. That is, source data is fetched from the memory 3,000 in the read/write buffer 2,500 on the basis of the signal 45b 1 which is synchronized with a first period of the synchronizing signal 40. Destination data is fetched from the memory 3,000 in the read/write buffer 2,600 in synchronism with a signal 45b 2 which is generated at a second period of the synchronizing signal 40. A signal generated at a third period of the synchronizing signal 40 activates the operation processor 2,800 to perform a logical operation between the source data and destination data, and to send the result of the logical operation to the read/write buffer 2,700. In synchronism with a signal 45b 4 generated at a fourth period of the synchronizing signal 40, the contents of the read/write buffer 2,700 are sent not to the CPU 10 but to the memory 3,000. Thus, data can be transferred between the memory control device 2,000 and memory 3,000, without passing through the buses 65, 110 and 115.
The address controller 2,300 computes respective addresses of source and destination, when the second mode is carried out.
The memory control device 2,000 can generate a graph and can carry out image conversion, in accordance with the following procedure.
(1) Various parameters necessary for data transfer (namely, the head address A 1 of the source, the head address A 2 of the destination, the effective data length l 1 of the source, the effective data length l 2 of the destination, a number N 1 indicating how many times a source is accessed, a number N 2 indicating how many times a destination is accessed, the skip length I 1 of source address, the skip length I 2 of the destination address, the scanning direction d 1 of the source data, the scanning direction d 2 of the destination data, the reskipping direction J 2 of the destination address, and the kinds C of operation) are specified as follows. Specified values are set in registers which are included in the CPU 10, and then control signals each for specifying a corresponding parameter are sent to the memory control device 2,000. The controller 2,100 decodes each of the control signals, and generates an initial-value setting signal corresponding to each control signal. Thus, initial values are set in registers which are included in the controller 2,100, and in registers or counters which are included in the address controller 2,300.
(2) The CPU 10 sends out a control signal for starting the data transfer carried out in the second mode. Then, a synchronizing signal generator included in the controller 2,100 begins to operate, and sends the synchronizing signal 40 to the address controller 2,300. A series of operations are performed at four periods of the synchronizing signal 40. That is, a reading operation for source data, a reading operation for destination data, a logical operation between the source data and destination data, and a writing operation for writing the result of the logical operation in the destination, are performed at first, second, third and fourth periods of the synchronizing signal 40, respectively. Such a series of operations are repeated several times.
(3) When the above-mentioned data transfer is carried out N 2 times, which are specified, the address controller 2,300 sends an end signal 130 to the controller 2,100. On receiving the end signal 130, the controller 2,100 sends an end interruption to the CPU 10, to inform the CPU 10 that data transfer is completed.
Next, explanation will be made of the operations of various devices shown in FIG. 2. When the name of document information to be displayed on the display device 26 is specified by the input keyboard 14, the file device 30 is searched to find therein the document information corresponding to the specified name. The document information is usually formed of characters, graphs and picture images. Of the document information searched out in the file device 30, the character information and the graph information are stored in the main memory 18, while picture image information which includes dot patterns is stored in the picture image memory 20. As to characters, font patterns corresponding to characters which exist in a window are read out from the font memory 22, to be written in the refresh memory 24. As to graphs, only that portion of a graph which exists in the window is converted by the well-known clipping algorithm into a dot pattern, which is written in the refresh memory 24. An example of the operation for writing a graph in a refresh memory in the form of a dot pattern is described in the previously-referred to Japanese patent application No. 61075/1982. As to picture images, only that portion of a dot pattern for a picture image which exists in the window is read out from the file device 30, and is written in the refresh memory 24. That is, in the refresh memory 24, a single image data is edited from document information which is obtained from a window and is formed of data with respect to characters, graphs and picture images.
In order to define a window arrangement on the display screen of the display device 26, a window management table such as shown in FIG. 4 is provided in the main memory 18. The window management table defines not only the position and size of each window on the display screen but also the position where each partial region is selected from a document. Each partial region is made equal in size to a corresponding one of the windows. The position of each window on the display screen is expressed by a coordinate system having its origin at the upper left corner of the display screen, and the position where each partial region is selected from the document is expressed by a coordinate system having its origin at the upper left corner of the document.
A search table such as shown in FIG. 5 is also provided in the main memory 18. In order to select desired document information from document information stored in the file device 30, the search table indicates the position of document information corresponding to a document's name, that is, a storage address and data length corresponding to a document's name. As shown in FIG. 6, the document information stored in the file device 30 includes format data, character data, graph data and picture image data. The format data specifies the format of a document, such as the character pitches in the longitudinal and transverse directions (namely, the distance between rows and the distance between columns), and top, bottom, left and right margins. The character data for forming a main part of a document is stored in the file device 30 in the form of a string of character codes. The graph data is stored in the form of a train of data which indicates the kind of curve, the thickness of the curve, and the X- and Y-coordinates of each of the starting and end points of the curve. The picture image data includes the attributes of a picture image, such as the size of the picture image, data length, and the position of the picture image on a document, and includes data values for indicating the degree of light and shade at each picture element.
The present invention is applicable to interactive document processing and the like. FIG. 7 shows some of the commands used in the present invention. When these commands are inputted by the input keyboard 14 together with needed parameters, a program stored in the processor 10 decodes the commands, and executes them in accordance with a processing procedure shown in FIG. 8. Referring to FIG. 8, the commands from the input keyboard 14 are taken in the processor 10, to be decoded (step 100). In step 200, the contents of the window management table are updated in accordance with each command. In step 300, predetermined document information is displayed on a predetermined window, by reference to the window management table and search table. Though the processing in steps 100 and 200 is described in detail in U.S. patent application Ser. No. 443872 (corresponding to Japanese Patent Application No. 189329/1981), the above processing will be briefly explained below.
(i) In step 100 for inputting and decoding commands, the position (X- and Y-directions) and size (X- and Y-directions) of a window which is to be produced, on the display screen are specified by the input keyboard, and these data are taken in the processor 10.
(ii) In step 200 for updating the window management table, the processing shown in FIG. 9 is carried out to produce a window. In step 210A, the contents WC of a window counter, which is provided in the processor 10 to indicate the number of windows having been produced on the display screen, are increased by one. Since the number of windows capable of entering the window management table (shown in FIG. 4) is limited, it is checked in step 210B whether the number of windows exceeds an upper limit or not. When the contents WC of the window counter exceed the above upper limit, the window management table overflows, and therefore error processing, such as sending an alarm message to the display device, is carried out in step 210E. When the window management table does not overflow, an unused (or empty) entry space exists in the window management table, and the window management table is searched to find out the unused entry space (step 210C). The flag in each entry space indicates whether an entry space has been used or not. When the i-th entry space is empty, that is, a flag F i indicates " 0", data necessary to produce the i-th window is written in the i-th entry space (step 210D). That is, data indicated by the input keyboard (namely, the position and size of a window) are entered, as the attributes of the i-th window (namely, the X-address X i , Y-address Y i , width S i of window, and height H i of window), in the window management table. The item "level" in the window management table indicates an overlapping relation between windows, at the display screen. That is, when a window with a high level and another window with a low level have a display position in common, the former is displayed on the latter. Further, the level of a newly produced window is made higher than those of windows having been already produced. The level L i of the i-th window which is newly produced, is determined on the basis of a relation L i =WC-1. For example, in the case where only the i-th window exists, the value WC is equal to 1 and therefore the level L i is equal to zero. In the case where only one window exists in addition to the i-th window, WC=2 and L i =1. The level of a window is determined in the above-mentioned manner, in order to be able to readily execute two commands ("POP" and "PUSH") for changing the overlapping state of windows. At a time when the i-th window is produced as above, image data to be displayed on the i-th window is not yet entered in the window management table. The following processing is carried out to produce the i-th window completely. In order that the i-th window contains a specified pattern (for example, a white or black area all over the window, or a checkerboard pattern), the name D 1 of the image data for producing the specified pattern is written in the window management table. When the name D 1 has been written, the flag F i in the window management table is set to "1", to indicate that the i-th window has been produced.
Next, the processing procedure of step 300 shown in FIG. 8 will be explained below in detail, with reference to FIG. 10. A window with the lowest level is first processed, and all of the windows entered in the window management table are processed in the order of increasing level. Image data having been supplied to the refresh memory 24 before a command is inputted, is held in the memory 24. When the command is inputted, the refresh memory is required to be rewritten for a window, and is not required to be rewritten for another window. In order to discriminate between these windows, an item "display requesting flag" is provided on the window management table. The display requesting flag is set to "ON" or "OFF" in accordance with each command in step 200 of FIG. 8. When the flag is "OFF", a window having this flag is not required to be rewritten, but the next window is processed. When the flag is "ON", the search table is searched on the basis of the name of a document to be displayed on a window with this flag, to find out the position of the document in the file device 30. Desired document information (having the contents shown in FIG. 6) is fetched from the file device 30 in the main memory 18 (step 340). The document is usually formed of characters, graphs and picture images.
Of the fetched information, only data with respect to those portions of characters and graphs which exist in the window are selectively taken out and converted into dot patterns. The dot patterns thus obtained are written in predetermined areas in the refresh memory 24 (steps 350 and 360). On the other hand, the picture image data with respect to that portion which exists in the window is selected from the picture image memory 20 and transferred to other predetermined areas in the refresh memory (step 370).
As has been explained in the foregoing, according to the present invention, an image memory having a storage capacity corresponding to one page of a document (that is, an image memory having a storage capacity of about 500 KB for storing therein information on one page of size A4 or an image memory having a storage capacity of about 1 MB for storing therein information on one page of size A3) is not required, but an inexpensive image memory can be used.
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A multimedia display system for efficiently and economically displaying document information containing characters, a graph and a picture image, without using a large-capacity image memory is disclosed in which information in a window is directly written in a bit-map memory or the display screen of a display device, without necessitating an image memory having a storage capacity corresponding to one page of a document. The multimedia display system is effectively used in the multiwindow display method, and includes a transfer controller for controlling data transfer between the bit-map memory and a memory device including a main memory, a picture image memory and a font memory, to control the size, position and contents of each window and to make possible image synthesis or image conversion.
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DETAILED DESCRIPTION OF THE INVENTION
This invention relates to the improved structure of a manhole. The improvement includes the structure of the manhole cover, the ring for elevating the manhole cover and its base.
Car drivers and passengers often feel the bouncing and jerking of the car or a sharp noise of knocking metal when the car was driven past a manhole in a city road. The cause of car bouncing and jerking is that the manhole cover is bulging out or hollow into the road surface, and the cause of metal knocking noise is that there is no means to secure the manhole cover and the ring which become loose or unlevel due to sand, mud or other foreign materials infiltrating therebetween, the result is that when the wheel of a passing car rolls over one side, the other side goes up and down to make a knocking noise.
As a result of investigation, the main causes for the unevenness of the manhole and the road surface are found to be:
(1) In raising the road surface, the manhole should also be raised at the same time so that it becomes level with the road surface. Because the conventional method of securing the manhole base is unsatisfactory, the work to raise the manhole is difficult, so it is not raised at the same time as the road is paved. Day after day and month after month, there are manholes left to be raised in almost every street.
(2) Generally, a manhole is raised by fixing it with concrete. If it needs to be raised again, the concrete must be knocked off to fix the manhole again. This method not only wastes manpower and money but also necessitates blocking the road to prevent cars running over till the concrete is solidified. This is unsightly and obstructing the traffic.
(3) In another conventional method of raising the manhole by adding rings (as shown in FIG. 1), the design is unsatisfactory and cannot overcome the practical difficulties, because the thickness of manhole cover 1 is 5 cm due to the restricted material strength and ring 2 for raising the manhole is also designed as 5 cm thick (it cannot be less than 5 cm), but usually the thickness of the additional pavement is 3 cm at a time (to raise the road surface 5 cm thick each time is very wasteful). Therefore after the manhole is raised, it bulges 2 cm above the road surface. If it is not raised, it hollows 3 cm below the road surface. This causes the unevenness of the road. The only way to solve this problem is to raise the manhole once for two layers of pavement. To compensate the 2 cm bulging above the road surface, the surface within 1 meter around the manhole is raised to form a slope. Therefore, the manhole on a newly paved road is like a dome. When a car is driven past, the car is still bouncing and jerking.
In addition to the above-mentioned situation, there is no device to secure the contact area between the manhole cover and the structure under it. Furthermore, a manhole cover is made of cast iron and becomes rusted after a certain period. It is difficult to open it without using special tools. This affects the efficiency of the work and delays the completion date.
This invention is to eliminate the shortcomings or the above-mentioned and to provide an improved manhole cover, a ring for raising manhole cover and an improved base.
The first object of this invention is to provide a manhole cover with securing means and a ring for raising the manhole for use in conjunction with such manhole cover.
The second object of this invention is to provide a base for use in conjunction with above-mentioned manhole cover or ring for raising manhole cover.
According to the above-mentioned improved structures of this invention, the thickness of the raised road surface can be kept always at level with the manhole and the work is quite simple.
How the foregoing objects and advantages are attained will appear more fully from the following description referring to the accompanying drawings in which:
FIG. 1(A) is a sectional schematic illustration of a conventional manhole structure;
FIG. 1(B) is a perspective illustration of a ring used in the conventional manhole structure shown in FIG. 1(A);
FIG. 2(A) is a partially plan view of the manhole cover of the present invention;
FIG. 2(B) is a sectional view of the manhole cover shown in FIG. 2(A);
FIG. 3(A) is a partially plan view of the ring used in connection with manhole cover of the present invention;
FIG. 3(B) is a sectional view of the ring shown in FIG. 3(A);
FIG. 4(A) is a partially plan view of the base used in connection with the ring of FIG. 3;
FIG. 4(B) is a sectional view of the base shown in FIG. 4(A);
FIG. 5 is a sectional view of the present manhole structure.
The special feature in the construction of the present manhole cover 1 is shown in FIG. 2. The rim of manhole cover 1 has a surface inclining inwardly at 45° and in the middle of the inclining surface a suitable number of protrusions 1' for insertion are formed downwards. In the drawing, protrusions 1' are formed at the meeting place of the right angled diameters passing through the centre of manhole cover 1 and the inclining surface. Thus 4 protrusions 1' are formed. The other structure of the manhole cover is the same conventional one and is made of cast iron.
The ring 2 for raising the manhole cover of this invention as shown in FIG. 3 has a perpendicular inner wall 2a and outer wall 2b, and upper wall 2c and lower wall 2d which are parallel and inclined inwardly at 45° with walls 2a or 2b forming a ring shape structure. In the middle of the upper wall 2c a hole 2" is formed for receiving the corresponding protrusions 1' of the above-mentioned manhole cover. In the middle of lower wall 2d a downward protrusions 2' is formed in corresponding to the above-mentioned hole 2".
The base 3 for manhole cover of this invention as shown in FIG. 4 is a ring shape structure like ring 2 but its base 3d has a protruding rim without protrusions. In the middle of the inclined surface of its upper wall 3c, holes 3" are formed in corresponding to the above-mentioned protrusions 1' or 2'.
The assembly of manhole cover 1, ring 2 and base 3, having the above-mentioned structure, is shown in FIG. 5 embodiment. In installation, base 3 is placed first on concrete base 4 and then protrusions 1' of the manhole cover 1 are inserted into the holes 3" in base 3, thus the manhole cover 1 is securely positioned on base 3, after that, the road surface is raised 3 cm to G1. If the road surface is required to be raised again after a certain time of use, a ring 2 can be placed on base 3 in the same manner as described above. After covering the manhole with manhole cover 1, a proper thickness of road surface G2 can be raised. Therefore, the operation of raising the manhole is quite simple and the engagement of cover and manhole is firm and secure. Unlike the conventional ring formed by coupling 2 rings of different diameters (as shown in element 2 in the cross section of FIG. 1), the height of ring 2 of this invention is not fixed and may be made to conform with the height of the road surface to be raised, e.g. 3 cm. After the installation of above said ring, the road surface can be raised 3 cm according to the work specification without any bulging part on the road surface and the surface will remain level, thus bouncing and jerking of the car running thereon and knocking noise from unlevel cover would not occur. Furthermore, to prevent the manhole cover from sticking onto the base or the ring due to rusting, a rubber cushion may be provided between the adjoining surfaces so as to facilitate opening the manhole cover and to save working time.
While a preferred embodiment has been described, variations thereto will occur to those skilled in the art within the scope of the present inventive concepts. The scope of the invention is therefore to be determined solely by the appended claims.
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An improved manhole structure is disclosed which comprises a cover having a rim inclined inwardly at 45°, on which a plurality of protrusions are provided; a ring for elevating the cover, having an upright inner wall and outer wall and an upper face and lower face, both inclined inwardly at 45°, on the said upper face a plurality of holes are formed for engagement with the protrusions formed on the cover, and on the said lower face a plurality of protrusions are formed; and a base having an upper surface inclined inwardly at 45°, and a flat lower face, on the said upper surface a plurality of holes are formed for engagement with the protrusions formed on the lower face of the said ring.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a memory refresh circuit. More specifically, this invention relates to a memory refresh circuit for operating a fixed-timing circuit over a substantial range of clock frequencies.
2. Description of the Relevant Art
Due to the complex nature of VLSI circuit designs, including microprocessor circuit designs, validation of the designs includes debugging of circuitry on several levels. For example, a processor design may be tested using silicon parts operating in a motherboard at full speed. The same processor design may also be tested using an emulator operating in a motherboard at low speed.
Silicon parts operate in the motherboard at an operating speed in the range of tens of megahertz. In contrast, the emulator operates in the motherboard at an operating speed in the range of hundreds of kilohertz. Accordingly, the operating speed of the motherboard varies at a ratio of approximately 100 to 1 in this example. Although separate motherboards may be utilized for different testing levels including a high-speed motherboard and a low-speed motherboard, advantages are gained by using the same motherboard for all testing and validation. In particular, usage of a single motherboard substantially reduces the number of variables or differences in operating conditions. Furthermore, usage of a single motherboard is convenient. If the same motherboard is used for both the high speed and low speed applications, the motherboard must have an operating range at least from the hundreds of kilohertz to the tens of megahertz.
Several problems are raised by attempting to operate a motherboard over this wide range of frequencies. For example, the wide range of operating frequencies raises problems with regard to dynamic random access memory (DRAM) refresh. FIG. 1 is a schematic block diagram which illustrates a conventional refresh circuit 100. The conventional refresh circuit 100 includes a refresh clock generator circuit 110, a refresh flip-flop 112, a dynamic random access memory (DRAM) controller 116 and a dynamic random access memory (DRAM) 118. The refresh clock generator circuit 110 generates a rising edge of a periodic signal at a specified rate, for example 15 μs. A typical DRAM, such as DRAM 118, has 256 rows that are refreshed in 4 milliseconds (ms) so that the average refresh rate is 15 microseconds (μs). Accordingly, the typical refresh clock generator circuit 110 generates a refresh signal every 15 μs. The refresh signal sets the flip-flop 112. A refresh cycle takes place when a refresh circuit 100 gains control of the DRAM 118. Once the refresh cycle is completed, the flip-flop 112 is cleared. The underlying implication is that the DRAM 118 must become available to the refresh circuit 100 for refresh before another 15 μs time slice expires. Thus, the typical refresh circuit 100 is synchronized with the typical DRAM 118 on the basis that the average refresh rate of the DRAM 118 is similar to the refresh rate generated by the refresh clock generator circuit 110. No circuits or memory are generally used to enforce this synchronization.
The refresh timing requirement of a DRAM remains the same regardless of the clock rate and operating speed of a processor 106. The DRAM continues to require a designated refresh time. Thus at very low-speed operating rates, such as the rates used in emulation, the very slow access to DRAM 118 of the processor 106 may extend for several refresh cycles. For example, if the processor 106 access is extended to 100 μs, then the refresh time of the DRAM 118 is exceeded. The refresh generator generates six refresh cycles of which only one results in a refresh cycle to the DRAM 118. Five refresh cycles are missed. So much time has transpired between refresh signals to the DRAM 118 that a few refresh cycles are skipped. Under these circumstances, the refresh specification for the DRAM 118 will eventually be violated.
What is needed is a circuit that is functionally the same while operating at high frequency and at low frequency. What is needed is a timing refresh circuit that refreshes a DRAM in a functionally equivalent manner, whether the timing refresh circuit is operated at a high frequency or a low frequency.
SUMMARY OF THE INVENTION
In accordance with the present invention, a timing refresh circuit refreshes a timed circuit in a functionally equivalent manner, whether the timing refresh circuit is operated at a high frequency or a low frequency. The two-stage timing refresh circuit includes a counter and combinational logic, in combination, connected between a refresh timing signal generator and a control circuit. The counter is incremented for each refresh timing signal and decremented for each refresh cycle realized by the control circuit. The combinational logic converts the counter count to a refresh signal by generating a refresh request to the control circuit whenever a count is pending in the counter.
In accordance with one embodiment of the present invention, a timing control circuit controls timing signals to a fixed-timing circuit in a variable-time system. The fixed-timing circuit has an input terminal for receiving a timing signal and an output terminal for generating a timing signal indicative of fixed-timing circuit timing. The fixed-timing circuit is accessible to timing signals of the timing control circuit in a first state and inaccessible to timing signals of the timing control circuit in a second state, the timing control circuit includes a fixed timing signal generator, a counter having a first input terminal connected to the fixed timing signal generator, a second input terminal connected to the output terminal of the fixed-timing circuit and a plurality of output bit lines. The timing control circuit also includes a combinational logic circuit having a plurality of input bit lines connected to the plurality of output bit lines of the counter and an output line connected to the input terminal of the fixed-timing circuit.
In accordance with another embodiment of the present invention, a timing refresh control circuit controls timing signals to a fixed-timing DRAM circuit in a variable-time system. The fixed-timing DRAM circuit has an input terminal for receiving a timing signal and an output terminal for generating a timing signal indicative of fixed-timing circuit timing. The fixed-timing DRAM circuit is accessible to timing signals of the timing refresh control circuit in a first state and inaccessible to timing signals of the timing refresh control circuit in a second state. The timing refresh control circuit includes a fixed timing refresh clock signal generator and a counter having a first input terminal connected to the fixed timing refresh clock signal generator, a second input terminal connected to the output terminal of the fixed-timing DRAM circuit and a plurality of output bit lines. The timing refresh control circuit also includes a combinational logic circuit having a plurality of input bit lines connected to the plurality of output bit lines of the counter and a refresh cycle output line connected to the input terminal of the fixed-timing DRAM circuit.
In accordance with a third embodiment of the invention, a circuit board operates both at emulation speed in a first operating state and at a circuit speed in a second operating state. The circuit board includes a fixed-timing circuit having an input terminal for receiving a timing signal and an output terminal for generating a timing signal indicative of fixed-timing circuit timing. The fixed-timing circuit is accessible to timing signals of the timing control circuit in a first state and inaccessible to timing signals of the timing control circuit in a second state. The circuit board further includes a fixed timing signal generator and a counter having a first input terminal connected to the fixed timing signal generator, a second input terminal connected to the output terminal of the fixed-timing circuit and a plurality of output bit lines. The circuit board also includes a combinational logic circuit having a plurality of input bit lines connected to the plurality of output bit lines of the counter and an output line connected to the input terminal of the fixed-timing circuit.
In accordance with a fourth embodiment of the present invention, a method of controlling timing signals to a fixed-timing circuit in a variable-time system is disclosed. The fixed-timing circuit has an input terminal for receiving a timing signal and an output terminal for generating a timing signal indicative of fixed-timing circuit timing. The fixed-timing circuit is accessible to timing signals of the timing control circuit in a first state and inaccessible to timing signals of the timing control circuit in a second state. The method includes the steps of generating a fixed timing signal, incrementing a count of the number of fixed timing signals and decrementing the count by the number of signals indicative of fixed-timing circuit timing. The method further includes the steps of applying a fixed timing signal to the fixed-timing circuit when the count is greater than one and terminating application of the fixed timing signal to the fixed-timing circuit when the count is decremented to zero.
Numerous advantages are attained by the described circuit and method. One advantage is that the same circuit board may be conveniently used for various test and verification purposes without alteration. Thus, the board may be used for emulating a design at slow clock speeds and for operating an integrated circuit version of the emulated system at high clock speeds. In either case, timing of fixed-timing circuits is maintained at the same operating frequency. Another advantage is that usage of a single board at different operating frequencies substantially improves design verification and debugging by minimizing the number of test variations between an emulated system and an integrated-circuit system. A further advantage is that the described circuit and method is useful for maintaining a substantially constant refresh rate across all of the rows of a memory.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention may be better understood, and its numerous objects, features, and advantages made apparent to those skilled in the art by referencing the accompanying drawings.
FIG. 1, labeled PRIOR ART, is a schematic block diagram which illustrates a conventional refresh circuit.
FIG. 2 is a schematic block diagram of a two-stage refresh circuit in accordance with an embodiment of the present invention.
FIG. 3 is a timing diagram which illustrates the timing operation of the two-stage refresh circuit shown in FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
The following sets forth a detailed description of the best contemplated mode for carrying out the invention. The description is intended to be illustrative of the invention and should not be taken to be limiting.
Referring to FIG. 2, a two-stage refresh circuit 200 is shown which includes a refresh clock generator circuit 210, an up/down counter 212, a multiple-input 0R gate 214, a dynamic random access memory (DRAM) controller 216 and a dynamic random access memory (DRAM) 218. The two-stage refresh circuit 200 includes a first stage 202 and a second stage 204. The first stage 202 is the refresh clock generator circuit 210 which generates a periodic refresh clock signal. In an illustrative embodiment, the refresh clock generator circuit 210 generates the refresh clock signal every 15 μs. The second stage 204 includes the up/down counter 212, the multiple-input OR gate 214, the DRAM controller 216 and the DRAM 218. The DRAM controller 216 is a suitable dynamic RAM controller, as is known in the an of memory circuits. Typical DRAM controllers are used to supply control signals, such as timing control signals, to a DRAM memory. DRAM controllers also receive and generate control signals such as timing signals from circuit blocks such as a processor 206. The DRAM 218 is a suitable dynamic RAM memory, as is known in the art of memory circuits.
The refresh clock signal is communicated from the refresh clock generator circuit 210 to the up/down counter 212. The up/down counter 212 is updated by incrementing for each refresh cycle of 15 μs timing signals generated by the refresh clock generator circuit 210. The up/down counter 212 is also updated by decrementing for each refresh cycle signal from the DRAM controller 216. In this manner, when a processor 206 is operating at a low speed and accessing the DRAM 218 so that the DRAM 218 is not available to the refresh circuit 200 for refreshing at the high rate of the refresh clock generator circuit 210, the number of refresh clock signals is continually counted up. At the same time, because the DRAM 218 is not available to the refresh circuit 200 for refreshing, the DRAM controller 216 does not generate refresh cycle signals and the up/down counter 212 is not counted down.
When the refresh circuit 200 gains access to the DRAM 218 to pass refresh timing signals to the DRAM 218, the DRAM 218 is refreshed under control of DRAM controller 216. For each refresh cycle, the refresh cycle signal is applied to the up/down counter 212 to decrement the count so that the refresh circuit 200 runs the number of refresh cycles that are accumulated in the up/down counter 212. When the count in the up/down counter 212 reaches a predefined number, for example zero, refresh timing signals are no longer applied to the DRAM controller 216. Thus, for an extended DRAM access time resulting in an extended time without DRAM refresh cycles, the up/down counter 212 counts the number of missed refresh events. When the DRAM becomes accessible for refresh, the counter generates refresh signals in a sequence of refresh counts until all missed refresh cycles are restored. The DRAM 218 is not available to the processor 206 until all refreshes are completed.
The refresh circuit 200 serves to synchronize the timing of refresh events across a memory circuit so that a substantially constant refresh rate is advantageously maintained across all of the rows of a memory.
When the count in the up/down counter 212 is updated to a designated value, for example zero, the refresh circuit 200 relinquishes control of the DRAM 218. When the refresh clock generator circuit 210 is running at a high operating speed, for example tens of megahertz, the two stage refresh circuit 200 operates in the manner of a conventional refresh circuit since the count of the up/down counter 212 never exceeds one. Thus, when the refresh circuit 200 runs at a high operating speed, the up/down counter 212 behaves like a single flip-flop.
The refresh clock generator circuit 210 generates a rising edge of a periodic signal at a specified rate, for example 15 μs. These periodic signals are used to synchronize operations in a computer system, for example. The refresh clock generator circuit 210 is connected to an up-count input terminal of the up/down counter 212. The up/down counter 212 also has a down-count input terminal and a plurality of output lines which generate a digital count signal. The up/down counter 212 counts up on a rising edge of a signal from the refresh clock generator circuit 210 on the up-count input terminal. The up/down counter 212 counts down on a rising edge of a signal on the down-count input terminal. The size of the up/down counter, in bits, is selected based on the duration of the high-speed clock interval and the low-speed clock interval for the system into which the two-stage refresh circuit 200 is implemented. Specifically, in one embodiment the bit-width of the up/down counter 212 is set according to equation (1), as follows:
bitwidth=1+log.sub.2 (T.sub.l /T.sub.c),
where T 1 is the time of the longest access and T c is the high speed clock interval.
A refresh request is generated by the up/down counter 212 and applied to the DRAM controller 216 when any of the bits in the up/down counter 212 is equal to 1. Thus, the only time a refresh request is not generated is when all bits in the up/down counter 212 are equal to zero. The DRAM controller 216 generates a refresh signal, such as a RAS#-only refresh signal or a CAS#-before-RAS#refresh, for application to the DRAM 218. The DRAM controller 216 also generates a refresh cycle signal that is applied to the down-count input terminal of the up/down counter 212.
A DRAM controller 216 typically affords a refresh signal the highest priority when arbitrating for control of the DRAM 218 so that the refresh circuit 200 retains control of the DRAM 218 as long as outstanding refresh requests are logged by the up/down counter 212.
Referring to FIG. 3, a timing diagram illustrates timing relevant to the operation of refresh circuit 200. An external clock signal 310 is operating at a low frequency relative to the rate of the refresh clock signal 320 which is generated by the refresh clock generator circuit 210. At time A 330, an external circuit such as a processor 206 accesses the DRAM 218 so that access is denied to the refresh circuit 200. Cycles of the refresh clock signal 320 are not applied as timing signals to the DRAM 218. Instead, the count 340 of the up/down counter 212 is incremented for each refresh clock signal 320 cycle. At time B 332 when the external circuit cedes access to the refresh circuit 200, the refresh clock signal 320 is applied to the DRAM 218 and the counter is decremented to zero at time C 334.
Other Embodiments
While the invention has been described with reference to various embodiments, it will be understood that these embodiments are illustrative and that the scope of the invention is not limited to them. Many variations, modifications, additions, and improvements of the embodiments described are possible.
For example, the illustrative embodiment specifically states various refresh and system clock rates and durations. These specific rates and durations are expressed merely to clarify the operation of the refresh circuit. Numerous other clock rates and durations may be implemented, without limitation, within the scope of the present invention. For example, one specific embodiment includes a processor operating on a silicon validation board. The silicon validation board is used for circuit emulation while operating a processor at an 80 kHz rate and used for silicon testing while operating at a 30 MHz rate.
Also, the illustrative embodiment particularly identified as a DRAM refresh circuit. The inventive circuit and circuit operating method is also applicable to other types of circuits to generally include all types of circuits that maintain the same time scale despite changes in overall circuit operating speed. For example, in a processor circuit certain operating signals are appropriate for scaling in proportion to the speed of the processor. Other signals are maintained and not scaled.
These and other variations, modifications, additions, and improvements may fall within the scope of the invention as defined in the claims which follow.
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A timing refresh circuit refreshes a timed circuit in a functionally equivalent manner, whether the timing refresh circuit is operated at a high frequency or a low frequency. The two-stage timing refresh circuit includes a counter and combinational logic, in combination, connected between a refresh timing signal generator and a control circuit. The counter is incremented for each refresh timing signal and decremented for each refresh cycle realized by the control circuit. The combinational logic converts the counter count to a refresh signal by generating a refresh request to the control circuit whenever a count is pending in the counter.
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BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention relates generally to a system for automatically shutting down cooking appliances and/or associated equipment in accordance with NFDA recommended standards in the event of a fire, and in particular to a fail-safe system of this type that will also shut down in the event of a failure in the system, and which will continue to indicate a failure until corrections are made by authorized personnel.
(2) Description of the Prior Art
Commercial kitchens and related facilities having a plurality of cooking appliances are normally equipped with a fire extinguishing mechanism that is automatically activated in the event of a fire, such as a grease fire, at one of the appliances. The extinguishing mechanism is usually comprised of a source of an extinguishing chemical that is connected via a piping network to discharge ports that are directed toward the cooking surfaces of the appliance. A discharge valve is used to control the flow of chemicals from the source. The discharge valve is adapted to be opened when an associated mechanism detects a fire.
For example, a spring-loaded discharge valve may be held in a closed position by a taut cable, which includes one or more fusable heat links positioned above the cooking appliances. When one of the links is melted by the heat from a cooking fire, the cable is released, opening the discharge valve, and discharging fire extinguishing chemicals onto the surfaces of the cooking appliances to extinguish the fire.
An effective, complaint fire extinguishing system must also include means to disconnect the cooking appliances from the energy source when a fire is detected. Otherwise, the fire-extinguishing chemical will be exhausted, and the fire may continue or restart due to the continuing supply of energy, i.e., electricity or gas. In the case of an electrical appliance, the appliance is de-energized by opening the electrical circuit to the appliance. In the case of an gas fueled appliance, the appliance is de-energized by shutting off the gas supply, e.g., by closing a valve, such as a solenoid actuated valve.
An effective system should also include an alarm to alert others to the existence of the fire. This alarm can be activated at the time the chemical is discharged, and continues to emit a signal, e.g., a sound and/or a light signal, until manually disconnected. The inclusion of a signal mechanism is mandated by NFPA-17A of the National Fire Protection Codes for “Wet Chemical Extinguishing Systems” used for restaurant canopy hoods. NFPA-17A states:
“A signal shall be provided to show that the system has operated, that personnel response is needed, and that the system is in need of recharge. The extinguishing system shall be connected to the fire alarm system, if provided, in accordance with the requirements of NFPA 72, National Fire Alarm Codes, so that the actuation of the extinguishing system will sound the fire alarm as well as provide the function of the extinguishing system.”
Various fire extinguishing systems for use with restaurant cooking appliances have been proposed in the prior art. The following patents are representative of prior art systems:
3,653,443
Dockery
4,356,870
Gaylord et al.
4,675,541
Peters et al.
4,773,485
Silverman
4,830,116
Walden et.al.
4,979,572
Mikulec
5,127,479
Stehling et al.
5,297,636
North
5,351,760
Tabor. Jr.
5,628,368
Sundholm
5,871,057
Stehling et al.
Despite considerable efforts, there is still a need for a system for effectively de-energizing a plurality of cooking appliances and other restaurant equipment, as required, in the event of a fire, while emitting a signal as required by NFPA-17A. In particular, a system of this type is needed that will not only de-energize appliances in the event of a fire, but which will de-energize appliances in the event of a detected failure in the microswitch or other circuit component. Therefore, the user will not be falsely assured that a functional system is being used to monitor conditions when, in fact, the system is not functioning.
A system of this type should also be designed so that the alarm cannot be fully deactivated until the system has been recharged after a discharge of chemical, or has been repaired after a malfunction has been detected. For example, if the alarm system includes both a sound and light emitting components, the operator should be prevented from disconnected both components until the system has be recharged or repaired by authorized and skilled personnel.
SUMMARY OF THE INVENTION
The present invention is directed to a shutdown or control system for de-energizing kitchen appliances in the event of a fire. The system is used in conjunction with a fire extinguishing system comprised of a source of fire extinguishing chemical or other material, a release mechanism for releasing the fire extinguishing material in the event of a fire.
Basically, the shutdown system is comprised of a normally closed switch, positioned to be opened when the fire extinguishing system is activated, a plurality of relays that change state when the switch is opened, the relays being capable of de-energizing appliances, and an alarm mechanism that includes an audible component that can be deactivated by an operator, and a visual component that can only be deactivated by repair and recharging of the fire extinguishing system.
Preferably, the normally closed switch is positioned in the path of a component of the fire extinguishing system that moves from a ready position to a released position when a fire is detected, so that the component engages the switch to move the switch from a closed state to an open state. For example, the switch can be a microswitch that is positioned adjacent a component of a fire extinguisher discharge valve control mechanism that moves from a restrained position to a released position when a fire is detected, so that the component engages the microswitch when at the released position.
More specifically, the fire extinguishing system may be comprised of a control mechanism that includes a pivotal member moveable between first and second positions, with the pivotal member being urged toward the second position by a spring, and held in the first position by a cable that includes a heat fusable link. In the event of a fire, the heat fusable link is severed by the heat from the fire, releasing the cable and allowing the pivotal member to move under the influence of the spring to the second position.
A microswitch is positioned at the second position in the path of the pivotal member, so that a component of the pivotal member engages the microswitch to move the switch from the closed state to the open state. The pivotal member also engages a release member, such as a valve, to release fire extinguishing chemicals from a supply source, such as a pressurized tank.
The microswitch is in a primary circuit with a plurality of relays that are in secondary circuits with different appliance controllers, e.g., switches or valves. The circuits are designed so that the circuits to the appliances are in a closed or completed state when the microswitch is closed. These circuits may be designed with the relays in an open state or a closed state. Thus, for purposes of description, when the appliances are energized, the relays will be described as being in the energized state, and in the deenergized state when the appliances are deenergized.
The microswitch is also in a circuit with an audible alarm, such as a horn, and a visual alarm, such as a strobe light. The audible and visual alarms are in a deenergized state when the microswitch is closed, and are moved to the energized state when the microswitch is opened. The horn is also in a circuit with a switch that can be used to deactivate the horn.
During the monitoring cycle, the control system is plugged into a power source, normally a 120 volt AC source, that provides energy to a closed primary circuit including the microswitch and a plurality of appliance control relays that are each connectable to a switch or valve (collectively referred to as controllers) that is interposed between an appliance or other powered device in the kitchen area, and its respective source of energy. The primary circuit is also connected to secondary circuits that include audible and visual alarms.
Fires are detected by a fire detection system that includes a tensioned cable positioned above the areas where fires may occur. For example, the cable may be positioned inside a hood that is located over the cooking applicances. The cable includes heat fusable links above each appliance. Such links are known in the relevant art and include means for connecting cable segments to opposite sides of the link, with the link being constructed of a material that melts at relatively low temperatures.
When exposed to a cooking fire, the link melts to separate the cable. The cable is attached to a moveable member, preferably a pivotal member that has a pivot end and a distal end. The pivotal member is held at a restrained position when the cable is under tension, and moves to a released position when the cable is released.
The fire extinguishing system also includes a source of fire extinguishing chemicals, e.g., a pressurized tank, and conduits or a piping network leading from the fire extinguishing chemical source to discharge nozzles positioned above the cooking appliances. A normally closed control valve is positioned between the chemical source and the nozzles, preventing discharge of chemicals. This valve is positioned in the path of, and engaged by, the moveable member when the movable member is in the released position.
The microswitch in the control circuit is also positioned in the path of the moveable member, and is also engaged by the moveable member in the released position. Thus, when the moveable member is released, the moveable member contacts the fire extinguisher valve, opening the valve to release the extinguishing material. Also, the moveable member contacts the microswitch to open the primary control circuit. As a result, the relays in the primary circuit change state, activating the controller, e.g., opening an electrical switch, or closing a control valve. As a result the supply of energy, e.g., electricity or gas, is terminated.
Another relay in the primary circuit is also in a second circuit with a normally open, audible alarm circuit, and a normally open visual alarm circuit. Opening of the primary circuit causes the relay to change state, closing the alarm circuits to activate the audible and visual alarms, thereby alerting appropriate personnel. The audible alarm can be immediately deactivated by a pushbutton switch or another kind of a switch. However, no provision for opening the visual alarm circuit is provided. Therefore, the visual alarm continues to signal until the primary circuit is restored to its closed state. This restoration cannot occur until the microswitch is again closed, which requires authorized personnel to recharge the fire extinguishing system and restore the cable to its tensioned state.
Accordingly, one aspect of the present invention is to provide an emergency shutdown system to deenergize appliances upon activation of a fire extinguishing system comprising a microswitch moveable between from a closed position to an open position upon activation of the fire extinguishing system. A plurality of relays are in a first circuit with the microswitch, each of the relays being in a second circuit with an applicance controller. The second circuits are closed when the microswitch is in a closed position, and the relays change from a first state to a second state, opening the second circuits when the microswitch is moved to an open position. An audible alarm is in the circuit with the microswitch, the audible alarm being moveable from an unenergized state to an energized state when the microswitch is opened, the audible alarm also being in a circuit with a silencing switch adapted to return the audible alarm to the unenergized state. A visual alarm is also in the circuit with the microswitch, the visual alarm being moveable from an unenergized state to an energized state when the microswitch is opened, the visual alarm being returnable to the unenergized state only when the fire extinguishing system is returned to the recharged and ready state.
Another aspect of the present invention is to provide a fire control system for use with at least one kitchen appliance comprising a fire detection means to activate a fire extinguishing system; a fire extinguishing system activated upon detection of a fire; and a control system. The control system includes a microswitch moveable between from a closed position to an open position upon detection of a fire; a plurality of relays in a first circuit with the microswitch, each of said relays being in a second circuit with an applicance controller; the second circuits being closed when the microswitch is in a closed position. The relays change from a first state to a second state and open the second circuits when the microswitch is moved to an open position. An audible alarm is in a circuit with the microswitch, with the audible alarm being moveable from an unenergized state to an energized state when the microswitch is opened, the audible alarm also being in a circuit with a silencing switch adapted to return the audible alarm to the unenergized state. A visual alarm is also in the circuit with the microswitch, the visual alarm being moveable from an unenergized state to an energized state when the microswitch is opened, the visual alarm being returnable to the unenergized state only when said fire extinguishing system is returned to the recharged and ready state.
These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic of a fire detection and extinguishing system joined to the control system.
FIGS. 2 and 3 are diagram of the electrical circuit of the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, terms such as horizontal, upright, vertical, above, below, beneath, and the like, are used solely for the purpose of clarity in illustrating the invention, and should not be taken as words of limitation. The drawings are for the purpose of illustrating the invention and are not intended to be to scale.
FIG. 1 illustrates a fire detection system, generally 10 , that includes a tensioned cable 12 positioned above a typical cooking appliance 14 . Cable 12 includes a plurality of heat fusable links 16 positioned above burners 18 . Cable 12 has a fixed end 20 attached to a support, and is strung around pulleys 22 to attach at its opposite end to a pivotal member 24 . Member 24 includes a pivotal end 26 , a first contact element 28 and a second contact element 30 . Spring 32 urges pivotal member 24 in a downward direction toward a released position. Pivotal member 24 is held in a restrained position, as illustrated, by cable 12 .
A fire extinguishing system comprises a pressurized container 34 connected by conduit 36 through normally closed control valve 38 to discharge nozzles 39 positioned above burners 18 . Valve 38 is mounted for engagement by contact element 30 of pivotal member 24 when member 24 is in the released position. Microswitch 40 is positioned for engagement by contact element 28 of pivotal member 24 when member 24 is in the released position.
Refer now to FIG. 2 and FIG. 3 . The control system, generally 50 , is comprised of a lockable housing 52 , with a strobe light 54 and audible alarm release button 56 on the front panel of housing 52 . A circuit board 58 , audible alarm 60 , and relevant wiring (not shown) are mounted inside housing 52 .
As best illustrated in FIG. 2, the circuit of the invention is comprised of first and second DPDT relays R 1 and R 2 that are in a primary circuit with DPDT relay R 3 , and SPST relays R 4 and R 5 . Relay R 1 is connected to terminal blocks TB 4 and TB 5 , and relay R 2 is connected to terminal blocks TB 6 and TB 7 . Pin connector J 1 connects the primary circuit to strobe 54 and horn 60 . TB 2 connects to a 120 volt AC source rated at a maximum of 10 amps.
The 120 volt AC input power is connected to terminal block TB 2 , terminals 3 , 4 , and 5 . These connections are referred to herein by the abbreviations TB 2 - 3 , TB 2 - 4 , and TB 2 - 5 . Other connections will be similarly abbreviated. TB 2 - 3 is used for connection of the hot, 120 volt power source side. TB 2 - 4 is used for connection of the neutral side of the 120 volt power source. TB 2 - 5 is used for connection of the 120 volt AC input ground wire. Terminal block TB 3 connects the primary circuit to microswitch 40 .
TB 2 - 3 grounding wire is routed, via a solder joint connection, to the chassis connection between circuit board 58 and housing 52 to allow further connection to earth ground via conduit connections per the National Electric Code requirements. TB 2 - 3 is routed to J 1 - 8 (pushbutton common) and TB 3 - 6 (remote microswitch common). TB 3 - 6 is connected to R 3 - 6 and R 3 - 5 .
The 120 volt AC neutral connection, TB 2 - 4 , is routed to TB 1 - 1 (remote contactor), which is connected to J 1 - 3 (power light), J 1 - 7 (horn), and J 1 - 8 (strobe light). TB 1 - 1 is also attached to R 1 - 7 (coil), R 4 - 8 (coil), and to R 2 - 8 , R 3 - 7 and R 5 - 7 . The 120 volt AC ground connection, TB 2 - 5 , is routed to the chassis ground connection located on circuit board 58 .
During normal operation, AC current is routed TB 3 - 6 to the common connection of microswitch 40 . The normally closed contact of microswitch 40 is then routed back to TB 3 - 7 , and from TB 3 - 7 to R 1 - 8 (coil) and R 3 - 8 (coil) of R 2 and R 5 . Since a circuit now complete, relays R 1 , R 2 , R 3 , and R 5 are energized. The relay contacts of R 1 and R 2 are routed to terminal blocks located on circuit board 58 . R 1 contacts are routed to TB 4 - 8 (common), TB 4 - 9 (normally open), TB 4 - 10 (normally closed), TB 5 - 11 (normally closed), TB 5 - 12 (normally open), and TB 5 - 13 (common). R 2 contacts are routed to TB 6 - 14 (common), TB 6 - 15 (normally open), TB 6 - 16 (normally closed), TB 7 - 17 (normally closed), TB 7 - 18 (normally open), and TB 7 - 19 (common).
TB- 4 , TB- 5 , TB- 6 , and TB- 7 are adapted to connect with connectors (either electrical switches or valves) used to control the flow of energy (either electricity or gas) to appliances. Relay contacts are rated 10 amps at 24 volts DC, 120 and 220 volts AC. Relay R 3 , when energized (the “normal” condition), transfers 120 volt AC hot, from pin R 3 - 4 (normally open when relay R 3 is not energized) to TB 1 - 2 . TB- 1 will then create a 120 volt AC output for remote connection of relays or contactors rated for “normally energized” use. The 120 volt AC output is rated at 10 amps at 24 volts DC, 120 and 220 volts AC.
Using normal operating conditions, the contacts of microswitch 40 are in the normally closed position, all relay contacts are in the working position, and the remote contactor/relay output is energized. Upon loss of wiring integrity between TB 3 - 6 and TB 3 - 7 , due to opening of microswitch 40 or a fault in the field wiring, 120 volt AC power will be lost to Relays R 1 , R 2 , R 3 , and R 5 , causing contacts on TB- 4 , TB- 5 , TB- 6 , and TB- 7 to change state. Output on TB 1 - 1 and TB 1 - 2 will drop out.
The 120 volt AC hot, connected to R 3 - 6 (common) will now be routed from pin 2 (normally open when R 3 is energized under normal operating condition) to J 1 - 2 . J 1 - 2 is routed to the + input of strobe light 54 . 120 volt AC hot, connected to R 3 - 5 (common) is routed from pin 1 (normally open when R 3 is energized under normal operating condition), to R 4 - 6 (common). R 4 - 6 (common) is routed through R 4 - 2 (normally closed), which is then routed to J 1 - 3 , which is connected to an the + input of horn 60 . The circuit is now in “alarm” condition, shutdown relay contacts have operated, the contactor/relay output is deactivated, alarm horn 60 is sounding, and strobe light 54 is flashing.
Depressing momentary pushbutton 56 causes contact closure of a normally open contact block. One side of the contact block is connected to J 1 - 1 , and the other side of the contact block is connected to J 1 - 4 . Closure of the contact block allows 120 volt AC power to pass from J 1 - 1 (120 volt AC hot), to J 1 - 4 , which is connected to R 5 - 6 (common). R 5 - 6 (common) is routed to R 5 - 2 (normally open when R 5 is energized under normal operating condition). R 5 - 2 is connected to R 4 - 3 (normally open when R 4 is energized under normal operating condition), and R 4 - 7 (coil).
R 4 is thereby energized, allowing power from R 4 - 6 (via contact pin 3 ) to the coil. This is in turn energizes the relay in a “latched” mode. With R 4 in a “latched” mode (energized), R 4 - 2 (normally open under normal operating condition) returns to a normally open state, and breaks the 120 volt AC Hot connection directed to J 1 - 3 , in turn silencing alarm horn 60 . Even though horn 60 has been silenced, strobe light 54 will still flash, the shutdown contacts will remain in the “off” mode, and the contactor/relay output remain de-energized. Strobe 54 continues to flash until the fire detection system has be repaired, the fire extinguishing systems have been recharged, and the entire system has been returned to its ready state.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. It should be understood that all such modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the follow claims.
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Fires in kitchen appliances are detected and controlled by a detection and control system that activates a fire extinguishing system when the fire is detected, terminates the supply of electricity and/or gas to the appliances, and initiates audible and visual alarms. The audible alarm can be terminated, while the visual alarm continues until the system is restored to a pre-detection state. The system includes a control circuit, and a fire detection means with a moveable member that engages a normally closed microswitch in the control circuit to open the control circuit. Relays in the control circuit change state upon opening of the control circuit to de-energize the appliance, and audible and visual alarms are activated. The audible alarm can be manually terminated. However, the visual alarm remains activated until the system is recharged and returned to the ready state.
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